Xerox Docucolor 12

DocuColor 12/DCCS50
Service Manual
January 2005
CAUTION
Certain components in the DocuColor 12/
DCCS50 are susceptible to damage from electrostatic discharge. Observe all ESD procedures to
avoid component damage.
NOTICE
While every care has been taken in the preparation of this manual, no liability will be accepted by Xerox Corporation arising out of any inaccuracies or
omissions.
NOTICE
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 personal only. Xerox does not warrant or
represent that such documentation is complete, nor does Xerox represent
or warrant that it will notify or provide to such customer any future changes
to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty
offered by Xerox with respect to such equipment. You should consult the
applicable warranty for its terms regarding customer or third party provided
service. If the customer services such equipment, modules, components or
parts thereof, the customer releases Xerox from any and all liability for the
customer actions, and the customer agrees to indemnify, defend and hold
Xerox harmless from any third party claims which arise directly or indirectly
from such service.
Prepared by:
Xerox Corporation
800 Phillips Road
Bldg. 845-17S
Webster, New York 14580-9791 USA
2001, 2002, 2004 by Xerox Corporation.
Xerox and The Document Company
are trademarks of Xerox Corporation.
Xerox product names mentioned in this publication are trademarks of the
XEROX CORPORATION.
Introduction
Introduction .....................................................................................................................
About This Documentation..............................................................................................
Organization....................................................................................................................
Reference Symbology.....................................................................................................
AC and DC Voltage Nomenclature .................................................................................
Translated WARNINGS ..................................................................................................
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Introduction
Photoreceptor Drum Light Shock

CAUTION
Safety
Protect the Photoreceptor Drum from the light by covering it with the bag when the Drum is
removed from the machine or exposed to light. The bag is stored in the Tray 1 storage compartment. The Drum can be damaged by light shock.
WARNING
The DocuColor 12/DCCS50 contains an invisible laser. There is no visual indication that
the laser beam is present. During servicing, the DocuColor 12/DCCS50 is a Class 3B
product because of the invisible laser. the laser beam could cause eye damage if looked
at directly. Service procedures must be followed exactly as written without change. The
service representative must observe the established local laser safety precautions
when servicing the DocuColor 12/DCCS50. Do not place tools with a reflective surface
in the area of the Charge Corotron or the ROS opening. Do not look in the area of the
Charge Corotron or the ROS window if the power is On and the laser is energized with
the Toner Cartridge Unit removed.
Electrostatic Discharge Damage

CAUTION
Use the ESD Kit and the established ESD procedures when accessing parts of the machine
other than those normally accessed by the operator. The Kit and procedures must be used
even though PWBs are not touched directly. Components of the machine can be damaged by
electrostatic discharge.
Toner, Developer and Drum
The following symbol and statement appear on a label in the machine when the Toner
Cartridge Cover or the Toner Cartridge Unit are removed. The symbol by itself, or the
symbol and the statement may also appear in the service documentation and in the
training program. When this symbol appears, the service representative is warned that
conditions exist that could result in exposure to the laser beam.
CAUTION
Do not store the Toner, the Developer, or the Drum in the service vehicle.
Disconnecting and Reconnecting Electrical Connectors.

CAUTION
WARNING
Disconnecting and reconnecting electrical connectors while power is On can cause damage
to PWBs and other electrical components. Always switch OFF power before disconnecting or
reconnecting electrical connectors.
Do not try to bypass any laser interlocks for any reason. Permanent eye damage could
result if the laser is accidentally directed into your eye.
Figure 1 Laser Hazard Symbol

Laser Hazard Statement
DANGER INVISIBLE LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO
BEAM.
CAUTION
The use of controls or adjustments other than those specified in the Laser Safety Training Program may result in an exposure to dangerous laser radiation.
For additional information, review the Laser Safety Training program.
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Introduction
About This Documentation
Organization
This Service Manual is part of the multinational documentation system for the DocuColor 12/
DCCS50 Machine. This manual will help in the isolation and repair of faults that may occur in
the machine.
In printed form, this publication is divided into ten sections, which are described below. The
electronic format is also divided into the same ten sections for editing purposes; however,
these sections are rarely apparent to the user. For ease of access, the information contained in
the principles of operation, installation, and training are electronically integrated.
Section 1. Service Call Procedures

This section contains the following:
Call Flow
Initial Actions
Repair Actions
Detailed Maintenance Activities
Cleaning Procedures
Final Actions
Service Log
Call Flow
Call Flow is a summary of the sequence of the major activities of the service call procedures.
Initial Actions
The purpose of the Initial Actions is to gather information about the service call and the condition of the machine and to classify the information.
Repair Actions
This is the overall procedure to diagnose and repair problems.
This section provides the information needed for the High Frequency Service Items (HFSI).
Cleaning Procedures
This section provides the information needed to clean the DocuColor 12/DCCS50.
Final Actions
The Final Actions are intended to ensure that the DocuColor 12/DCCS50 is operating correctly
and is in good condition when it is returned to the customer.
Service Log
A master Service Log sheet is provided to be copied and used by the service representative.
Section 2. Status Indicator Repair Analysis Procedures (RAPs)

This section contains the Repair Analysis Procedures (RAPs) necessary to repair the faults
other than the image quality faults. When using a RAP, always exit the procedure when the fault
is fixed. Do not perform the remaining steps.
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Section 3. Image Quality Repair Analysis Procedures (IQ RAPs)

This section contains the Repair Analysis Procedures (RAPs) necessary to repair the image
quality faults. When using a RAP, always exit the procedure when the fault is fixed. Do not perform the remaining steps.
Section 4. Repairs and Adjustments

This section contains the repair and adjustment procedures for the DocuColor 12/DCCS50.
Section 5. Parts List

This section contains the detailed Parts List for the DocuColor 12/DCCS50.
Section 6. General Procedures

This section contains General Procedures, Diagnostic Procedures, Product Specifications, and
Tools and Supplies information.
Section 7. Wiring Data

This section contains the Plug/Jack Listings, Plug/Jack Location Drawings, PWB Location Diagrams, Power Distribution Wirenets, and the Block Schematic Diagrams (BSDs).
NOTE: Chain 1 of the BSDs shows the generation of power. The Power Distribution Wirenets
show how the power is distributed to the machine.
Section 8. Accessories / Options

This section contains a separate service document for each of the accessories. The service
representative will be directed to Section 8 from the main service documentation when it is
appropriate.
Section 9. Installation and Removal

This section contains instructions for installation of the machine at the customers site. It also
contains instructions for repacking and removal when appropriate.
Section 10. Principles of Operations

This section contains information on how the machine operates.
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Reference Symbology
Figure 1 General Information
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AC and DC Voltage Nomenclature
Translated WARNINGS
ACH is used in the documentation to designate the hot, or power, side of the AC line. The voltage level on this line depends upon the local AC power supplied to the machine.
WARNING
For some installations, (typically Xerox Europe), the ACN line may NOT be neutral. It
may have power applied. Check local power standards.
ACN is used in the documentation to designate the neutral side of the AC line. The voltage
level on this line depends upon the local AC power supplied to the machine.
DC Voltage Levels
DC voltages should be measured between the test point and the machine frame, unless
instructed otherwise. The table below shows the values of the voltages.
Table 1 DC Voltage Levels
Nominal
Voltage
Logic State
Actual Voltage Ranges
+5 VDC
+4.5 to +5.3 VDC
0.0 to +1.0 VDC
+3.0 to +4.2 VDC
0.0 to +1.0 VDC
+10.0 to +13.2 VDC
0.0 to +1.5 VDC
-10.0 to -13.2 VDC
0.0 to -1.5 VDC
+11.0 to +14.2 VDC
0.0 to +1.5 VDC
+22.0 to +25.7 VDC
0.0 to +3.0 VDC
+3.5 VDC
+12 VDC
-12 VDC
+13.3 VDC
+24 VDC
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Publication Information
WARNING
WARNING
Do not try to bypass any laser interlocks for any reason. Permanent eye damage could
result if the laser is accidentally directed into your eye.
This equipment generates, uses and can radiate radio frequency energy, and if not
installed and used in accordance with the instructions documentation, may cause interference to radio communications. It has been tested and found to comply with the limits
for a Class A computing device pursuant to subpart J of part 15 of FCC rules, which are
designed to provide reasonable protection against such interference when operated in a
commercial environment. Operation of this equipment in a residential area is likely to
cause interference in which case the user, at his own expense, will be required to correct the interference.
DANGER: Ne pas essayer de shunter les contacts de scurit laser, quelle que soit la
raison. Si le faisceau laser est dirig accidentellement vers les yeux il peut en rsulter
des lsions oculaires permanentes.
AC and DC Voltage Nomenclature
WARNING
For some installations (typically Xerox Europe), the ACN line may NOT be neutral. It may
have power applied. Check local power standards.
DANGER: Cet quipement gnre, utilise et peut mettre des frquences radio, et, s'il
n'est pas install et utilis selon les recommandations du manuel d'instructions, peut
causer des interfrences aux communications radio. Il a t test et jug conforme aux
limites des systmes de catgorie A, conformment la partie 15 de l'alina J des rglements FCC, tablis pour protger contre de telles interfrences pendant le fonctionnement en milieu commercial. Dans une zone rsidentielle, il peut causer des
interfrences; dans ce cas, l'utilisateur devra corriger le problme ses propres frais.
DANGER: Lors de certaines installations (particulirement en Europe), le neutre peut

avoir une faible tension (10 20 volts). Vrifier l'alimentation client.
3 Image Quality RAPs

Image Quality RAPs
IQ 5 Xerographic Subsystem Checkout Procedure
Introduction
WARNING
Introduction
Electrocution Hazard! Do not disconnect the red lead labeled \nC (Charge Supply Wire).
This wire carries over 8000VDC.
WARNING
DANGER: Risque d'lectrocution! Ne pas dconnecter le fil rouge identifi \nC (fil d'alimentation de charge). Une tension de plus de 8000 VCC est prsente.
The DocuColor 12/DCCS50 contains an invisible laser. There is no visual indication that
the laser beam is present. During servicing, the DocuColor 12/DCCS50 is a Class 3B
product because of the invisible laser. the laser beam could cause eye damage if looked
at directly. Service procedures must be followed exactly as written without change. The
service representative must observe the established local laser safety precautions
when servicing the DocuColor 12/DCCS50. Do not place tools with a reflective surface
in the area of the Charge Corotron or the ROS opening. Do not look in the area of the
Charge Corotron or the ROS window if the power is On and the laser is energized with
the Toner Cartridge Unit removed.
IQ 37 Developer Bias HVPS RAP
WARNING
Electrical Shock Hazard. In the following procedure, high DC voltage circuits will be
tested. Use extreme caution when testing these circuits. Do not touch the multimeter or
the meter leads while testing the circuits.
DANGER: Risque de choc lectrique. Dans la procdure suivante, des circuits de haute
tension CC doivent tre tests. Faire trs attention en vrifiant ces circuits. Ne pas
toucher le multimtre ou ses fils pendant les tests des circuits.
DANGER: DocuColor 12/DCCS50 contient un faisceau laser invisible et aucune indication visible signale la prsence du faisceau laser. De ce fait le produit est class 3B pour
tout ce qui concerne la maintenance. L'exposition directe des yeux au faisceau laser
peut entraner des lsions visuelles. Les procdures de maintenance doivent tre ralises sans aucun changement comme indiqu dans la documentation. Le reprsentant
Xerox lors d'interventions sur DocuColor 12/DCCS50 doit respecter les consignes de
scurit locales concernant les faisceaux laser. Ne pas placer d'objet rflchissant dans
la zone du corotron de charge ou de la fentre du ROS. Ne pas intervenir dans la zone
du corotron de charge ou de la fentre du ROS lorsque la machine est sous tension et
que le laser est en fonctionnement quand le module cartouche toner est enlev.
IQ 38 Charge Corotron HVPS RAP
WARNING
The following symbol and statement appear on a label in the machine when the Toner
Cartridge Cover or the Toner Cartridge Unit are removed. The symbol by itself, or the
symbol and the statement may also appear in the service documentation and in the
training program. When this symbol appears, the service representative is warned that
conditions exist that could result in exposure to the laser beam.
IQ 39 Preclean Corotron HVPS RAP
WARNING
DANGER: Ces symboles et instructions sont indiqus sur des tiquettes dans la
machine quand la cartouche toner ou le module toner est retir. Dans la documentation
technique et dans le manuel de formation ces informations sont indiques. Quand ce
symbole s'affiche le reprsentant Xerox est prvenu des risques encourus concernant
une exposition au rayon laser.
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DANGER: Mettre la machine sur Arrt et dbrancher le cordon d'alimentation.

2. PAPER TRANSPORT
IQ 40 2nd BTR HVPS RAP

REP 2.1.1 Tray 1 Set Sensor
WARNING
WARNING
Turn the power off and disconnect the power plug.

REP 2.1.2 Tray 2/3/4 Size Sensor
WARNING
IQ 41 1st BTR HVPS RAP
Turn power off and disconnect the power plug.

WARNING
REP 2.4.1 Tray 1/2/3/4 Feeder
Failure to operate ALL the dC330 output components listed below will result in permanent damage to the photoreceptor.
WARNING
DANGER: dfaut de faire fonctionner TOUS les lments de sortie dC330 numrs cidessous, le photorcepteur sera endommag dfinitivement.

4 Repairs and Adjustments
REP 2.5.1 Tray 1/2/3/4 Feed/Nudger Roll Assembly
REPAIRS
1. DRIVE
WARNING
REP 1.3.1 Belt (Developer Drive)
WARNING
REP 2.6.1 Feed Lift Motor
WARNING
REP 1.4.1 Belt (2nd BTR, Auger)
WARNING
REP 2.6.2 Retard Roll
WARNING
REP 1.5.1 Tray 5/Regi. /Tray 1 Take Away Drive
WARNING
REP 2.7.1 Tray 2-4 Take Away Drive
WARNING
REP 1.6.1 Exit Drive
WARNING
REP 2.7.2 Tray 2/3/4 Feed T/A Clutch
WARNING
REP 1.6.2 Fuser Drive
WARNING
REP 2.7.3 T/A Motor

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WARNING
WARNING
REP 2.8.1 Tray 1 Feed-out Sensor, T/A Sensor
REP 2.15.2 Regi. Roll
WARNING
WARNING
REP 2.8.2 Tray 2/3/4 Feed-out Sensor
REP 2.15.3 Regi. Motor
WARNING
WARNING
REP 2.9.1 Tray 5
REP 2.16.1 Pre Regi. Sensor
WARNING
WARNING
REP 2.11.1 Tray 5 Nudger Roll
REP 2.16.2 Pre Regi. Roll
WARNING
WARNING
REP 2.11.2 Tray 5 Feed Roll
REP 2.17.1 Vacuum Transport
WARNING
WARNING
REP 2.12.1 Tray 5 Lift Motor
REP 2.17.2 Vacuum Transport Belt
WARNING
WARNING
REP 2.12.2 Tray 5 Retard Roll
REP 2.21.1 Duplex Path Sensor
WARNING
WARNING
REP 2.14.1 Regi. Unit
REP 2.21.2 Duplex Out Sensor
WARNING
WARNING
REP 2.15.1 Regi. Sensor
REP 2.21.3 Duplex Belt 1/2
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WARNING
REP 3.3.1 Carriage Cables
WARNING
Turn power off disconnect the power plug.
REP 2.23.1 Inverter 1
WARNING
REP 3.3.2 Carriage Motor
WARNING
WARNING
REP 3.4.1 Exposure Lamp
WARNING
REP 2.24.1 Inverter Motor
WARNING
REP 3.4.2 Lamp Wire Harness
WARNING
REP 2.24.2 Release Solenoid
WARNING
REP 3.5.1 IPS Chassis
WARNING
REP 2.26.1 Exit Roll
WARNING
4. ROS
REP 4.1.1 ROS

3. IIT
WARNING
REP 3.1.1 Platen Glass
WARNING
5. XEROGRAPHICS
REP 5.1.1 Erase Lamp

REP 3.1.2 IIT Opening/Closing
WARNING
WARNING
REP 5.3.1 Drum Unit

REP 3.2.1 CCD PWB
WARNING
WARNING
REP 5.3.3 Cleaning Brush

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WARNING
REP 6.1.4 Bias Brush
WARNING
REP 5.3.4 Cleaning Blade
WARNING
REP 6.2.1 Toner Cartridge Unit
WARNING
REP 5.4.1 Charge Corotron
WARNING
REP 6.3.1 Toner Cartridge Housing (Cyan, Magenta, Yellow, Black)
WARNING
REP 5.4.2 PCC Wire
WARNING
REP 6.3.2 Cartridge/Dispense Motor (Cyan, Magenta, Yellow, Black)
WARNING
REP 5.5.1 Waste Toner Auger
WARNING
REP 6.4.1 Dispense PWB
WARNING
REP 5.5.2 Auger Belt
WARNING
REP 6.6.1 Development Housing
WARNING
6. DEVELOPMENT
WARNING
REP 6.1.1 Rotary PWB
Do not put the Developer or Developer Unit into a fire. If the Developer or Developer Unit
is placed into a fire, it may explode and cause injury.
WARNING
DANGER: Ne pas brler du dveloppeur ou le module dveloppeur. Si du dveloppeur

ou un module dveloppeur est brl, il y a des risques d'explosion et d'accidents corporels.

REP 6.1.2 Rotary Home Position Sensor
REP 6.6.2 Developer Replacement
WARNING
WARNING
Switch off the power and disconnect the power cord.

REP 6.1.3 Rotary Latch Lever
WARNING
WARNING
DANGER: Ne pas brler du dveloppeur ou le module dveloppeur. Si du dveloppeur
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WARNING
ou un module dveloppeur est brl, il y a des risques d'explosion et d'accidents corporels.
REP 6.7.1 Rotary Auger (Cyan, Magenta, Yellow, Black)

REP 7.6.4 Contact Roll
WARNING
WARNING
REP 6.7.2 Trickle Auger

REP 7.9.1 2nd BTR
WARNING
WARNING
7. IBT

REP 7.10.1 2nd BTR Roll
REP 7.1.1 IBT
WARNING
WARNING
8. FUSER
REP 7.1.2 IBT Cleaner
REP 8.1.1 Fuser Unit
WARNING
WARNING
WARNING
Do not put the IBT Cleaner into a fire. If the IBT Cleaner is placed into a fire, it may
explode and cause injury.
REP 8.2.1 Donor Roll Assembly
WARNING
DANGER: Ne pas brler le systme de nettoyage IBT. Si le systme de nettoyage IBT est
brl, il y a des risques d'explosion et d'accidents corporels.
REP 7.5.1 IBT Belt

REP 8.3.1 Heat Roll
WARNING
WARNING
REP 7.6.1 Bias Roll

REP 8.3.2 Heat Roll Heater Rod
WARNING
WARNING
REP 7.6.2 Drive Roll

REP 8.3.3 Pressure Roll
WARNING
WARNING
REP 7.6.3 Back-up Roll

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REP 8.3.4 Pressure Roll Heater Rod

WARNING
REP 9.2.2 IOT Drive PWB
WARNING

REP 8.3.5 Heat Roll Stripper Finger

WARNING
REP 9.2.3 Half-tone PWB
WARNING

REP 8.4.1 Web Motor/EXT-HR Retract Motor

WARNING
REP 9.3.1 Power Chassis
WARNING

REP 8.7.1 Oil Pump

WARNING
REP 9.3.2 IOT LVPS
WARNING

REP 8.7.2 Oil Wick

WARNING
REP 9.3.3 Printer B3H LVPS [AP Only]
WARNING

REP 8.8.1 External H/R Heater Rod

WARNING
REP 9.5.1 Control Panel
WARNING

REP 8.8.2 External Heat Roll

WARNING
10. AIR SYSTEM

REP 10.2.1 Fuser Fan

REP 8.10.1 Pressure Roll Stripper Finger
WARNING
WARNING
REP 10.2.2 Blower Suction
9. ELECTRICAL
WARNING
REP 9.2.1 Opening/Closing the IOT Control PWB Chassis

WARNING
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REP 11.1.1 Platen Cushion
REP 12.4.3 Feed Roll
WARNING
WARNING
12. DADF
REP 12.5.1 Document Feed Lower Chute
WARNING
REP 12.1.1 DADF
WARNING
WARNING
WARNING
The DADF is heavy (37.5lbs). Take care to avoid injury when handling the DADF.
DANGER: Le Chargeur de Documents est lourd (17kg). Le manipuler avec prcaution

afin d'viter tout risque d'accident.

REP 12.5.3 Set Gate Solenoid
REP 12.2.2 Registration Gate Solenoid
WARNING
WARNING
REP 12.5.4 Registration Sensor
REP 12.3.1 Left/Right Counter Balance
WARNING
WARNING
REP 12.5.5 Size Sensors 1/2 (Rear/Front)
WARNING
WARNING
DANGER: Le Chargeur de Documents est lourd (17kg). Le manipuler avec prcaution
afin d'viter tout risque d'accident.
REP 12.3.2 DADF Control PWB
REP 12.6.1 DADF Belt Motor
WARNING
WARNING
REP 12.4.1 Feed Motor
REP 12.7.1 Duplex Sensor
WARNING
WARNING
REP 12.4.2 Nudger Roll
REP 12.8.1 Registration Pinch Roll
WARNING
WARNING
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REP 12.9.1 Exit Motor

WARNING
14. OCT

REP 14.1.1 Offset Motor

REP 12.10.1 Platen Belt
WARNING
WARNING
ADJUSTMENTS
13. MAIL BOX SORTER
3. IIT
REP 13.3.1 Decurler
ADJ. 3.4.1 FULL RATE/HALF RATE CARRIAGE POSITION
WARNING
WARNING
TURN POWER OFF AND DISCONNECT THE POWER PLUG.
DANGER: METTRE LA MACHINE SUR ARRT ET DBRANCHER LE CORDON D'ALIMENTATION.
REP 13.5.1 Vertical LED/Sensor
6. DEVELOPMENT
WARNING
ADJ 6.6.1 ROTARY DEVELOPMENT HOUSING POSITION

WARNING
REP 13.5.2 Bin Tray 1

WARNING
12. DADF

REP 13.6.1 Bin Trays 2 - 10
ADJ 12.3.1 LEFT/RIGHT COUNTER BALANCE
WARNING
WARNING
REP 13.13.1 Decurler Rolls 1/2
ADJ 12.3.2 DADF PARALLELISM
WARNING
WARNING

REP 13.13.2 Gear and Cam
WARNING
ADJ 12.3.3 DADF HEIGHT
WARNING
REP 13.14.1 Decurler Stepping Motor
WARNING
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8 Accessories/Options
WARNING
HCF
To avoid electrical shock, switch-OFF the Main Power Switch and disconnect the Power
Cord.
REP 2.7.5 HCF Assembly
DANGER: Afin d'viter tout risque d'lectrocution, mettre la machine sur Arrt et
dbrancher le cordon d'alimentation.
WARNING
REP 2.8.35 HCF Front/Rear Spring
Cord.
WARNING
Cord.
REP 2.7.6 HCF Elevator Motor
WARNING
REP 2.8.36 HCF Baffle Assembly
Cord.
WARNING
Cord.
REP 2.7.7 HCF Elevator Long/Short Cables
WARNING
REP 2.8.37 HCF Feed Belt
Cord.
WARNING
Cord.
REP 2.7.8 HCF Brake
WARNING
REP 2.8.38 HCF Feed/Nudger/Retard Rolls
Cord.
WARNING
Cord.
REP 2.7.9 HCF Control PWB
WARNING
REP 2.8.39 HCF One-Way Feed/Gear Clutch
Cord.
WARNING
Cord.
REP 2.8.26 HCF Feed Motor
WARNING
REP 2.8.40 HCF Friction Clutch
Cord.
WARNING
Cord.
REP 2.8.27 HCF Feeder Assembly
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WARNING

REP 2.8.41 HCF Feed Clutch
To avoid personal injury or shock, disconnect the Finisher cable connector. Switch off
the machine power and disconnect the Machine Power Cord.
WARNING
DANGER: Afin d'viter des accidents ou une lectrocution, dbrancher la prise du module de finition. Mettre la machine sur Arrt et dbrancher le cordon d'alimentation.
Cord.
REP 15.1.5 Entrance Lower Chute and Pinch Roll
WARNING
REP 2.8.42 HCF TAR Sensor
WARNING
Cord.
REP 15.1.6 Exit Lower Baffle and Pinch Roll
WARNING
REP 2.8.43 HCF Tray Empty/Stack Height Sensors
WARNING
Cord.
REP 15.1.7 Decurler PWB
WARNING
FINISHER
REP 15.1.1 Decurler
WARNING
REP 15.1.8 Cam Drive Shaft
WARNING
REP 15.1.2 Decurler Rolls 1 and 2
WARNING
To avoid personal injury or shock, disconnect the Finisher Cable Connector. Switch off
REP 15.1.9 Torque Limiter Gear and Stopper
WARNING
REP 15.1.3 Reflector and Cam
WARNING
REP 15.1.10 Decurler Drive Roll 2
WARNING
REP 15.1.4 Decurler Stepper Motor
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ule de finition. Mettre la machine sur Arrt et dbrancher le cordon d'alimentation.
WARNING
REP 15.1.18 SCT Static Eliminator
WARNING
REP 15.1.12 Decurler Entrance Roll
WARNING
REP 15.1.19 SCT Exit Sensor
WARNING
REP 15.1.13 Decurler Exit Roll
WARNING
REP 15.1.20 SCT Pinch Roll
WARNING
REP 15.1.14 Entrance Upper Baffle and Pinch Roll
WARNING
REP 15.1.21 Finisher Transport Roll 1
WARNING
REP 15.1.15 Finisher Transport Motor
WARNING
WARNING
REP 15.1.16 Finisher Drive Belt
WARNING
REP 15.2.1 Compiler Tray Solenoid
WARNING
the machine power and disconnect the machine Power Cord.
REP 15.1.17 Single Catch Tray (SCT) Assembly
WARNING
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Introduction
REP 15.2.2 Stacker Tray Assembly

WARNING
REP 15.2.10 Stacker Tray
WARNING
REP 15.2.4 Stacker Full Sensors
WARNING
REP 15.2.11 Tamper Motor
WARNING
REP 15.2.5 Stacker Upper and Lower Limit Sensors
WARNING
REP 15.2.12 Tamper Home Sensor
WARNING
REP 15.2.6 Stacker Tray Paper Sensor
WARNING
REP 15.2.13 Compiler Paper Sensor
WARNING
REP 15.2.7 Stacker Motor
WARNING
REP 15.2.14 End Wall Open Sensor
WARNING
REP 15.2.8 Lower Exit Chute Assembly
WARNING
REP 15.2.15 Tamper Motor Drive Belt
WARNING
REP 15.2.9 Stacker Tray Drive Belts
WARNING
Introduction
REP 15.2.16 End Wall Motor
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WARNING

REP 15.2.23 Eject Pinch Roll Shaft Assembly
WARNING
REP 15.2.17 Eject Clamp Sensor
WARNING
REP 15.2.24 Upper Exit Chute Assembly
WARNING
REP 15.2.18 Stacker Offset Home Sensor
WARNING
WARNING
REP 15.2.19 Eject Bracket Assembly
WARNING
REP 15.2.26 Compiler Paddle Shaft Assembly
WARNING
REP 15.2.20 Eject Paddle Motor and Drive Belt
WARNING
REP 15.2.27 Paddle Drive Belt
WARNING
REP 15.2.21 Eject Shaft Assembly
WARNING
REP 15.2.28 Stacker Height Sensor
WARNING
REP 15.2.22 Compiler Cover Assembly
WARNING
REP 15.2.29 Unload While Run Switch
WARNING
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Introduction
REP 15.3.3 Stapler Cover Assembly
WARNING
REP 15.2.30 Compiler Entrance Sensor
WARNING
REP 15.3.4 Decurler Door Assembly
WARNING
REP 15.2.31 Eject Paddle Home Sensor
WARNING
REP 15.3.5 Mailbox Door Assembly
WARNING
REP 15.2.32 Eject Motor
WARNING
REP 15.3.6 Left Lower Cover
WARNING
REP 15.2.33 Eject Clamp/Offset Motor
WARNING
REP 15.3.7 Rear Upper Cover
WARNING
REP 15.3.1 Finisher
WARNING
REP 15.3.8 IOT Connector Cover
WARNING
REP 15.3.2 Stapler Door Assembly
WARNING
REP 15.3.9 Finisher PWB Cover
WARNING
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WARNING

REP 15.3.10 Left Upper Cover
WARNING
REP 15.3.17 Stapler Position Sensors
WARNING
REP 15.3.11 Top Cover
WARNING
REP 15.3.18 Stapler Rail Belt
WARNING
REP 15.3.12 Decurler Top Cover
WARNING
REP 15.3.19 Stapler Position Motor
WARNING
REP 15.3.13 Decurler Rear Cover
WARNING
REP 15.3.20 Mailbox Drive Motor
WARNING
REP 15.3.14 Decurler Inner Cover
WARNING
REP 15.3.21 Mailbox Drive Belt
WARNING
REP 15.3.15 Rear Lower Cover
WARNING
REP 15.3.23 Docking Interlock Switch
WARNING
REP 15.3.16 Stapler Assembly
DANGER: Afin d'viter des accidents ou une lectrocution, dbrancher la prise du mod-
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Introduction
REP 15.3.25 Decurler Door Interlock Switch
WARNING
WARNING
REP 15.3.28 Finisher PWB
9 Installation
WARNING
High Capacity Feeder (HCF) Installation
WARNING
The underside of the HCF has very sharp edges! Use caution when adjusting.
REP 15.3.29 Finisher PWB EPROM
DANGER: La partie infrieure du magasin grande capacit (HCF) a des bords trs
coupants! Faire trs attention lors de rglages dans cette zone.
WARNING
Foreign Interface Install Instructions
WARNING
Power-OFF the machine and disconnect the Power Plug.
REP 15.3.30 Vertical LED and Sensor
WARNING
10 Principles of Operation
12. Finisher
Finisher Power Components
WARNING
In the undocked condition, +24VDC to the finisher is NOT interrupted.

DANGER: Avec les modules spars, le +24VCC au module de finition N'EST PAS
coup.
WARNING
REP 15.3.32 Bin Trays 2 - 10
WARNING
ADJ 15.3.1 Staple Position Adjustment
WARNING
Introduction
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1 Service Call Procedures

Service Strategy .............................................................................................................
Initial Actions ...................................................................................................................
Call Flow .........................................................................................................................
Detailed Maintenance Activities (HFSI)...........................................................................
Cleaning Procedures.......................................................................................................
Final Actions....................................................................................................................
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Service Call Procedures
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Service Strategy
Initial Actions
The service strategy of the DocuColor 12 copier/printer is to perform any High Frequency Service Item (HFSI) actions before attempting to repair any problems. Some problems will be corrected by this strategy without the need to diagnose them. The Repair Analysis Procedures
(RAPs) will be used for any remaining problems.
Purpose
The purpose of the Initial Action section of the Service Call Procedures is to determine the reason for the service call and to identify and organize the actions which must be performed.
Procedure
Problems that occur in the BASIC COPIER mode will be repaired before problems that occur
when using the accessories.
1.
Gather the information about the service call and the condition of the copier/printer.
a.
Question the operator(s). Ask about the location of most recent paper jams. Ask
about the image quality and the copier/printer performance in general, including any
unusual sounds or other indications.
b.
Check that the power cords are in good condition, correctly plugged in the power
source, and free from any defects that would be a safety hazard. Ensure that the
connector for the IDFE Wiring Harness is properly connected. Repair or replace the
power cords as required. Check that the circuit breakers are not tripped.
c.
Inspect any rejected copies. Inquire as to, or otherwise determine, the paper quality
and weight. The specified paper for optimum image quality with the DocuColor 12
copier/printer is 24# Xerox COLOR Xpressions (NASG), or Colotech + 90 gsm
(ESG). Look for any damage to the copies, oil marks, image quality defects, or other
indications of a problem.
Image Quality problems will be repaired after all other problems are repaired.

The Service Call Procedures are a guide for performing any service on the DocuColor 12
copier/printer. The procedures are designed to be used with the DocuColor 12 Service Manual.
Perform each step in order.
The Service Call Procedures contain the following sections:
Initial Actions
The Initial Actions gather information about the condition of the copier/printer and the problem
that caused the service call.
Call Flow
d.
Record the billing meter readings.
e.
Enter the Diagnostics Mode. Go to the Dark Screen RAP IN SECTION 2 if the Diagnostic Mode can not be entered. Return here after repairing the Diagnostics entry
problem.
Call Flow summarizes the sequence of the Service Call Procedures.
NOTE: If a Fault Code is displayed while performing a Diagnostics Procedure, go to

that Fault Code RAP and repair the fault. Return to Diagnostics and continue with
the DC Procedure that you were performing.

This section provides the information needed to perform the DC135 High Frequency Service
Item (HFSI) actions.
f.
Go to DC135 HFSI Table and determine what HSFI action is required based on the
customer output volume. Refer to the Detailed Maintenance Activities section for the
detailed HSFI information. Record any items that require action.
g.
Select the History File. Display and record the information in the Fail History, Jam
History, Fail Counter, and Jam Counter. Classify this information into categories:
Cleaning Procedures
This section provides the information needed to clean some components of the copier/printer.
Final Actions
The Final Actions test the copier/printer and return it to the customer. Administrative activities
are also performed in the Final Action.
Information that is related to the problem that caused the service call.
Information that is related to secondary problems.
Information that does not require action, such as a single occurrence of a problem.
h.
Check the Service Log for any recent activities that are related to the problem that
caused the service call or any secondary problem.
2.
Perform any required HSFI activities. Refer to the Detailed Maintenance Activities section.
3.
Exit diagnostics. Try to duplicate the problem by running the same type jobs, as the customer was running.
4.
Check the image quality in the BASIC COPIER MODE. Select the tray that is loaded with
11 X 17 or A3 paper. If unable to complete this step, go to step 5.
a.
Set the copier/printer controls:

Output Color to Auto
Original Type to Photo and Text Halftone
Reduce/Enlarge Auto
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Service Strategy , Initial Actions
Call Flow
Lighter/Darker to Auto Contrast

Sharpness to Normal
This procedure should be performed at every service call.
Preset Color Balance Normal

Color Shift to Normal
Procedure
Color Saturation to Normal
The machine is a DC12 Printer.

Y
N
Place the Color Test Pattern on the Document Glass. Make a copy from each paper tray.
The Copier/Printer can copy from all trays.
Y
N
Copy Position to No Shift

Variable Color Balance Normal
b.
Run four copies of the Color Test Pattern.
c.
Check the image quality. If the customer has identified any Image Quality Defects or
problems, Go to IQ 1 Image Quality Troubleshooting Entry RAP.
5.
If there is a problem in the BASIC COPIER MODE, go to the Call Flow.
6.
For DC12 with a Digital Front End (DFE): if there is a problem associated with the DFE or
Print mode, refer to the service documentation for the installed DFE.
NOTE: Not all fault codes can be displayed on the UI. Connect the PWS and launch
the DC12 diagnostic tool to ensure that any fault code is displayed. Some codes will
appear only the Last 40 Faults list.
A fault code is displayed.
Y
N
Go to the GP 4 Intermittent Problem RAP.
For DCCS50: if there is a problem associated with the DFE or Print mode, go to the
OF19-1 IDFE Fault Entry RAP.
7.
If there are no problems in the BASIC COPIER MODE, go to Final Actions.
NOTE: Most RAPs are in Section 2, but the RAPs for Accessories are located in
Section 8. Sorter fault code appear in both sections; the Chain 11 RAPs in Section
8 are for the Sorter bins of the optional Finisher - be sure to select the correct
RAP when troubleshooting Chain 11 faults.
Go to the RAP for the displayed fault code.
Place two originals into the DADF and program a duplex job. The Copier/Printer can
copy from the DADF
Y
N
Y
N
The problem is with jam recovery.
Y
N
Check the DADF Document Sensors for debris or damage. Check the
document mechanical drives and Feed Rolls for contamination, wear,
damage, or binding.
.Go to the OF5-1 DADF Jam Recovery RAP.
Check for installed Accessories (Foreign Interface, Edit Pad, EPC, Finisher, Convenience
Stapler, or HCF). Check for correct operation. The Accessories function correctly.
Y
N
Y
N
For Foreign Interface problems go to the 3-333 Foreign Interface RAP.
A
Initial Actions, Call Flow
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For Stapler problems go to the ST-1 Convenience Stapler RAP.
For EPC failures, go to the OF3-1, Fault Entry RAP.
For Edit Pad problems, go to the 02-282 Edit Pad PWB Communication
Fail RAP.
C
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C
Go to the RAP in Section 8 for the displayed fault code.
The Image Quality of the copies produced is acceptable.

Y
N
Go to the IQ 1 Image Quality Troubleshooting Entry RAP.
The machine is a DCCS50 or a DC12 C/P with DFE.
Y
N
Go to Final Actions
Send a simple print job. The Copier/Printer produces acceptable prints.
Y
N
For DC12 with a Digital Front End (DFE): refer to the service documentation for the
installed DFE.
For DCCS50: go to the OF19-1 IDFE Fault Entry RAP.
Go to Final Actions
The Printer can print from all trays.
Y
N
Connect the PWS. Print test pattern 99. The test pattern can be printed
Y
N
NOTE: Not all fault codes can be displayed on the UI. Connect the PWS and launch
the DC12 diagnostic tool to ensure that any fault code is displayed. Some codes will
appear only the Last 40 Faults list.
Y
N
Go to the GP 4 Intermittent Problem RAP.
NOTE: Most RAPs are in Section 2, but the RAPs for Accessories are located in
Section 8. Sorter fault code appear in both sections; the RAPs in Section 8 are for
the Sorter bins of the optional finisher - be sure to select the correct RAP when troubleshooting Chain 11 faults.
Refer to the service documentation for the installed DFE. If this does not resolve the problem, check the DDI Cables. and VSEL PWB for loose or damaged connectors.
Check for installed Accessories (Finisher, Convenience Stapler, or HCF). Program jobs to
check for correct operation. The Accessories function correctly.
Y
N
Go to the RAP in Section 8 for any displayed fault code.
For Convenience Stapler problems go to the ST-1 Convenience Stapler RAP.
The Image Quality of the prints produced is acceptable.
Y
N
Go to the IQ 1 Image Quality Troubleshooting Entry RAP.
Go to Final Actions
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Call Flow
Detailed Maintenance Activities (HFSI)
4.
Perform the Service Action in Table 1 for High Frequency Service Item (HFSI) counters
that are over threshold or approaching the threshold. Using the customer's output volume
numbers (high, medium, or low volume), evaluate which HFSI actions should be accomplished now to avoid an additional service call in the near future.
5.
Refer to Cleaning Procedures for detailed cleaning instructions.
Procedure
1.
Clean the ADC Sensor (PL 7.5) on every call.
2.
Check Developer Housings for loose bearings or worn shaft at every service call
3.
Enter Diagnostics and select dC 135.

Table 1 HFSIs
ChainLink
Component
Increment Criteria
Threshold
Service Action Required
006-801 Counter only
Feed Count
-1
No service required - counter only
006-802 Counter only
Scan Count
-1
No service required - counter only
007-800 HCF Feed Counter
Total feeds from HCF
100K
Replace the HCF Feeder Nudger Assembly (PL 15.14) and Retard Assembly (PL 15.15). Reset
the counter.
008-801 Tray 1 Feed Roll
Total feeds from Tray 1
300K
Replace the Feed/Nudger Roll Assembly (PL 2.5) and Retard Assembly (PL 2.6). Reset the
counter.
300K
counter.
300K
counter.
300K
counter.
80K
counter.
008-825 Duplex Aligner Roll
Total feeds from Duplex
9999K
Run-to-failure
009-805 IBT Belt: CV, PV
Total A4/LTR LEF copies (larger paper = 2 counts) 120K
Replace the IBT Belt (PL 7.5). Reset this counter and counter 009-806.
009-806 IBT Belt: Cycle
Total IBT Belt revolutions
Replace the IBT Belt (PL 7.5). Reset this counter and counter 009-805.
009-807 1st BTR
Run-to-failure
009-808 Back Up Roll
Run-to-failure
009-809 2nd BTR Unit
Replace the 2nd BTR (PL 7.9). Reset the counter.
009-812 CC Assy
Discharge time (0.1 hr./count)
009-819 Transfer Trim
660K
NOTE: Perform GP 20 2nd BTR Service Procedure at 100K intervals
009-823 Bracket Assembly - Oil
9999K
This location does not automatically reset when CRU is replaced -DISREGARD
Clean inside of Transfer Module and reset the counter.
9999K
No longer used - DISREGARD
009-835 Belt Cleaner Blade
Run-to-failure
009-838 Drive Roll Cleaner
Run-to-failure
009-841 Ozone Filters
Each color pass (4C = 4, B/W = 1)
320K
Replace both Ozone Filters (PL 10.2) and reset the counter.
009-843 Suction Filter
320K
Replace the Suction Filter (PL 10.2) and reset the counter.
009-846 CC Dust Filter
9999K
009-850 Developer Housing - K
Developer Motor ON time (0.1 hr./count)
1000
Replace Developer Housing (PL 6.6).
009-851 Developer Housing - Y
1000
009-852 Developer Housing - M
1000
009-853 Developer Housing - C
1000
009-880 Trickle Bottle
Dispense Motor ON time (0.01 hr./count)
200
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Table 1 HFSIs
ChainLink
Component
Increment Criteria
Threshold
Service Action Required
010-800 Heat Roll
Total sheets through Fuser
80K
Replace the Heat Roll (PL 8.3) and reset the counter.
010-802 Pressure Roll
80K
Replace the Pressure Roll (PL 8.3) and reset the counter.
010-803 External Heat Roll
80K
Replace the External Heat Roll (PL 8.8) and reset the counter.
010-811 Oil System
80K
Replace the Oil System Kit (PL 8.2). Reset this counter and counter 010-814.
010-814 Fuser Wick
80K
Replace the Fuser Wick (PL 8.7) and reset the counter.
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Cleaning Procedures
Final Actions
Purpose
Purpose
These cleaning procedures are to be performed at every call.
The intent of this procedure is to be used as a guide to follow at the end of every service call.
Procedure
Procedure
CAUTION
Do not use any solvents unless directed to do so by the Service Manual.
1.
Reset the History File.
2.
Ensure that the exterior of the copier/printer, IDFE and the adjacent area are clean. Use a
dry cloth or a cloth moistened with water to clean the copier/printer. Do not use solvents.
3.
Check the supply of consumables. Ensure that an adequate supply of consumables is

available according to local operating procedures.
4.
Conduct any operator training that is needed. Ensure that the operator understands that
the Tools Mode should be used to adjust the default colors. Ensure that the operator can
perform color calibration and print a configuration report. If necessary, obtain permission
for access to the customers workstation.
5.
Complete the Service Log.
6.
Perform the following steps to make a copy of the Demonstration Original for the Customer:
General cleaning
Use a dry lint free cloth or a lint free cloth moistened with water for all cleaning unless directed
otherwise by the Service Manual. Wipe with a dry lint free cloth if a moistened cloth is used.
Feed Components (Rollers and Pads).
Follow the General cleaning procedure above
ESV Sensor
CAUTION
Do not use a vacuum on the ESV Sensor.
Carefully brush or wipe the ESV Sensor.
Toner Dispense Units
Vacuum the Toner Dispense Units.
a.
Load Paper Tray 2 with 8 1/2 x 11 inch (A4) or 11 x 17 inch 24# Xerox COLOR
Xpressions (NASG) A4, A3 Colotech + 90 gsm (ESG).
b.
Place the Color Test Pattern on the platen, with the short edge of the test pattern
registered to the left edge of the platen. Select Tray 2, make the following copier/
printer settings, and make a single copy.
ADC and Jam Sensors
Clean the sensors with a dry cotton swab.
Output Color - Auto
Optics Cleaning
1.
Switch power off and allow the Exposure Lamp to cool off.
2.
Using the optical Cleaning Cloth, clean the front and rear of the Document Glass, Document Cover, White Reference Strip, Reflector, and Mirror.
3.
Clean the Exposure Lamp with a clean cloth and film remover.
Original Type - Photo and Text Halftone

Reduce/Enlarge - Auto
Lighter/Darker - Auto Contrast
Sharpness - Normal
Preset Color Balance - Normal
IBT Cleaning
Color Shift - Normal
Check the IBT Belt surface and wipe with a dry lint free cloth. If the surface is excessively
dirty, replace the IBT Belt (PL 7.5).
Color Saturation - Normal

Copy Position - No Shift
Fuser Components (best cleaned when HOT).

1.
Heat Roll and Pressure Roll;
2.
External Heat Roll, Cleaning Roll, and Pickup Roll;
3.
Variable Color Balance - Normal
wipe with a lint free cloth moistened with fuser oil.

use a lint free cloth and oil. For heavy contamination, use the edge of a rolled up
tube of paper to scrape off the chunks of toner.
Donor Roll and Metering Blade
wipe with a lint free cloth moistened with fuser oil.
Cleaning Procedures, Final Actions
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c.
Print a Configuration Report (GP 12 Printing Configuration Reports).
d.
Print a Test Page (for the printer only) (GP 13 Printing a Complex Test Page).
e.
Present the copies to the customer.
7.
Issue copy credits as needed.
8.
Discuss the service call with the customer to ensure that the customer understands what
has been done and is satisfied with the results of the service call.
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DocuColor 12/DCCS50
2 Status Indicator RAPs

STANDBY POWER
1-300 Front Door Interlock Open RAP ............................................................................
1-304 L/H Cover Interlock Open RAP .............................................................................
+3.5 VDC Power (IIT/IPS LVPS) RAP ............................................................................
+5 VDC Power (IOT LVPS) RAP ....................................................................................
+5 VDC Power (IIT/IPS) RAP..........................................................................................
+12 VDC Power (IOT LVPS) RAP .................................................................................
-12 VDC Power (IOT LVPS) RAP ...................................................................................
+13.3 VDC Power (IIT/IPS LVPS) RAP ..........................................................................
+24 VDC Power (IOT LVPS) RAP ..................................................................................
+24 VDC Power (IIT/IPS LVPS) RAP .............................................................................
AC Power RAP................................................................................................................
Interlock Relay Failure RAP ............................................................................................
Power Save and LED RAP .............................................................................................
2-5
2-5
2-6
2-6
2-7
2-7
2-8
2-8
2-9
2-10
2-10
2-11
2-12
3-535 Whole Image NG RAP ..........................................................................................

3-536 Platen No Original .................................................................................................
3-537 Repeat NG - Number RAP....................................................................................
3-538 Repeat NG-MAG RAP ..........................................................................................
3-539 MPE MAG NG RAP ..............................................................................................
3-541 APS NG RAP ........................................................................................................
3-542 AMS NG RAP........................................................................................................
3-543 Rotation NG RAP ..................................................................................................
3-550 Original Patch Not Exist RAP................................................................................
3-560 Copy Limit Exceed RAP........................................................................................
3-580 IOT System Timing Fail RAP ................................................................................
3-581 Dead Cycle Fail RAP ............................................................................................
3-600 Billing Adjust NVM Failure RAP ............................................................................
3-601 Billing Adjust IOSS Failure RAP............................................................................
3-602 Billing Adjust Half-Tone Failure RAP ....................................................................
2-13
2-13
2-14
2-14
OF4-001 Main Motor RAP...............................................................................................

OF4-002 Drum Motor RAP..............................................................................................
USER INTERFACE
2-310 UI Panel Fail RAP .................................................................................................
2-340 UI RAM Fail RAP ..................................................................................................
Dark Screen RAP ............................................................................................................
Two Sided Copy Feature Not Available RAP ..................................................................
DRIVES
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DADF
MACHINE RUN CONTROL

3-311 IOT-SYS Logic Fail RAP .......................................................................................
3-315 IOT/IPS Communications Fail RAP ......................................................................
3-317 UI/IOT Communications Fail RAP ........................................................................
3-318 IOT/IPS Communications Fail RAP ......................................................................
3-319 MailBox Communication Failure RAP ...................................................................
3-327 2nd DDI IOSS I/F Failure RAP..............................................................................
3-328 DDI IOSS Communication Failure RAP ................................................................
3-329 DDI IISS Communication Failure RAP..................................................................
3-330 2nd DDI IISS Communication Failure RAP...........................................................
3-333 Foreign Interface RAP ..........................................................................................
3-340 IOT RAM Fail RAP ................................................................................................
3-356 IOT NVM Failure RAP...........................................................................................
3-380 TR0 Fail RAP ........................................................................................................
3-393 Half-Tone EEP-ROM Limit Failure RAP ...............................................................
3-394 IOT EEP-ROM Limit Failure RAP .........................................................................
3-395 Half-Tone EEP-ROM R/W Failure RAP ................................................................
3-396 IOT EEPROM R/W Failure RAP ...........................................................................
3-397 X ID DATA NG Failure RAP..................................................................................
3-510 APS NG-Image Loss RAP ....................................................................................
3-511 APS NG-Not in Position RAP................................................................................
3-512 APS NG-No Paper RAP........................................................................................
3-518 APS Mix NG Image Loss RAP..............................................................................
3-527 Original Change During Job RAP .........................................................................
3-528 Platen Document Size Unknown RAP ..................................................................
3-529 AMS Mix NG RAP.................................................................................................
3-530 AMS NG RAP .......................................................................................................
2-28
2-29
2-29
2-30
2-30
2-31
2-31
2-32
2-32
2-33
2-33
2-34
2-34
2-35
2-35
5-110 DADF Registration Sensor ON Dynamic Jam RAP ..............................................

5-111 DADF Registration Sensor OFF Dynamic Jam RAP ............................................
5-112 DADF Registration Sensor ON Dynamic Jam (during Original Reverse) RAP .....
5-113 DADF Registration Sensor OFF Dynamic Jam (during Original Reverse) RAP ...
5-115 DADF Exit Sensor ON Dynamic Jam RAP ...........................................................
5-116 DADF Exit Sensor OFF Dynamic Jam RAP..........................................................
5-189 No Object Sensor Static Jam RAP........................................................................
5-195 No Mix - Size Mismatch Jam RAP ........................................................................
5-196 DADF Document Sensor Static Jam RAP ............................................................
5-197 DADF Registration Sensor Static Jam RAP..........................................................
5-198 DADF Exit Sensor Static Jam RAP.......................................................................
5-199 DADF Duplex Sensor Static Jam RAP..................................................................
5-274 Original Size Sensor Fail RAP ..............................................................................
5-275 DADF RAM Check Fail RAP .................................................................................
5-301 Top Cover Open RAP ...........................................................................................
5-500 DADF No Originals RAP .......................................................................................
5-501 DADF Document Size Irregular RAP ....................................................................
5-503 Miss Doc Reset RAP.............................................................................................
5-999 ADF Document Misfeed RAP................................................................................
OF5-1 DADF Jam Recovery RAP ...................................................................................
2-15
2-15
2-16
2-16
2-17
2-17
2-18
2-18
2-19
2-19
2-20
2-20
2-21
2-22
2-22
2-23
2-23
2-24
2-24
2-25
2-25
2-26
2-26
2-27
2-27
2-28
2-39
2-40
2-41
2-42
2-42
2-43
2-44
2-45
2-45
2-46
2-46
2-47
2-47
2-48
2-49
2-50
2-50
2-51
2-52
2-52
OPTICS
6-275 Angle Sensor Fail RAP .........................................................................................
6-277 IISS - DADF Communications Fault RAP .............................................................
6-300 Platen Cover Open RAP .......................................................................................
6-312 Memory Hotline Fail RAP......................................................................................
6-340 Pre IPS RAM Test Error RAP ...............................................................................
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2-53
2-54
2-54
2-55
2-55
Status Indicator RAPs
6-345 Pre IPS EEPROM Failure RAP.............................................................................

6-355 IPS Fan Fail RAP ..................................................................................................
6-360 Carriage Position Failure RAP ..............................................................................
6-361 Scan Initialize Regi Sensor Failure RAP...............................................................
6-371 Exposure Lamp Fail RAP......................................................................................
6-389 Carriage Overrun Fail (Scan End) RAP ................................................................
6-390 Carriage Overrun Fail (Home End) RAP...............................................................
6 391 Scan Initialize Failure RAP....................................................................................
6-500 Lamp Not Ready RAP...........................................................................................
6-615 b* Failure RAP ......................................................................................................
6-620 Reflection Rate Failure RAP .................................................................................
2-56
2-56
2-57
2-58
2-59
2-59
2-60
2-60
2-61
2-61
2-62
8-172 Tray 2 Pre Registration Sensor On Jam RAP.......................................................

8-175 Tray 5 Registration Sensor On Jam RAP .............................................................
8-305 Tray 5 Interlock Open RAP ...................................................................................
8-306 Drawer Interlock Open RAP..................................................................................
Main Motor 2 RAP ...........................................................................................................
Takeaway Motor RAP .....................................................................................................
Registration Motor RAP...................................................................................................
PAPER SUPPLY
7-281 Tray 1 Lift Motor Failure RAP ...............................................................................
7-286 Tray 5 Broken (UP) RAP.......................................................................................
7-287 Tray 5 Broken (Down) RAP ..................................................................................
7-340 All Tray Broken RAP .............................................................................................
7-500 Tray out of position during Job RAP .....................................................................
7-501 Tray No Paper RAP ..............................................................................................
7-502 Tray 5 Paper Size Mismatch (Width) RAP ............................................................
7-503 Tray 5 Paper Size Mismatch (Length) RAP ..........................................................
7-504 Tray Size Change during Job RAP .......................................................................
7-600 Tray 5 Adjustment Side Guide out of specified Range RAP .................................
2-63
2-64
2-66
2-67
2-69
2-71
2-72
2-73
2-75
2-76
2-77
2-78
2-80
XEROGRAPHICS
9-271 Yellow Toner Empty RAP......................................................................................
9-272 Magenta Toner Empty RAP ..................................................................................
9-273 Cyan Toner Empty RAP........................................................................................
9-274 Black Toner Empty RAP .......................................................................................
9-311 Xerographic CRU (Drum) Type Mismatch RAP ....................................................
9-342/9-432 2nd BTR Contact Fail RAP .........................................................................
9-343/9-433 2nd BTR Retract Fail RAP ..........................................................................
9-344/9-434 IBT Cleaner Contact Fail RAP ....................................................................
9-345/9-435 IBT Cleaner Retract Fail RAP .....................................................................
9-354 Yellow Toner Dispenser Broken RAP ...................................................................
9-355 Magenta Toner Dispenser Broken RAP................................................................
9-356 Cyan Toner Dispenser Broken RAP .....................................................................
9-357 Black Toner Dispenser Broken RAP .....................................................................
9-358 Cleaning Auger Full RAP ......................................................................................
9-363 Rotary Home Position Fail RAP ............................................................................
9-365/9-450 Toner Dispenser Near Broken Yellow RAP ................................................
9-366/9-451 Toner Dispenser Near Broken Magenta RAP.............................................
9-367/9-452 Toner Dispenser Near Broken Cyan RAP ..................................................
9-368/9-453 Toner Dispenser Near Broken Black RAP ..................................................
9-369 Rotary Lock Fail RAP............................................................................................
9-370 Rotary Release Fail RAP ......................................................................................
9-372 Xerographic CRU (Drum) Not In Position RAP .....................................................
9-374 Waste Bottle Not In Position RAP .........................................................................
9-376 Waste Bottle Full RAP...........................................................................................
9-378 Xerographic CRU (Drum) Change RAP................................................................
9-379 Trickle Bottle Full RAP ..........................................................................................
9-400 Black Toner Near Empty RAP...............................................................................
9-402 Yellow Toner Near Empty RAP.............................................................................
9-403 Magenta Toner Near Empty RAP .........................................................................
9-404 Cyan Toner Near Empty RAP ...............................................................................
9-410 Xerographic CRU (Drum) Change Soon RAP ......................................................
9-420 Waste Bottle Near Full RAP..................................................................................
9-423 Trickle Bottle Near Full RAP .................................................................................
9-424 Cleaning Auger Near Full RAP .............................................................................
9-601 Humidity Out Of Range RAP.................................................................................
9-610 VPatch Out Of Range RAP ...................................................................................
9-612 TRC RADC Out Of Range RAP ............................................................................
PAPER FEED
8-104 Tray 1 Prefeed Sensor On Jam RAP ....................................................................
8-105 Tray 1 Feed Out Sensor On Jam RAP .................................................................
8-107 Tray 1 Feed Out Sensor On RAP .........................................................................
8-147 Tray 1 Takeaway Sensor On Jam RAP ................................................................
8-152 Takeaway Sensor On RAP ...................................................................................
8-154 Pre Registration Sensor On RAP..........................................................................
8-157 Registration Sensor On Jam RAP ........................................................................
8-158 Pre IBT Sensor On Jam RAP ...............................................................................
8-163 Pre IBT Sensor On Jam RAP ...............................................................................
2-99
2-100
2-100
2-101
2-101
2-102
2-102
2-103
2-103
2-104
2-104
2-105
2-105
2-81
2-82
2-83
2-83
2-84
2-85
2-86
2-87
2-88
2-88
2-89
2-90
2-91
2-92
2-92
2-93
2-94
2-95
2-96
2-97
2-97
2-98
2-98
2-99
1/05
2-2
2-107
2-107
2-108
2-108
2-109
2-109
2-110
2-111
2-112
2-112
2-114
2-115
2-117
2-118
2-119
2-120
2-120
2-121
2-121
2-122
2-123
2-124
2-124
2-125
2-125
2-126
2-126
2-127
2-127
2-128
2-128
2-129
2-129
2-130
2-130
2-131
2-131
Reissue
DocuColor 12/DCCS50
9-614 VClean Out Of Range RAP...................................................................................

9-619 VClean TRC Out Of Range RAP ..........................................................................
9-634 ADC Out Of Range RAP .......................................................................................
9-662 LD Out Of Range RAP..........................................................................................
9-667 VH/VM Out Of Range RAP ...................................................................................
2-132
2-132
2-133
2-133
2-134
10-379 Power On External Heat Roll Not Ready RAP....................................................

10-382 Stand By External Heat Roll Not Ready RAP .....................................................
10-383 Job Complete External Heat Roll Not Ready RAP..............................................
10-384 Job Incomplete External Heat Roll Not Ready RAP ...........................................
10-386 External Heat Roll Control Thermistor Overheat Failure RAP ............................
10-387 External Heat Roll Overheat Thermistor Overheat Failure RAP .........................
10-389 Fuser Nip Contact Failure RAP...........................................................................
10-390 Fuser Nip Retract Failure RAP............................................................................
10-391 Fail Unit Failure RAP...........................................................................................
10-398 Fuser Fan Failure RAP .......................................................................................
10-399 Fuser Intake Fan Failure RAP.............................................................................
10-421 Fuser Oil Level RAP............................................................................................
10-422 Web CRU RAP....................................................................................................
10-500 Fuser Web CRU Not Present RAP .....................................................................
10-900 Fuser Cycle Down RAP ......................................................................................
OF10-1 OCT Detection Failure RAP ...............................................................................
OF10-2 Fuser Oil Pump RAP..........................................................................................
OF10-3 Heat Roll AC Power RAP...................................................................................
OF10-4 Pressure Roll AC Power RAP ............................................................................
OF10-5 External Heat Roll AC Power RAP.....................................................................
OF 10-6 Fuser Out of Oil Rap .........................................................................................
FUSING, EXIT TRANSPORTATION

10-102 Pre Fuser Sensor On Jam RAP..........................................................................
10-103 Pre Fuser Sensor On RAP..................................................................................
10-105 Fuser Exit Sensor On Jam RAP .........................................................................
10-106 Fuser Exit Sensor Off Jam RAP .........................................................................
10-107 Fuser Exit Sensor On RAP .................................................................................
10-110 Machine Exit Sensor On Jam RAP .....................................................................
10-111 Machine Exit Sensor Off Jam RAP .....................................................................
10-112 Machine Exit Sensor On RAP .............................................................................
10-115 Exit Path Sensor On Jam RAP ...........................................................................
10-117 Exit Path Sensor On Jam RAP ...........................................................................
10-120 Inverter Path Sensor On Jam RAP .....................................................................
10-127 Duplex Registration Sensor On Jam RAP ..........................................................
10-128 Duplex Pre Regi. Sensor On Jam RAP ..............................................................
10-130 Duplex In Sensor On Jam RAP ..........................................................................
10-132 Duplex Path Sensor On Jam RAP .....................................................................
10-133 Duplex Out Sensor On Jam RAP .......................................................................
10-160 Duplex In Sensor On Jam RAP ..........................................................................
10-162 Duplex Path 1 Sensor On Jam RAP ...................................................................
10-163 Duplex Out Sensor On Jam RAP........................................................................
10-280 OCT Offset Sensor Failure RAP .........................................................................
10-300 Inverter Cover Open RAP ...................................................................................
10-341 Fuser Oil Empty RAP ..........................................................................................
10-342 Fuser Web Change RAP ....................................................................................
10-355 External Heat Roll Contact Failure RAP ............................................................
10-356 External Heat Roll Retract Failure RAP .............................................................
10-359 Heat Roll Control Thermistor Failure RAP ..........................................................
10-360 Heat Roll Overheat Thermistor Failure RAP .......................................................
10-361 Power On Heat Roll Not Ready RAP ..................................................................
10-362 Standby Heat Roll Not Ready RAP.....................................................................
10-363 Job Complete Heat Roll Not Ready RAP............................................................
10-364 Job Incomplete Heat Roll Not Ready RAP .........................................................
10-366 Heat Roll Control Thermistor Overheat Failure RAP ..........................................
10-367 Heat Roll Overheat Thermistor Overheat Failure RAP .......................................
10-368 Pressure Roll Control Thermistor Failure RAP ...................................................
10-369 Pressure Roll Overheat Thermistor Failure RAP ................................................
10-370 Power On Pressure Roll Not Ready RAP ...........................................................
10-371 Stand By Pressure Roll Not Ready RAP ............................................................
10-372 Job Complete Pressure Roll Not Ready RAP.....................................................
10-373 Job Incomplete Pressure Roll Not Ready Failure RAP.......................................
10-375 Pressure Roll Control Thermistor Overheat Failure RAP ...................................
10-376 Pressure Roll Overheat Thermistor Overheat Failure RAP ................................
10-377 External Heat Roll Control Thermistor Failure RAP ............................................
10-378 External Heat Roll Overheat Thermistor Failure RAP.........................................
Reissue
DocuColor 12/DCCS50
2-135
2-135
2-136
2-137
2-138
2-138
2-140
2-141
2-141
2-142
2-143
2-143
2-145
2-146
2-147
2-148
2-149
2-150
2-151
2-151
2-152
2-152
2-153
2-154
2-154
2-155
2-156
2-157
2-157
2-158
2-158
2-159
2-159
2-160
2-161
2-162
2-162
2-163
2-163
2-164
2-164
2-165
2-166
2-167
2-167
2-168
2-169
2-169
2-170
2-171
2-172
2-173
2-174
2-175
2-175
2-176
2-176
2-177
2-177
2-178
2-178
2-179
2-179
2-181
2-182
2-183
SORTING
11-107 OCT Exit Sensor On Jam Long RAP ..................................................................
11-108 OCT Exit Sensor Off Jam RAP ...........................................................................
11-109 OCT Exit Sensor On Jam Short RAP.................................................................
11-110 Paper Remains at Decurler Exit Sensor Long RAP ............................................
11-111 Paper Remains at Decurler Exit Sensor Short RAP ...........................................
11-115 Mail Box Vertical Sensor / Bin 1 Sensor On Jam RAP .......................................
11-116 Mail Box Vertical Sensor / Bin 1 Sensor Off Jam RAP .......................................
11-142 V-Tra In Sensor On Jam Long RAP....................................................................
11-143 V-Tra In Sensor Off Jam RAP.............................................................................
11-144 V-Tra In Sensor On Jam Short RAP ...................................................................
11-145 Decurler Exit Sensor On Jam Long RAP ............................................................
11-146 Decurler Exit Sensor On Jam Short RAP............................................................
11-190 Paper Remains on V-Tra In Sensor RAP............................................................
11-191 Paper Remains at Mail Box Vertical Sensor / 1 Bin Sensor RAP .......................
11-192 Paper Remains at OCT Exit Sensor RAP ...........................................................
11-193 Decurler Exit Sensor Static Jam RAP .................................................................
11-273 Mail Box OCT Offset Fail RAP ............................................................................
11-301 Front Cover A Interlock Open RAP .....................................................................
11-302 Front Cover B Interlock Open RAP .....................................................................
11-303 Docking Interlock Open RAP ..............................................................................
11-350 Decurler 1 Fail RAP ............................................................................................
11-512 Offset Catch Tray / Simple Catch Tray Full Stack RAP ......................................
11-911 Bin 1 Full Stack RAP...........................................................................................
1/05
2-3
2-185
2-186
2-187
2-189
2-189
2-190
2-191
2-192
2-193
2-194
2-196
2-198
2-200
2-200
2-201
2-201
2-202
2-203
2-204
2-204
2-205
2-207
2-207
2-208
2-208
2-209
2-209
2-210
2-210

11-920 Bin 10 Full Stack RAP.........................................................................................
11-921 Offset Catch Tray Full Stack RAP.......................................................................
11-922 Sorter Stacker Full RAP......................................................................................
2-211
2-211
2-212
2-212
2-213
ROS
14-372 ROS Motor Fail RAP ........................................................................................... 2-215
14-376 Half Tone PWB Fail RAP .................................................................................... 2-215
........................................................................................................................................ 14-380
SOS Fail 1 RAP .............................................................................................................. 2-216
14-384 SOS Fail 2 RAP .................................................................................................. 2-216
14-388 XPC ASIC Fail RAP ............................................................................................ 2-217
IPS
15-270 Coordinate Bus Fail RAP ....................................................................................
15-281 Pre-IPS X Recognize Fail RAP ...........................................................................
15-284 POST IPS X Recognize Fail RAP .......................................................................
15-342 IPS NVM Fail RAP ..............................................................................................
15-361 POST IPS PWB Fail (Self Test) RAP .................................................................
15-362 X Hard Fail RAP..................................................................................................
15-363 IIT Memory Fail RAP...........................................................................................
15-365 X Comm Fail RAP...............................................................................................
15-367 X - Fail 4 RAP .....................................................................................................
15-370 X - Fail 5 RAP .....................................................................................................
15-371 X - Fail 6RAP ......................................................................................................
15-380/15-381 / 15-382 / 15-383 / 15-384 / 15-385 CCD AGC Fail RAP .......................
15-386 / 15-387 / 15-388 / 15-389 / 15-390 / 15-391 CCD AOC Fail RAP .....................
15-560 Expected Time Margin Fault RAP.......................................................................
2-219
2-219
2-220
2-220
2-221
2-221
2-222
2-222
2-223
2-223
2-224
2-224
2-225
2-226
IDFE
OF19-1 IDFE Fault Entry RAP ........................................................................................
19-001 DC Power Fault RAP ..........................................................................................
19-002 BIOS/Self-Test Fault RAP...................................................................................
19-003 Hard Disk Fault RAP ...........................................................................................
19-004 Printer DDI Communication Fault 1 RAP ............................................................
19-005 Printer DDI Communication Fault 2 RAP ............................................................
19-006 Scanner DDI Communication Fault 1 RAP .........................................................
19-007 Scanner DDI Communication Fault 2 RAP .........................................................
19-012 Network Connection Fault RAP ..........................................................................
19-013 Network Connection Fault RAP ..........................................................................
19-014 Ethernet Speed Detection Fault RAP .................................................................
19-015 Token Ring Speed Detection Fault RAP.............................................................
19-016 Token Ring Troubleshooting RAP ......................................................................
2-227
2-230
2-231
2-231
2-232
2-232
2-233
2-233
2-234
2-235
2-236
2-237
2-237
1/05
2-4
Reissue
DocuColor 12/DCCS50
1-300 Front Door Interlock Open RAP
1-304 L/H Cover Interlock Open RAP
The Control Logic has detected that the Front Door Cover is open.
This RAP should be used to repair the Left Hand Cover Interlock circuit.
Initial Actions
Initial Actions
Refer to BSD 1.4 in the following procedure
Refer to BSD 1.4 in the following procedure:
Visually inspect the Front Door Interlock Switch (PL 9.1) and the Drawer Accessory (PL
2.18) for damage, misalignment, dirt or any other visible mechanical or electrical cause
for malfunction.
Visually inspect the L/H Cover Interlock Switch (PL 2.8) for damage, misalignment, dirt or
any other visible mechanical or electrical cause for malfunction. Make sure the Left Lower
Cover actuates the switch when it closes.
Procedure
Procedure
PO/PO the Machine Fault Code 1-300 is still declared.

Y
N
Inspect and reseat connectors P/J712, P/J14, P/J419B, P/J724, and P/J11A.
PO/PO the machine. Fault Code 1-304 is still declared.

Y
N
Reseat connectors P/J800 and P/J805.
Open the Front Door. +5 VDC is measured at P/J712-3.

Y
N
Perform the following:
Close the L/H Cover Interlock Switch. Go to Flag 4 and Flag 5 on BSD 1.4, and check for
continuity through the switch while it is closed.
Observe the operation of the Drawer Interlock Switch while opening and closing the
drawer.
Check the Drawer Interlock Switch for damage or misalignment.
Go to Flag 1 and Flag 7 on BSD 1.4, and check the wires between P/J712-3 and P/
J724-2 for an open circuit.
Replace the Drawer Interlock Switch (PL 2.18).
Close the L/H Cover Interlock Switch, and go to Flag 5 on BSD 1.4. +24 VDC is measured at
P/J805-2 on the Tray PWB.
Y
N
Go to Flag 4 and Flag 5 on BSD 1.4. Check for an open circuit between P/J805-1
and P/J805-2 on the Tray PWB.
Cheat the Front Door Interlock Switch. +5 VDC is measured at P/J712-4

Y
N
+5VDC is measured at P/J19-4 on the AC Driver PWB.
Y
N
Replace the AC Driver PWB (PL 9.3).
Replace the L/H Cover Interlock Switch (PL 2.8).
Go to BSD 1.4, and check for an open/short circuit at P/J801B-4.
Go to Flag 1 and Flag 7 on BSD 1.4, and check the wiring between P/J14-1 on the AC
Driver PWB and P/J19-4 on the AC Driver PWB (PL 9.2) for an open or a short. If the
problem continues,
Replace the Front Door Interlock Switch (PL 9.1).
Open the L/H Cover Interlock Switch, and go to Flag 5 on BSD 1.4.
+24 VDC is measured at P/J805-1.

Y
N
Go to the +24 VDC Power (IOT LVPS) RAP.
Replace the Tray PWB (PL 9.3).
Replace the Drawer Interlock Switch (PL 2.18).
Go to the Interlock Relay Failure RAP.
Reissue
DocuColor 12/DCCS50
1/05
2-5
1-300 Front Door Interlock Open RAP, 1-304 L/H
+3.5 VDC Power (IIT/IPS LVPS) RAP
+5 VDC Power (IOT LVPS) RAP
This RAP is used to repair failures in the +3.5 VDC Power (IIT/IPS LVPS) circuit when directed
by another RAP.
This RAP is used to repair failures in the +5 VDC Power circuit when directed by another RAP.
Initial Actions
Use BSD 1.2 in the following procedure:
P/O P/O the machine, and look for symptoms of a blank UI and a machine locked into the
Power Save Mode.
Initial Actions
Procedure
Procedure
Disconnect J5. Go to Flag 1 on BSD 1.3, and check for ACH between J5-3 and J5-2 on the
harness side. ACH is measures between J5-3 and J5-2 on the harness side.
Y
N
Go to the AC Power RAP.
The machine exits Energy Saver Mode when the Main Switch is switched ON.
Y
N
Refer to BSD 1.2. Check for +5 VDC between P/J25-1 and P/J25-2 on the IOT LVPS.
+5 VDC is measured between P/J25-1 and P/J25-2.
Y
N
Go to Flag 4 and Flag 5 on BSD 1.2, and check for an open circuit.
Go to Flag 2 on BSD 1.3. Less than +1 VDC is measured at P/J11A-1.

Y
N
Y
N
Replace the IOT Drive PWB (PL 9.2).
Replace the IOT CPU PWB (PL 9.2).
Replace the IIT LVPS (PL 3.5).
3.
Replace the PRE IPS PWB (PL 3.5).
4.
Replace the POST IPS PWB (PL 3.5).
+3.5 VDC Power (IIT/IPS LVPS) RAP, +5 VDC Power
Replace the IOT LVPS (PL 9.3).
Replace the Half Tone PWB (PL 9.2).
Go to the Power Save and LED RAP.
Go to Flag 5 on BSD 1.3, and perform the following:

1. Check the wiring at P/J31 for an open/short circuit to the POST IPS.
2.
Go to the Power Save and LED RAP.
1/05
2-6
Reissue
DocuColor 12/DCCS50
+5 VDC Power (IIT/IPS) RAP
This RAP is used to repair failures in the +5 VDC Power circuit (IIT LVPS) when directed by
another RAP.
This RAP is used to repair short circuits in the +12 VDC Power circuit when directed by another
RAP.
Initial Actions
Initial Actions
Procedure
Procedure
Disconnect J5. Go to Flag 1 on BSD 1.3, and check for ACH between J5-3 and J5-2 on the
harness side. ACH is measures between J5-3 and J5-2 on the harness side.
Y
N
Disconnect P/J22 from the IOT LVPS and check for +12 VDC at P/J22-1 on the IOT LVPS.
+12 VDC at P/J22 on the IOT LVPS checked OK.
Y
N

Y
N
Y
N
Disconnect the following connectors from their respective PWBs:
P/J395 from the Half Tone PWB (PL 9.2).
Measure for +12 VDC at P/J22-1 after reconnecting P/J395, and P/J411 one by one to their
respective PWBs. Note what PWB, if any, loads down the +12 VDC. +12 VDC was OK after
reconnecting P/J395 to the Half Tone PWB.
Y
N
Go to Wirenet +12/-12V DC involving the Half Tone PWB and disconnect all components from the Half Tone PWB which are supplied with +12 VDC.

1. Check the wiring at P/J33 for open/short circuits (between the IIT/IPS LVPS and the
DADF, and the PRE IPS).
2.
P/J411 from the IOT Drive PWB (PL 9.2).
Reconnect P/J22 to the IOT LVPS, and check for +12 VDC at P/J22-1. +12 VDC is measured at P/J22-1.
Y
N
Go to Flag 6 on BSD 1.2, and check the wires for a short circuit to ground.
Replace the IIT LVPS (PL 3.5).
Reconnect the components one-by-one to the Half Tone PWB, while checking which
component/circuit loads down the +12 VDC.
Check the wiring to the suspected component for an open/short circuit.
Replace the component, which loads down the +12 VDC.
Go to Wirenet +12/-12V DC involving the IOT Drive PWB and disconnect all components
from the IOT Drive PWB which are driven by +12 VDC (and not checked earlier in this
RAP).
Reissue
DocuColor 12/DCCS50
1/05
2-7
Reconnect the components one-by-one to the IOT Drive PWB, while checking which component/circuit loads down the +12 VDC.
Replace the component, which loads down the +12 VDC.
+5 VDC Power (IIT/IPS) RAP, +12 VDC Power (IOT
-12 VDC Power (IOT LVPS) RAP
+13.3 VDC Power (IIT/IPS LVPS) RAP
This RAP is used to repair short circuits in the -12 VDC Power circuit when directed by another
RAP.
This RAP is used to repair failures in the +13.3 VDC Power (IIT/IPS LVPS) circuit when
directed by another RAP.
Initial Actions
Initial Actions
Procedure
Procedure
Disconnect P/J22 from the IOT LVPS and check for -12 VDC at P/J22-4. -12 VDC at P/J224 on the IOT LVPS checked OK.
Y
N
Disconnect P/ J5. Go to Flag 1 on BSD 1.3, and check for ACH between P/ J5-3 and P/ J5-2
on the harness side. ACH is measures between P/ J5-3 and P/ J5-2.
Y
N
P/J395 from the Half Tone PWB (PL 9.2).

Y
N
Y
N
Reconnect P/J22 to the IOT LVPS, and check for -12 VDC at P/J22-4. -12 VDC is measured
at P/J22-1.
Y
N
Go to Flag 7 on BSD 1.2, and check the wires for a short circuit to ground.
Measure for -12 VDC at P/J22-4 after reconnecting P/J395, and P/J411 one by one to their
respective PWBs. Note what PWB, if any, loads down the -12 VDC. -12 VDC was OK after
reconnecting P/J395 to the Half Tone PWB.
Y
N
Go to Wirenet +12/-12V DC involving the Half Tone PWB and disconnect all components from the Half Tone PWB which are supplied with -12 VDC.

1. Check the wiring from P/J34 on the IIT/IPS LVPS to the PRE IPS and the CCD for an
open/short circuit.
Reconnect the components one-by-one to the Half Tone PWB, while checking which
component/circuit loads down the -12 VDC.
Replace the component, which loads down the -12 VDC.
2.
Replace the IIT/IPS LVPS (PL 3.5).
3.
4.
Replace the IIT Driver PWB (PL 3.2).
Go to Wirenet +12/-12V DC involving the IOT Drive PWB and disconnect all components
from the IOT Drive PWB which are driven by -12 VDC (and not checked earlier in this
RAP).
Reconnect the components one-by-one to the IOT Drive PWB, while checking which component/circuit loads down the -12 VDC.
Replace the component, which loads down the -12 VDC.
-12 VDC Power (IOT LVPS) RAP, +13.3 VDC Power
1/05
2-8
Reissue
DocuColor 12/DCCS50
This RAP is used to repair short circuits in the +24 VDC Power circuit when directed by another
RAP.
Reconnect the components one-by-one to the IOT Drive PWB, while checking which component/circuit loads down the +24 VDC.
Replace the component which loads down the +24 VDC.
Initial Actions
Disconnect P/J24 from the IOT LVPS and check for +24 VDC at P/J24-2,3. +24 VDC at
J24-2, 3 on the IOT LVPS (PL 9.3) checked OK
Y
N
Procedure
Disconnect P/J23 from the IOT LVPS and check for +24 VDC at P/J23-1,2,3 on the IOT
LVPS. +24 VDC at P/J23-1, 2, 3 on the IOT LVPS (PL 9.3) checked OK.
Y
N
Disconnect P/J14 from the AC Driver (PL 9.3)
P/J800 from the Tray PWB (PL 9.3)
P/J14 from the AC Driver PWB (PL 9.3).
P/
Reconnect P/J23 to the IOT LVPS (PL 9.3) and check for +24 VDC at P/J23-1,2,3. +24 VDC
is measured at P/J23-1,2,3.
Y
N
Go to BSD 1.2, Flag 1, Flag 2 and check the wires for an open circuit or a short circuit to
ground.
Check for +24 VDC at P/J24-2,3 at the IOT LVPS (PL 9.3).
Go to BSD 1.2, Flag 3, and check for open/short circuits.
Reconnect P/J23 to the AC Driver (PL 9.3) and check for +24 VDC at P/J23-1,2,3.
Go to Wirenet +24 VDC involving the AC Driver PWB and disconnect all components from
the AC Driver PWB which are driven by +24 VDC (and not checked earlier in this RAP).
Reconnect the components one-by-one to the AC Driver PWB, while checking which
Go to the Interlock Relay Failure RAP. Check for a short circuit of +24 VDC.
Measure for +24 VDC at P/J23-1,2,3 after reconnecting P/J800, P/J14, and P/J411 one by
one to their respective PWBs. Note what PWB, if any, loads down the +24 VDC. +24
VDC
was OK after reconnecting P/J800 to the Tray PWB.
Y
N
Go to Wirenet +24 VDC involving the Tray PWB and disconnect all components from
the Tray PWB which are driven by +24 VDC.
Reconnect the components one-by-one to the Tray PWB, while checking which component/circuit loads down the +24 VDC.
+24 VDC was OK after reconnecting P/J14 to the AC Driver PWB.

Y
N
Go to Wirenet +24 VDC involving the AC Driver PWB and disconnect all components
from the AC Driver PWB which are driven by +24 VDC.
Reconnect the components one-by-one to the AC Driver PWB, while checking which
Go to Wirenet +24 VDC involving the IOT Drive PWB and disconnect all components from
the IOT Drive PWB which are driven by +24 VDC.
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+24 VDC Power (IIT/IPS LVPS) RAP
AC Power RAP
This RAP is used to repair failures in the +24 VDC Power (IIT/IPS LVPS) circuit when directed
by another RAP.
This RAP is used to repair failures in the AC Power circuit when directed by another RAP.
Initial Actions
Initial Actions
Procedure
Procedure
With the machine plugged into the AC source and the Circuit Breaker and Main Switch
switched on, check that AC Line voltage is measured between P/J17-1,2,3 (ACH) and P/J174,5,6 (ACN). AC Line voltage checked OK between P/J17-1,2,3 and P/J17-4,5,6.
Y
N
Check for AC Line voltage between P/J16-1 (ACH) and P/J16-4 (ACN) on the AC Driver
PWB (PL 9.3). AC Line voltage checked OK between P/J16-1 and P/J16-4.
Y
N
Check for AC Line voltage between P/J15-1and P/J15-3 on the AC Driver PWB (PL
9.3). AC Line voltage is present between P/J15-1 and P/J15-3.
Y
N
Go to Flag 1 on BSD 1.1, and check for an open circuit between P/J16 on the
AC Driver PWB and the AC Plug on the Line Cord.
Disconnect P/ J5. Go to Flag 1 on BSD 1.3, and check for ACH between P/ J5-3 and P/ J5-2
on the harness side. ACH is measures between P/ J5-3 and P/ J5-2.
Y
N
Y
N
Y
N
With the machine plugged into the AC source, and the Circuit Breaker switched on, check
for 18 VAC between P/J19-6 and P/J19-12 on the AC Driver PWB (PL 9.3). 18 VAC is
present between P/J19-6 and P/J19-12.
Y
N
Go to Flag 2 on BSD 1.1, and check for an open circuit.

1. Check the wiring from P/J35 for an open/short circuit between the DADF Control PWB or
Lamp Ballast PWB.
2.
Check that the specified level of AC Line voltage is present at the wall receptacle.
Replace the IIT/IPS LVPS (PL 3.5).
Go to Flag 1, Flag 2, Flag 3, Flag 4, and Flag 5 on BSD 1.1 and check for open circuits. Also check for short circuits to ground at Flag 3, Flag 4, and Flag 5.
Replace the Main Switch (PL 9.1).
+5 VDC is measured between P/J11B-17 and P/J11B-19.

Y
N
Go to Flag 3 on BSD 1.1, and check for an open circuit. If the circuit is OK, replace the AC
Driver PWB (PL 9.3).
+24 VDC is measured between P/J11AB-15 and DC COM when the Main Switch is
switched ON.
Y
N
Go to Flag 5 on BSD 1.1, and check for an open/short circuit. If the circuit is OK, perform
the following:
Go to the +24 VDC Wirenet and check for an open/short circuit.
A
+24 VDC Power (IIT/IPS LVPS) RAP, AC Power RAP
1/05
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A
Replace the Main Power Switch (PL 9.1).
Interlock Relay Failure RAP

This RAP is used to repair +24 VDC Interlock Relay (located on the AC Driver PWB) Failures.
Initial Actions
Refer to BSD 1.4, Power Interlock Switching, in the following procedure:
Procedure
Go to Figure 7 (BSD 1.4) and check that the fuses F1, F2 and F5 on the AC Driver PWB
are OK.
Check that +5 VDC is available at P/J19-4 on the AC Driver PWB.
+5 VDC is measured at P/J19-4 on the AC Driver PWB.

Y
N
+24 VDC is measured at P/J45-5 on the Distribution PWB.
Y
N
Cheat the Front Door Interlock Switch. +24 VDC is measured at P/J14-10 on the AC Driver
PWB.
Y
N
Check for an open circuit between P/J45-5 on the Distribution PWB and P/J14-10
on the AC Driver PWB.
Replace the Front Door Interlock Switch (PL 9.1).
Go to Flag 2 on BSD 1.4,and check for an open circuit.
Reissue
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AC Power RAP, Interlock Relay Failure RAP
A
Check for +5VDC at P/J11A-A7 on the AC Driver PWB. +5VDC is measured at P/J11A-A7
on the AC Driver PWB.
Y
N
Preform the following:
Go to Flag 1 on BSD 2.3 and check for a short circuit
Power Save and LED RAP

This RAP is used to repair failures in the Power Save and LED Circuit.
Initial Actions
Check if the Power Save Mode activates continuously or will not activate.
Procedure
PO/PO the machine. The machine remains in the Power Save (Sleep) Mode.
Y
N
The machine wakes up. Check for +5 VDC at P/J11A-A7 on the AC Driver PWB.
+5 VDC is measured at P/J11A-A7 on the AC Driver PWB.
Y
N
Go to BSD 2.3, Flag 1 and check for a short circuit.
Go to +5 VDC Power (IOT LVPS) RAP
Replace the Control Panel (PL 9.2).
Enter dC330 001-200 Power Save Button, and exercise the Power Save Mode using the
following procedure:
1.
Press Start.
2.
Press and hold the [Power Save Button]. For normal operation the status indicator
should indicate Logic (H) and the counter should increment.
3.
Release the Power Save Button and the status should change to Logic (L), and the
counter should increment again.
The Power Save Mode behaved normally when it was exercised in the preceding
steps 1 through 3.
Y
N
Check the voltage at P/J11A-A12 on the AC Driver PWB (PL 9.3). +5 VDC is measured at P/J11A-A12 on the AC Driver PWB (PL 9.3).
Y
N
Check the wire between P/J11A-A12 on the AC Driver PWB, and P/J4922 on the Control Panel for a short circuit.
Check the wire between P/J11A-A12 on the AC Driver PWB, and P/J492-2 on
the Control Panel for an open circuit.

A
Power Save and LED RAP
1/05
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2-310 UI Panel Fail RAP
2-340 UI RAM Fail RAP
This Fault Code indicates that the UI Panel failed.
This Fault Code is detected at power on and indicates that the UI PWB RAM Test failed.
Initial Actions
Initial Actions
Refer to BSD 2.1, Control Panel (UI Panel) Switches and LEDs, in the following procedure:
Observe all LEDs on the top of the Control Panel for functional operation.
Procedure
Check all push-buttons on top of the Control Panel for electrical/mechanical function.
Check the Touch Panel at the UI for functional operation.

Y
N
Inspect the connections and connectors to the UI PWB, VR PWB, the Display, and
the Power Supply.
Procedure
Y
N
Check the connectors to the Control Panel.
All push-buttons are electrically and mechanically operational.

Y
N

Replace the UI PWB (PL 9.5).
Replace the Power Supply (PL 9.5).
Go to Flag 2 on BSD 2.2, and check between P/J486-2 and INVCN1 for an open/short
circuit.
All LEDs functioned in Initial Action.

Y
N
Go to Flag 5 on BSD 2.1, and check for +5 VDC at P/J482A-9,10 and CN1-9,10.
+5VDC is measured at P/J482A and CN1.
Y
N
Go to Flag 4 on BSD 2.1, and check the harness between P/J482A on the UI
PWB and CN1 on the Display Power Supply for a short/open circuit.
Reseat connectors P/J484, P/J486, CN5, CN6, and CN1.
Go to Flag 2 on BSD 2.2, and check for +24 VDC UI Power Supply voltage at P/J486-1. +24
VDC is measured at P/J486-1 on the UI PWB.
Y
N
Go to Flag 1 on BSD 2.2, and check the wires for an open/short circuit.
Reseat connectors P/J482A, CN2, CN3, and CN1.
Refer to BSD 2.2 UI Display in this procedure:
Replace the VR PWB (PL 9.5).
Replace the Display (PL 9.5)

Go to Flag 1, Flag 2, and Flag 3 on BSD 2.1, and check the harness for open/short circuits.
Replace the Touch Panel (PL 9.5).
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2-310 UI Panel Fail RAP, 2-340 UI RAM Fail RAP
Dark Screen RAP
Two Sided Copy Feature Not Available RAP
This RAP is used to analyze and repair a Dark Screen at the UI. If the UI is still illuminated, but
no customer message is displayed go to OF19-1 IDFE Fault Entry RAP.
The Duplex option is not shown on the UI.
Initial Actions
Initial Actions
Ensure that the Left Side Option Memory PWB (side 2) is installed and properly seated on the
MEM SYS PWB.
Refer to BSD 2.2 UI Display in this procedure:
Procedure
Procedure
PO/PO the machine. The Dark Screen is still displayed.

Y
N
If the Dark Screen Display is intermittent, perform the following:
Go to BSD 2.2, UI Display. Inspect the connections and connectors to the UI PWB,
VR PWB, the Display, and the Power Supply in the UI Assembly.
Refer to 15-363 IIT Memory Fail RAP.
Reseat connectors P/J484, P/J486, CN5, CN6, and CN1.
NOTE: If the failure occurred immediately after installing or reconnecting the optional Edit Pad,
check that P/J 800 is connected correctly. It is possible to partially connect this plug upside
down, which will create a power supply short circuit. Check F3 on the Distribution PWB. This
may have also corrupted the UI software, requiring a reload of the software.
Check Fuses F1, F2, F3, F4, and F5 on the Distribution PWB (PL 9.3).
Check Fuses F1, F2, F3, and F5 on the AC Driver PWB (PL 9.3).
Go to BSD 2.2, UI Display and perform the following:
Inspect the connectors and connections to the UI PWB, VR PWB, the Display, and the
Power Supply in the UI Assembly.
Reseat connectors P/J484, P/J486, CN5, CN6, and INVCN1.
Replace the VR PWB (PL 9.5).
Replace the Power Supply (PL 9.5).
Replace the Display (PL 9.5).
Dark Screen RAP,
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3-311 IOT-SYS Logic Fail RAP
3-315 IOT/IPS Communications Fail RAP
The IOT-SYS Software Logic Failure was detected after a certain time period (the NVM value).
The 3-315 Fault Code indicates that a communication failure between the IOT PWB and the
Post IPS PWB was detected.
Initial Actions
Initial Actions
Refer to BSD 3.12 Monitoring in this procedure:
Procedure
Ensure that P571 is firmly connected to the Post IPS PWB.
Refer to BSD 3.2 PWB Communications (IPS) and BSD 3.12 Monitoring in this procedure:
PO/PO the machine
Procedure
Reset the connectors on the IOT CPU PWB (PL 9.2)
Replace the IOT CPU PWB (PL 9.2)
There is +3.5 VDC from J 570 pin 1 to pin 6 on the Post IPS PWB.
Y
N
Go to Flag 5 on BSD 3.2. Check for an open or a short circuit to GND. If the wires are OK,
replace the IIT LVPS (PL 3.5).
There is +3.5 VDC from J 517 pin 3 to pin 4 on the Pre IPS PWB.
Y
N
There is +5 VDC from J 517 pin 1 to pin 2 on the Pre IPS PWB.
Y
N
There is +13.3 VDC from J 517 pin 7 to pin 5 on the Pre IPS PWB.
Y
N
PO/PO the machine
Reissue
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Go to Flag 3 and Flag 4 on BSD 3.2. Check the following wires for a short/open circuit:
Between Post IPS PWB P571-23 and IOT CPU PWB P/J404-A13
Replace the PRE IPS PWB (PL 3.5)
Replace the Post IPS PWB (PL 3.5)
Replace the MEM SYS PWB (PL 3.5)
3-311 IOT-SYS Logic Fail RAP, 3-315 IOT/IPS Com-
3-317 UI/IOT Communications Fail RAP
3-318 IOT/IPS Communications Fail RAP
This Fault Code indicates that a communications failure between the UI PWB and the IOT
PWB was detected.
This Fault Code indicates that a communication failure between the IOT PWB and the IPS
PWB was detected.
Initial Actions
Initial Actions
Refer to BSD 3.1 PWB Communications (UI) and BSD 3.12 Monitoring, in this procedure:
Procedure
Procedure
PO/PO the machine. If Fault Code 3-317 is still declared, perform the following:
Go to Flag 3 on BSD 3.1. +24 VDC is measured at J490-7, and +5 VDC is measured at
J490-2 on the UI PWB (PL 9.5).
Y
N
Go to the +24 VDC-1 Wirenet and check for an open/short circuit
Go to the +24 VDC Power (IIT/IPS LVPS) RAP
Go to the +5 VDC-1 Wirenet and check for an open/short circuit
Go to the +5 VDC Power (IIT/IPS) RAP
Check the wire between IOT CPU PWB P/J404-B14 and UI PWB P/J490-10
Replace the UI PWB (PL 9.5)
3-317 UI/IOT Communications Fail RAP, 3-318 IOT/IPS
PO/PO the machine. If Fault Code 3-318 is still declared, perform the following:
Go to Flag 1 on Flag 2 on BSD 3.1 and check the following wires for an open/short circuit:
Refer to BSD 3.2 PWB Communications (IPS) and BSD 3.12 Monitoring in this procedure:
1/05
2-16
Go to Flag 1 and Flag 2 on BSD 3.2. Check the following wires for short/open circuit:
Replace the Post IPS PWB (PL 3.5)
Reissue
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3-319 MailBox Communication Failure RAP
3-327 2nd DDI IOSS I/F Failure RAP
The 3-319 Fault Code indicates a communication failure between the IOT PWB and the MailBox PWB.
3-327 Fault Code indicates a communication failure between the IOT PWB and the DDI
IISS.
Initial Actions
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 3-319 Finisher/
Sorter Communication Failure RAP to troubleshoot this Fault Code.
Refer to BSD 16.1 Printer IDFE.
Initial Actions
Procedure
Refer to BSD 3.4 PWB Communications (MailBox) and to BSD 3.12, Monitoring, in this procedure.
Procedure
Y
N
If an intermittent is suspected, perform the following:
Check the connections to the IOT CPU PWB and the MailBox Control PWB, and the
interconnecting harness
Reseat P/J405 at the IOT CPU PWB, P/J550 at the MailBox Control PWB, and
J880, the Double Plug
PO/PO the machine
Go to BSD 16.1 (Figure 1). Check the communications cables. Ensure that the cables are
seated properly and that there is no damage
Reset the IOT CPU connectors and reseat the IOT NVM PWB.
Reload IDFE System Software
Go to GP 10 Replacing Billing PWBs and replace the IOT CPU PWB (PL 9.2)
Replace the IDFE (PL 19.1)
Go to Flag 1 BSD 3.4, and check for +5 VDC at P/J569-1. +5 VDC is measured at P/J569-1
on the MailBox Control PWB.
Y
N
Go to Flag 1 on BSD 3.4, and check for an open/short circuit
Go to the +5 VDC Power (IOT LVPS) RAP
Go to Flag 1 on BSD 3.4, and check for +24 VDC at P/J563-1 on the Mail box Control PWB.
+24 VDC is measured at P/J563 -1.
Y
N
Go to Flag 1 on BSD 3.4, and check for an open/short circuit
Go to Flag 2 and Flag 3 on BSD 3.4, and check the following wires for an open/short circuit:
Check the wire between Mailbox Control PWB P/J550-1 and IOT CPU PWB P/
J405-1
J405-2
J405-3
J405-4
Replace the MailBox Control PWB (PL 13.10)
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3-319 MailBox Communication Failure RAP, 3-327
3-328 DDI IOSS Communication Failure RAP
3-329 DDI IISS Communication Failure RAP
The 3-328 Fault Code indicates that a communication failure between the IOT PWB and
the DDI IISS was detected.
The 3-328 Fault Code indicates that a communication failure between the IOT PWB and
the DDI IOSS was detected.
This RAP is incomplete pending full information disclosure.
3-329 Fault Code indicates that a communication failure between the IOT PWB and the
DDI IISS was detected.
Initial Actions
Initial Actions
Refer to BSD 16.1, Printer IDFE in this procedure.
Refer to BSD 16.1, Printer IDFE in this procedure.
Procedure
Procedure
PO/PO the machine
PO/PO the machine
Reset the IOT CPU connectors and reseat the IOT NVM PWB
3-328 DDI IOSS Communication Failure RAP, 3-329
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3-330 2nd DDI IISS Communication Failure RAP
3-333 Foreign Interface RAP
This Fault Code indicates that a communications failure was detected between the Foreign
Interface PWB and the IOT CPU PWB.
3-330 Fault Code indicates that a communication failure between the IOT PWB and the
DDI IISS was detected.
Initial Actions
Initial Actions
Refer to BSD 16.1, Printer IDFE, in this procedure.
Procedure
PO/PO the machine
Go to BSD 16.1 (Figure 1) and check the communications cables.
Check the connection between the Foreign Interface PWB and the Foreign Accessory (P/
J 940).
If you were sent to this RAP from Call Flow for a nonrecognized Foreign Device, go to
Flag 1 on BSD 3.6 and check for an open circuit.
Use BSD 3.6, Foreign Interface Accessory, and BSD 3.12, Monitoring, for this procedure.
Procedure
PO/PO the machine. Fault Code 3-333 is still present.
Y
N
If intermittent performance is suspected, reseat P/J406 at the IOT CPU PWB, P/J45 at
the Distribution PWB, and P/J 941at the FI PWB.
There is +24 VDC from J 941, pin 5 to pin 7.
Y
N
Go to Flag 2 on BSD 3.6. Check for an open circuit. If the wires are OK, go to the 24 VDC
wirenets to troubleshoot.
There is +5 VDC from J 941, pin 10 to pin 8.
Y
N
Go to Flag 3 on BSD 3.6. Check for an open circuit. If the wires are OK, go to the +5 VDC
wirenets to troubleshoot.
Go to Flag 4 and Flag 5 on BSD 3.6, and check for an open/short circuit.
Reissue
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Replace the Foreign Interface PWB (PL 9.4).
3-330 2nd DDI IISS Communication Failure RAP, 3-
3-340 IOT RAM Fail RAP
3-356 IOT NVM Failure RAP
This Fault Code indicates that it was detected at power on that the IOT PWB RAM Test failed.
This Fault Code indicates that the IOT PWB NVM test failed and was detected at Power On.
Initial Actions
Initial Actions
Check the NVM settings related to the IOT-SYS logic.
Procedure
Procedure

Y
N
If intermittent performance is suspected, inspect the IOT CPU PWB, and the IOT NVM
PWB for loose connections or any obvious electrical/mechanical cause for malfunction.

Y
N
If intermittent behavior is suspected, perform the following:
Inspect the IOT NVM PWB and the IOT CPU PWB connections.
Replace the IOT NVM PWB (PL 9.2).
Reseat connectors between the IOT NVM PWB and IOT CPU PWB
Replace the IOT NVM PWB (PL 9.2).
3-340 IOT RAM Fail RAP, 3-356 IOT NVM Failure RAP
1/05
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3-380 TR0 Fail RAP
N
Go to Flag 5 on BSD 1.2 and check the +5 VDC circuit to the AC Driver PWB.
A 3-380 fault indicates that the TR0 signal was not received on time.
Go to Flag 1 and Flag 7 on BSD 1.4. Check the circuit for Interlocked +5 VDC.
Initial Actions
NOTE: The following step requires the use of the Fluke 87 DVM, or other test meter with a voltage type diode test function.
Refer to BSD 9.8 for the following procedure.
Ensure that the TR0 Patch (reflector) on the IBT Belt is clean and in good condition.
Ensure that the Belt is installed correctly, with the reflector toward the Inboard edge.
Ensure that P/J398 on the Half Tone PWB, P/J345 on the LDD PWB, P/J416 on the
IOT Drive PWB, P/J140 on the TR0 Sensor, and Double Plug P702A/ J702A are connected before beginning this RAP.
1.
Set the meter rotary switch to the diode test position.
2.
Disconnect P/J 395 and P/J398 on the Half Tone PWB.
3.
Connect the red (+) lead to J395 pin 1 and the black (COM) lead to J398 pin 1
Ensure that the Drum CRU is properly installed.
The meter reads 0.3 VDC or less

Y
N
If the meter reads OL in both directions, CR13 on the Halftone PWB is open; replace the
PWB (PL 9.2).
Procedure
If Tag 38 is installed on the machine, it is possible that there is a shorting condition between the
EPC Scan Cable and the FPC-ROS Flat Cable connector ( P/J398). Foam on top of the connector is intended to insulate the pins from contact. However, the foam can be compressed by
the EPC Scan Cable and the pins may stick through and short against the Scan Cable connector housing.
Using a sheet of transparency or shim stock, cut a strip 45mm X 12mm and adhere to the top
of the foam on the FPC-ROS Cable connector ( P/J398). This strip will function as an insulator.
If this does not resolve the problem, or if Tag P-38 is not installed, continue with this procedure.
Reverse the leads. The meter reads OL.

Y
N
CR13 on the Halftone PWB is shorted; replace the PWB (PL 9.2).
There is +24 VDC from pin 3 to pin 4 of P/J2030 on the Drum Motor.
Y
N
Go to Flag 6 of BSD 4.1. Check for an open circuit. Refer to the 24 VDC wirenets as
required.
NOTE: The PWS display may not update the logic level display fast enough to show the state
of the TR0 Sensor. Observe the event Counter. If the event counter advances, the display is
changing.
Check the connections to the Drum Motor. If the connections are secure, replace the Drum
Motor (PL 1.1). If the problem persists, replace the IOT Drive PWB (PL 9.2).
Go to dC330. Stack the following codes. 004-007 Main Motor, 004-021 Drum Motor, 003-213
TRO Sensor. The display is H and changes to L momentarily.
Y
N
The display is always H.
Y
N
Less than +1 VDC is measured between P/J416A-7 and DC Com.
Y
N
Go to Flag 5 on BSD 9.8. Check the wire for a short circuit to ground. If the wire is
good, replace the TR0 Sensor (PL 7.5).
+5 VDC is measured between P/J416A-8 and DC COM
Y
N
Go to Flag 5 and Flag 6 on BSD 9.8. Check the wires for an open circuit. If the wires are
good, replace the TR0 Sensor (PL 7.5).
There is +5 VDC from J395 pin 1 to J395 pin 11 on the Half Tone PWB (BSD 6.5).
Y
N
There is +5 VDC from J19 pin 4 on the AC Driver PWB to GND (BSD 1.4).
A
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3-380 TR0 Fail RAP
3-393 Half-Tone EEP-ROM Limit Failure RAP
3-394 IOT EEP-ROM Limit Failure RAP
This fault code is declared when the limit of the allowable number of times to write on to the
EEP-ROM of the Half-Tone PWB is reached.
This fault code is declared when the limit of the allowable number of times to write on the EEPROM of the IOT CPU PWB is reached.
Initial Actions
Initial Actions
Refer to BSD 3.12, Monitoring in this procedure:
Procedure
Procedure
PO/PO the machine.

Fault Code 3-393 is still declared.
Y
N
If intermittent operation is suspected, inspect the IOT CPU PWB and the Half-Tone PWB
for loose connections or any obvious electrical/mechanical cause for malfunction.
PO/PO the machine.

Fault Code 3-394 is still declared.
Y
N
If intermittent operation is suspected, inspect the IOT CPU PWB, and the Half-Tone PWB
3-393 Half-Tone EEP-ROM Limit Failure RAP, 3-394
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3-395 Half-Tone EEP-ROM R/W Failure RAP
3-396 IOT EEPROM R/W Failure RAP
This fault code is declared when writing to the EEP-ROM of the Half-Tone PWB failed.
This fault code is declared when writing to the EEPROM of the IOT CPU PWB failed.
Initial Actions
Initial Actions
Refer to BSD 3.12 Monitoring (2 of 2) in this procedure.
Enter Diagnostics Mode and compare the NVM last entry to the Half-Tone PWB with
those to the IOT NVM PWB and to the IOT CPU PWB.
Enter Diagnostics Mode and compare the NVM last entry to the Half-Tone PWB with
those to the IOT NVM PWB and to the IOT CPU PWB.
Procedure
Procedure

Y
N
If intermittent operation is suspected, inspect the IOT CPU PWB, and the Half-Tone PWB
PO/PO the machine. Fault Code is still declared.

Y
N
If intermittent operation is suspected, inspect the IOT CPU PWB (PL 9.2) and the HalfTone PWB (PL 9.2) for loose connections or any obvious electrical/mechanical cause for
malfunction.

Reissue
DocuColor 12/DCCS50
1/05
2-23
3-395 Half-Tone EEP-ROM R/W Failure RAP, 3-396
3-397 X ID DATA NG Failure RAP
3-510 APS NG-Image Loss RAP
The machine serial number and billing data are stored in three locations:
The 3-510 fault code indicates that a tray containing the size of paper closest to the size of the
image was not detected while APS was enabled.
IOT NVM PWB
IOT CPU PWB
Half Tone PWB
Initial Actions
This fault is declared when the data stored are mismatched, or when an automatic correction
was impossible after a billing mismatch occurred.
If the fault occurs while performing Max Setup, ensure that Automatic Tray switching for Trays 1
- 4 is enabled in Customer Tools.
Initial Actions
Ensure that appropriate paper is loaded when APS is enabled. If the fault code persists with
correct paper loaded, continue with the RAP.
PO/PO the machine.
If intermittent operation is suspected, inspect the IOT CPU PWB, the IOT NVM PWB, and
the Half Tone PWB for loose connections or any obvious electrical/mechanical cause for
malfunction.
Procedure
Y
N
Refer to the User Guide, Selecting Document Size, and help the customer to understand
how to avoid recurrence of the problem.
Procedure
Connect the PWS. Select dC132 from the DC Quick pull-down menu. Refer to GP 10 Replacing Billing PWBs .
Compare the displayed Serial Numbers for the IOT CPU PWB, the IOT NVM PWB, and the
Half Tone PWB with serial number printed on the machine label. All three PWB Serial Numbers
should agree with the label.
CAUTION
To maintain intergrity of the serial number and billing data, NEVER replace more that one PWB
at the same time. Follow the procedure in GP10.
The IOT NVM PWB serial number is correct.
Y
N
Attempt to synchronize the serial numbers (GP 10 Replacing Billing PWBs ). If unsuccessful, replace the IOT NVM PWB (PL 9.2). After replacing the IOT NVM PWB, set the
serial number (GP 10 Replacing Billing PWBs ).
The IOT CPU PWB serial number is correct.
Y
N
Attempt to synchronize the serial numbers (GP 10 Replacing Billing PWBs ). If unsuccessful, replace the IOT CPU PWB (PL 9.2). After replacing the IOT CPU PWB, set the
serial number (GP 10 Replacing Billing PWBs ).
Attempt to synchronize the serial numbers (GP 10 Replacing Billing PWBs ). If unsuccessful,
replace the Half Tone PWB (PL 9.2). After replacing the Half Tone PWB, set the serial number
(GP 10 Replacing Billing PWBs ).
3-397 X ID DATA NG Failure RAP, 3-510 APS NG-Im-
1/05
2-24
Reissue
DocuColor 12/DCCS50
3-511 APS NG-Not in Position RAP
3-512 APS NG-No Paper RAP
The 3-511 Fault Code indicates that the Tray selected by the APS was not in position.
The 3-512 Fault Code indicates that the Tray selected by the APS had no paper.
Initial Actions
Initial Actions
Refer to the User Guide in this procedure.
Procedure
Procedure

Y
N
Refer to the User Guide, Selecting a Paper Tray, and help the customer to understand

Y
N
Refer to the User Guide, Loading Paper, and help the customer to understand how to
avoid recurrence of the problem.
Reissue
DocuColor 12/DCCS50
1/05
2-25
3-511 APS NG-Not in Position RAP, 3-512 APS NG-
3-518 APS Mix NG Image Loss RAP
3-527 Original Change During Job RAP
The 3-518 Fault Code indicates that the Tray selected by the APS had no paper.
The 3-527 Fault Code indicates that the original returned according to the original return
instruction did not match the size or color of the original recognized by the machine because it
was returned by mistake on the part of the user.
Initial Actions
Initial Actions
Procedure
Y
N
Refer to the User Guide, Loading Paper, and help the customer to understand how to
Procedure
Y
N
Refer to the User Guide, Storing Frequently-used Job Settings (Stored Programming),
and help the customer to understand how to avoid recurrence of the problem.
3-518 APS Mix NG Image Loss RAP, 3-527 Original
1/05
2-26
Reissue
DocuColor 12/DCCS50
3-528 Platen Document Size Unknown RAP
3-529 AMS Mix NG RAP
The 3-528 Fault Code indicates that the machine does not recognize the document size automatically detected.
The 3-529 Fault Code indicates that the result of the magnification calculation was outside of
the range of 25%~400%.
Initial Actions
Initial Actions
Refer to the User Guide in this Procedure.
Procedure
Procedure

Y
N
Refer to the User Guide, Loading Documents, Document Size Sensing, and help the customer to understand how to avoid recurrence of the problem.

Y
N
Refer to the User Guide, Reducing/Enlarging Copies, and help the customer to understand how to avoid recurrence of the problem.
Reissue
DocuColor 12/DCCS50
1/05
2-27
3-528 Platen Document Size Unknown RAP, 3-529
3-530 AMS NG RAP
3-535 Whole Image NG RAP
The 3-530 Fault Code indicates that the result of the magnification calculation was outside of
the range of 25%~400%.
The 3-535 Fault Code indicates that the whole image did not fit to the paper.
Initial Actions
Initial Actions
Procedure
Procedure

Y
N

Y
N

3-530 AMS NG RAP, 3-535 Whole Image NG RAP
1/05
2-28
Reissue
DocuColor 12/DCCS50
3-536 Platen No Original
3-537 Repeat NG - Number RAP
The 3-536 Fault Code indicates that no original is on the platen.
The 3-537 Fault Code indicates that the specified number of images did not fit on the paper.
Initial Actions
Initial Actions
Procedure
Procedure

Y
N

Y
N
Refer to the User Guide, Copying Several Documents onto One Copy, and help the customer to understand how to avoid recurrence of the problem.
Reissue
DocuColor 12/DCCS50
1/05
2-29
3-536 Platen No Original, 3-537 Repeat NG - Num-
3-538 Repeat NG-MAG RAP
3-539 MPE MAG NG RAP
The 3-538 Fault Code indicates that no image fit to paper.
The 3-539 Fault Code indicates that magnification of the output was specified at beyond 400%
at continuous enlargement copying mode.
Initial Actions
Initial Actions
Procedure
Procedure

Y
N

Y
N

3-538 Repeat NG-MAG RAP, 3-539 MPE MAG NG RAP
1/05
2-30
Reissue
DocuColor 12/DCCS50
3-541 APS NG RAP
3-542 AMS NG RAP
The 3-541 Fault Code indicates that the tray corresponding to the standard size of paper
slightly larger than the size of the image did not exist while executing the APS.
The 3-542 Fault Code indicates that the calculated magnification was beyond the range of
400%~25%.
Initial Actions
Initial Actions
Refer to the User Guide during this procedure.
Procedure
Procedure

Y
N
Refer to the User Guide, Selecting a Paper Tray, and help the customer to understand

Y
N
Reissue
DocuColor 12/DCCS50
1/05
2-31
3-541 APS NG RAP, 3-542 AMS NG RAP
3-543 Rotation NG RAP
3-550 Original Patch Not Exist RAP
The 3-543 Fault Code indicates that the rotation could not be done because the magnification
exceeded 100%.
The 3-550 Fault Code indicates that there was no position-detection patch on the original while
executing an automatic KAICHO revision.
Initial Actions
Initial Actions
Procedure
Procedure

Y
N
Refer to the User Guide, Document Rotation, and help the customer to understand how to

Y
N
Refer to the User Guide, Loading Documents, and help the customer to understand how
to avoid recurrence of the problem.
3-543 Rotation NG RAP, 3-550 Original Patch Not Ex-
1/05
2-32
Reissue
DocuColor 12/DCCS50
3-560 Copy Limit Exceed RAP
3-580 IOT System Timing Fail RAP
The 3-560 Fault Code indicates that it reached the pre-set copy limit value (specified for/by the
User Password at the Auditron Administrator Mode) during the copying operation.
This Fault Code is declared when the machine was not able to receive the print from/against
the Hint within the specified time.
Initial Actions
Initial Actions
Procedure
Procedure

Y
N
Refer to the User Guide, Using the Auditron Administration Mode, and help the Customer/
Auditron Administrator to understand how to avoid recurrence of the problem.

Y
N
Inspect the IOT CPU PWB, and the IOT NVM PWB for loose connections or any obvious
electrical/mechanical cause for malfunction.
Replace the IOT NVM PWB (PL 9.2)
Reissue
DocuColor 12/DCCS50
1/05
2-33
3-560 Copy Limit Exceed RAP, 3-580 IOT System
3-581 Dead Cycle Fail RAP
3-600 Billing Adjust NVM Failure RAP
The Dead Cycle continued for more than two minutes.
This Fault Code is declared when after the job ended, the billing mismatch occurred, and automatic correction implemented.
Initial Actions
Initial Actions
Procedure
Procedure

Y
N
Inspect the IOT CPU PWB and the IOT NVM PWB for loose connections or any obvious
electrical/mechanical cause for malfunction.

Y
N
If intermittent operation is suspected, inspect the IOT CPU PWB and the IOT NVM PWB
Replace the IOT NVM PWB (PL 9.2)
Enter [DC122, Failure History]. If this failure has occurred many times, replace the IOT NVM
PWB (PL 9.2).
3-581 Dead Cycle Fail RAP, 3-600 Billing Adjust NVM
1/05
2-34
Reissue
DocuColor 12/DCCS50
3-601 Billing Adjust IOSS Failure RAP
3-602 Billing Adjust Half-Tone Failure RAP
After the job ended, the billing mismatch occurred, and automatic correction implemented.
This Fault Code is declared when after the job ended, the billing mismatch occurred, and automatic correction was implemented.
Initial Actions
Initial Actions
Procedure
Procedure
PO/PO the machine and make a billable copy. Fault Code 3-601 is still declared.
Y
N
If intermittent operation is suspected, inspect the IOT CPU PWB and the IOT NVM PWB
PO/PO the machine, and make a billable copy. Fault Code 3-602 is still declared.
Y
N
If intermittent operation is suspected, inspect the IOT CPU PWB and the Half Tone PWB
Enter [DC122, Failure History]. If this failure has occurred many times, replace the IOT CPU
PWB (PL 9.2).
Reissue
DocuColor 12/DCCS50
Enter [DC122, Failure History], If this failure has occurred many times, replace the Half-Tone
PWB (PL 9.2).
1/05
2-35
3-601 Billing Adjust IOSS Failure RAP, 3-602 Billing
3-601 Billing Adjust IOSS Failure RAP, 3-602 Billing
1/05
2-36
Reissue
DocuColor 12/DCCS50
OF4-001 Main Motor RAP
P/J417B-5, Logic (L)
This RAP is used to repair the Main Motor and Drum Motor circuit failures when directed by
another RAP.
P/J417B-4, +2.5 VDC
Initial Actions
Go to Flag 4 on BSD 4.1 and check for an open /short circuit.
Refer to BSD 4.1, Main and Drum Drive Control, in the following procedure:
Replace the Main Motor (PL 1.2).
Check the Drive Mechanism for damage, jams, and obstructions.
While in [04-007] Component Control and the Main Motor is running, check for the following conditions at
Procedure
Go to Flag 1 BSD 4.1 and check for +5 VDC at P/J42-14 on the Distribution PWB. +5 VDC is
measured at P/J42-14 on the Distribution PWB.
Y
N
Go to Flag 1 BSD 4.1 and check for a short/open circuit.
Enter DC330 004-007 Main Motor, Press Start and Stop.
Check for a change of state from (L) to +5 VDC at P/J417B-5 on the IOT Drive PWB.
P/J417B-4, +2.5 VDC
The voltage at P/J417B-5 switched between (L) and +5 VDC at P/J417B-5 on the IOT
Drive PWB.
Y
N
Go to Flag 3 on BSD 4.1 and check for an open/short circuit.
Go to Flag 2 on BSD 4.1 and check for +24 VDC at P/J42-11 and 12, on the Distribution PWB.
+24 VDC is measured at P/J42 -11 and 12, on the Distribution PWB.
Y
N
Go to Flag 2 on BSD 4.1 check for an open/short circuit.
Enter DC330 004-007 Main Motor. Press Start. The Main Motor runs.
Y
N
Check for Logic (L) at P/J417B-5. Logic (L) is measured at P/J417B-5.
Y
N
Go to on Flag 4 BSD 4.1 and check for an open/short circuit.
While exercising [04-021] in Component Control, check for a change of state on the
Main Motor On line P/J417B-5.
While in [04-021] Component Control and the Main Motor is running, check for the
following conditions at
A
Reissue
DocuColor 12/DCCS50
1/05
2-37
OF4-001 Main Motor RAP
OF4-002 Drum Motor RAP
P/J417B-17, +2.5 VDC
This RAP is used to repair the Main Motor and Drum Motor circuit failures when directed by
another RAP.
Initial Actions
Refer to BSD 4.1, Main and Drum Drive Control, in the following procedure:
Replace the Drum Motor (PL 1.1).
Check the Drive Mechanism for damage, jams, and obstructions.
While in [04-021] Component Control and the Drum Motor is running, check for the following conditions at
Procedure
Go to Flag 5 on BSD 4.1 and check for +5 VDC at P/J42-4 on the Distribution PWB. +5 VDC
is measured at P/J42-4 on the Distribution PWB.
Y
N
Go to Flag 5 on BSD 4.1 and check for a short/open circuit.
Enter DC330 004-021 Drum Motor. Press Start and Stop.
Check for a change of state from (L) to +5 VDC at P/J417B-18 on the IOT Drive PWB.
The voltage at P/J417B-18 switched between (L) and +5 VDC on the IOT Drive PWB.
Y
N
P/J417B-17, +2.5 VDC
Go to Flag 6 on BSD 4.1 and check for +24 VDC at P/J42-2 on the Distribution PWB. +24
VDC is measured at P/J42-2 on the Distribution PWB.
Y
N
Go to Flag 6 on BSD 4.1 and check for a short/open circuit.
Enter DC330 004-021 Drum Motor. The Drum Motor runs.

Y
N
Check for Logic (L) at P/J417B-18 Logic (L) is measured at P/J417B-18
Y
N
While exercising DC330 004-021 Drum Motor, check for a change of state on the
Drum Motor On line P/J417B.
While in [04-021] Component Control and the Drum Motor is running, check for the
following conditions at
A
OF4-002 Drum Motor RAP
1/05
2-38
Reissue
DocuColor 12/DCCS50
5-110 DADF Registration Sensor ON Dynamic Jam RAP
The DADF Registration Sensor did not actuate within 650 msec after the DADF Transport
Motor was energized.
Observe the Set Gate Fingers. Enter dC330 005-012 Set Gate Solenoid Close. Press Start.
Enter dC330 005-011 Set Gate Solenoid Open. Press Start. The Set Gate fingers rise up,
then fall back.
Y
N
Enter dC330 005-012 Set Gate Solenoid Close. Press Start. The Set Gate Solenoid
energizes.
Y
N
+24 VDC is measured between P/J586-1and P/J586-2 on the Set Gate Solenoid.
Y
N
+24 VDC is measured between P/J598-2 and P/J598-1 on the DADF Control PWB.
Y
N
+24 VDC is measured between P/J550-3 and P/J550-1 on the DADF
Control PWB.
Y
N
Go to the IIT/IPS +24VDC Wirenet and the DC COM (24V RET)
Wirenet. Check the wires between P/J550-2 and-1 on the DADF
Control PWB and P/J35-1 and -2 on the IIT/IPS LVPS, and the wires
between P/J550-4 and-3 on the DADF Control PWB, and P/J35-5
and -6 on the IIT/IPS LVPS for an open circuit.
Initial Actions
Check for the following:
Obstructions in the document transportation path.
Contamination on the DADF Registration Sensor.
Sufficient normal force at the Nudger Rolls
Nudger Rolls and Feed Rolls that are glazed or contaminated
Ensure that connectors P/J599 and P/J580 are seated correctly on the DADF Control
PWB and DADF Registration Sensor and there are no obvious crimped or broken wires.
Refer to BSD 5.1, 5.2, 5.3, 5.4 and 5.6 for the following procedure.
N
Check the belt on the DADF Feed Motor. Repair or replace the Belt (PL 12.4) as required.
Procedure
Enter dC330 005-110 Regi Sensor. Press Start. Block the DADF Registration Sensor. The
display changed from L to H.
Y
N
With paper at the DADF Registration Sensor, less than +1 VDC is measured at P/
J599-2 on the DADF Control PWB.
Y
N
+5 VDC is measured between P/J599-1 and P/J599-3 on DADF Control PWB.
Y
N
Go to Flag 5 on BSD 5.3. Check the wires for an open circuit or a short circuit. If
the wires are good, replace the DADF Control PWB (PL 12.3).
Replace the DADF Control PWB (PL 12.3).

Go to Flag 2 on BSD 5.2 and check the wires for an open circuit. If the wires are
good, replace the DADF Control PWB (PL 12.3).
Go to Flag 1 and Flag 5 on BSD 5.3. Check the wires for an open circuit. If the wires
are good, replace the DADF Registration Sensor (PL 12.5).
Replace the Set Gate Solenoid (PL 12.5).

Enter dC330 005-011 Set Gate Solenoid Open. Press Start. The Set Gate Solenoid
deenergizes.
Y
N
+24 VDC is measured between P/J598-2 and P/J598-1 on the DADF Control
PWB.
Y
N

Enter dC330 005-040 Feed Motor. Press Start. DADF Feed Motor cycles.
Y
N
+24 VDC is measured between P/J598-7 and P/J598-8 on the DADF Control PWB
with the motor on.
Y
N
Go to Flag 1 on BSD 5.2. Check the wires for a short circuit. If the wires are good,
replace the DADF Control PWB (PL 12.3)
+24 VDC is measured between P/J586-1 and P/J586-3 on the Set Gate Solenoid.
Y
N
Go to Flag 2 on BSD 5.2 and check the wires for an open circuit or a short circuit. If the wires are good, replace the Set Gate Solenoid (PL 12.5).
+24 VDC is measured between P/J588-1 and P/J588-2 on the DADF Feed Motor
with the motor on.
Y
N
Go to Flag 1 on BSD 5.2. Check the wires for an open circuit.
Check the in line fuse for an open circuit. If the fuse is good, replace the DADF Feed
Motor (PL 12.4)
Feed rolls turn.
Check the Solenoid for binding.
Check the Set Gate Fingers for binding.
A
Reissue
DocuColor 12/DCCS50
1/05
2-39
5-110 DADF Registration Sensor ON Dynamic Jam
5-111 DADF Registration Sensor OFF Dynamic Jam RAP
Obstructions in the document path.
Sufficient normal force at the Nudger Rolls
Nudger Rolls and Feed Rolls that are glazed or contaminated
The DADF Registration Sensor did not actuate within 640 msec. after the DADF Transport
Motor was energized while feeding the original.
Initial Actions
Contamination on the DADF Belt.
Contamination on the Platen Glass.
Refer to BSD 5.1, 5.2, 5.3 and 5.4 for the following procedure.
Procedure
The trail edge of the document is past the Registration Sensor.
Y
N
Enter dC330 005-055 Belt Motor CW. DADF Belt Motor energizes.
Y
N
Remove the DADF Rear Cover. Check the Fuse (F1) on the DADF Control PWB.
The fuse is good.
Y
N
Install a new fuse. If the fuse blows again, replace the DADF Belt Motor (PL
12.6). If the fuse blows again, replace the DADF Control PWB (PL 12.3).
Press Stop. +24 VDC is measured between P/J595-2, P/J595-3, P/J595-4 P/
J595-5 and GND on the DADF Control PWB.
Y
N
+24 VDC is measured between P/J595-1 and GND.
Y
N
Y
N
Y
N
Go to the IIT/IPS +24VDC Wirenet and the DC COM (24V RET)
Wirenet. Check the wires between P/J550-2 and-1 on the
DADF Control PWB and P/J35-1 and -2 on the IIT/IPS LVPS,
and the wires between P/J550-4 and-3 on the DADF Control
PWB, and P/J35-5 and -6 on the IIT/IPS LVPS for an open circuit.
Ensure that Fuse F1 on the DADF Control PWB is good. If the Fuse
is good, replace the DADF Control PWB (PL 12.3).
Go to Flag 5 and Flag 6 on BSD 5.1. Check the wires for an open circuit. If
the wires are good, replace the DADF Interlock Switch (PL 12.3).
A
5-110 DADF Registration Sensor ON Dynamic Jam
1/05
2-40
D
Reissue
DocuColor 12/DCCS50
D
Enter dC330 005-055 Belt Motor CW. Approximately +23 VDC is measured
between pins 2, 3, 4, and 5 of P/J595 and GND
Y
N
5-112 DADF Registration Sensor ON Dynamic Jam (during

Original Reverse) RAP
The DADF Registration Sensor did not actuate within 500 msec. after the DADF Transport
Motor was energized during reversal of the original.
Replace the DADF Belt Motor (PL 12.6).
Initial Actions
Go to Flag 1 on BSD 5.4. Check the wires for an open circuit. If the wires are good,
replace the DADF Belt Motor (PL 12.6).
The Platen Belt runs, without generating excessive noise.

Y
N
Check the Platen Belt and the Platen Belt Drive components. Repair or replace as
required. If the problem continues perform ADJ 12.3.3.
Clean Document Belt
Refer to BSD 5.2, 5.3 and 5.4 for the following procedure.
Check the following parts for wear slipping, damage or contamination.
Enter dC330 005-056 Belt Motor CCW. The DADF Document Transport is moving in the
reverse direction.
Y
N
required. If the problem continues perform ADJ 12.3.3. If the problem continues replace
the DADF Control PWB (PL 12.3). If the problem continues, replace the DADF Belt Motor
(PL 12.6).
Feed Roll Assembly
Registration Roll
Registration Pinch Roll
Document Belt
Procedure
Enter dC330 005-110 Regi Sensor. Press Start. Block the DADF Registration Sensor. The
display changed from L to H.
Y
N
With paper at the DADF Registration Sensor, less than +1 VDC is measured at P/
J599-2 on the DADF Control PWB.
Y
N
+5 VDC is measured between P/J599-1 and P/J599-3 on the DADF Control
PWB.
Y
N
Check the following parts for wear, slipping, or damage.
Duplex Drive Roll 1
Duplex Drive Roll 2
Registration Roll
Document Belt
If the above items are good, replace the Registration Sensor (PL 12.5).
Go to Flag 1 and Flag 5 on BSD 5.3. Check the wires for an open circuit. If the wires
are good, replace the DADF Registration Sensor (PL 12.5).
Check the following parts for wear slipping, damage or contamination.
Feed Roll Assembly
Registration Roll
Document Belt
Reissue
DocuColor 12/DCCS50
1/05
2-41
5-111 DADF Registration Sensor OFF Dynamic Jam

(during Original Reverse) RAP
5-115 DADF Exit Sensor ON Dynamic Jam RAP

The DADF Exit Sensor did not actuate within 800 msec. after the DADF Transport Motor was
energized, while exchanging or discharging the original.
The DADF Registration Sensor did not actuate within 1,150 msec. after the DADF Transport
Motor was energized during reversal of the original.
Initial Actions
Initial Actions
Contamination on the DADF Exit Sensor.
Clean Document Belt
Ensure that connectors P/J595, P/J599 and P/J589 are seated correctly on the DADF
Control PWB and DADF Exit Sensor and there are no obvious crimped or broken wires.
Procedure
Procedure
Enter dC330 005-056 Belt Motor CCW. The DADF Document Transport is moving in the
reverse direction.
Y
N
required. If the problem continues perform ADJ 12.3.3. If the problem continues replace
the DADF Control PWB (PL 12.3). If the problem continues, replace the DADF Belt Motor
(PL 12.6).
The lead edge of the document is past the Exit Sensor.

Y
N
Enter dC330 005-081 Exit Motor. The DADF Exit Motor energizes.
Y
N
The fuse is good.
Y
N
Install a new fuse. If the fuse blows again, replace the DADF Exit Motor (PL
12.9). If the fuse blows again, replace the DADF Control PWB (PL 12.3).
Check the following parts for wear, slipping, or damage.
Duplex Drive Roll 1
Duplex Drive Roll 2
Registration Roll
Document Belt
Press Stop. +24 VDC is measured between P/J596-2, P/J596-3, P/J596-4 P/

J596-5 and GND. on the DADF Control PWB.
Y
N
+24 VDC is measured between P/J596-1 and GND on the DADF Control
PWB.
Y
N
Ensure that Fuse F2 on the DADF Control PWB is good. If the Fuse is
Go to Flag 2 on BSD 5.5. Check the wires for an open circuit. If the wires are
good, replace the DADF Exit Motor (PL 12.9).
Enter dC330 005-081 Exit Motor. Press Start. Approximately +17 VDC is measured between pins 2, 3, 4, and 5 of P/J596 and GND on the DADF Control
PWB.
Y
N
Replace the DADF Control PWB (PL 12.3). If the problem continues, replace
the DADF Exit Motor (PL 12.9).
Replace the DADF Exit Motor (PL 12.9).
required. If the problem continues perform ADJ 12.3.3. If the problem continues check the
following parts for wear, slipping excessive contamination or damage.
Exit Roll Drive Belt
A
1/05
2-42
Reissue
DocuColor 12/DCCS50
Exit Roll
Exit Pinch Roll
Document Belt
5-116 DADF Exit Sensor OFF Dynamic Jam RAP

The DADF Exit Sensor did not deactuate within 650 msec after it was actuated.
Platen Glass
Initial Actions
Enter dC330 005-115 Exit Sensor. Press Start. Block the DADF Exit Sensor. The
display
changed from L to H.
Y
N
With paper at the DADF Exit Sensor, less than +1 VDC is measured at P/J599-19 on
the DADF Control PWB.
Y
N
+5 VDC is measured between P/J589-1 and P/J589-3 on the DADF Exit Sensor.
Y
N
Go to Flag 3 BSD 5.5. Check the wires for an open circuit or a short circuit. If
Check the following parts for wear, slipping excessive contamination or damage.
Exit Roll
Exit Pinch Roll
Document Belt
Platen Glass
Control PWB and DADF Exit Sensor and there are no obvious crimped or broken wires.
The trail edge of the document is past the Exit Sensor.

Y
N
Enter dC330 005-081 Exit Motor. The DADF Exit Motor energizes.
Y
N
The fuse is good.
Y
N
Install a new fuse. If the fuse blows again, replace the DADF Exit Motor. If the
fuse blows again, replace the DADF Control PWB.
Procedure
Go to Flag 1 on BSD 5.5. Check the wire for an open circuit. If the wire is good,
replace the DADF Exit Sensor (PL 12.9).
Press Stop. +24 VDC is measured between pins 2, 3, 4, 5 of P/J596 and GND.
on the DADF Control PWB.
Y
N
+24 VDC is measured between P/J596-1 and GND on the DADF Control
PWB.
Y
N
Ensure that Fuse F2 on the DADF Control PWB is good. If the Fuse is
If the above items are good and free from excessive contamination, replace the DADF Exit
Sensor (PL 12.9).
good, replace the DADF Exit Motor (PL 12.9).
Enter dC330 005-081 Exit Motor. The Press Start. Approximately +17 VDC is
measured between pins 2, 3, 4, and 5 of P/J596 and GND on the DADF Control
PWB.
Y
N
Replace the DADF Control PWB (PL 12.3). If the problem continues, replace
the DADF Exit Motor (PL 12.9).
Replace the DADF Exit Motor (PL 12.9).
required. If the problem continues perform ADJ 12.3.3. If the problem continues check the
following parts for wear, slipping excessive contamination or damage.
Exit Roll
A
Reissue
DocuColor 12/DCCS50
1/05
2-43
5-115 DADF Exit Sensor ON Dynamic Jam RAP, 5-
Exit Pinch Roll
Document Belt
5-189 No Object Sensor Static Jam RAP

The Control Logic has detected the document Handler was raised while running a DADF job.
Enter dC330 005-115 Exit Sensor. Press Start. Block the DADF Exit Sensor. The
display
changed from L to H.
Y
N
With paper at the DADF Exit Sensor, less than +1 VDC is measured at P/J599-19 on
the DADF Control PWB.
Y
N
+5 VDC is measured between P/J589-1 and P/J589-3 on the DADF Exit Sensor.
Y
N
Go to Flag 3 BSD 5.5. Check the wires for an open circuit or a short circuit. If
Initial Actions
Ensure that then document handler is fully closed.
Procedure
If the document Handler was not opened during a DADF job, go to 6-300 Platen Cover Open
RAP to troubleshoot the Platen Open Switch.
replace the DADF Exit Sensor (PL 12.9).
Check the following parts for wear slipping or damage.
Exit Roll
Exit Pinch Roll
Document Belt
Platen Glass
If the above items are good and free from excessive contamination, replace the DADF Exit
Sensor (PL 12.9).
5-116 DADF Exit Sensor OFF Dynamic Jam RAP, 5-
1/05
2-44
Reissue
DocuColor 12/DCCS50
5-195 No Mix - Size Mismatch Jam RAP
5-196 DADF Document Sensor Static Jam RAP
The DADF Control PWB detected different sized documents when the mixed sized feature has
not been selected.
The DADF Document Sensor detected paper when power was switched on.
Initial Actions
Procedure
This is a message Fault and requires operator actions. If this Fault occurs and the originals are
all the same size, check that the Side Guide can be properly adjusted against the stack. If so,
go to the 5-274 Original Size Sensor Fail RAP.
Contamination on the DADF Document Sensor.
PWB and DADF Document Sensor and there are no obvious crimped or broken wires.
Ensure that the DADF Entrance Tray is free of any paper or debris.
Procedure
Enter dC330 005-102 Document Sensor. Press Start. The display is H.
Y
N
+5 VDC is measured between P/J599-5 and GND on the DADF Control PWB.
Y
N
good, replace the DADF Document Sensor (PL 12.5).
The problem appears to be intermittent. Replace the DADF Document Sensor (PL 12.5). If the
problem continues, replace the DADF Control PWB (PL 12.3).
Reissue
DocuColor 12/DCCS50
1/05
2-45
5-195 No Mix - Size Mismatch Jam RAP, 5-196
5-197 DADF Registration Sensor Static Jam RAP
5-198 DADF Exit Sensor Static Jam RAP
The DADF Registration Sensor has detected the presence of a document after the power was
switched on and the DADF Top Cover was closed.
The DADF Exit Sensor has detected the presence of a document after the power was switched
on and the DADF Top Cover was closed.
Initial Actions
Initial Actions
Ensure that no documents remain in the DADF.
PWB and DADF Exit Sensor and there are no obvious crimped or broken wires.
Procedure
Procedure
Enter dC330 005-110 Regi Sensor. Press Start. The display is L.

Y
N
Y
N
Go to Flag 1 on BSD 5.3.Check the wire for a short circuit to ground. If the wire is
good, replace the DADF Registration Sensor (PL 12.5).
Enter dC330 005-115 Exit Sensor. Press Start. The display is L.

Y
N
Y
N
Go to Flag 1 on BSD 5.5.Check the wire for a short circuit to ground. If the wire is
good, replace the DADF Exit Sensor (PL 12.9).
The problem appears to be intermittent. Replace the DADF Registration Sensor (PL 12.5). If
the problem continues, replace the DADF Control PWB (PL 12.3).
5-197 DADF Registration Sensor Static Jam RAP, 5-
The problem appears to be intermittent. Replace the DADF Exit Sensor (PL 12.9). If the problem continues, replace the DADF Control PWB (PL 12.3).
1/05
2-46
Reissue
DocuColor 12/DCCS50
5-199 DADF Duplex Sensor Static Jam RAP
5-274 Original Size Sensor Fail RAP
The DADF Duplex has detected the presence of a document after the power was switched on
and the DADF Top Cover was closed.
The Control Logic has detected a DADF Size Sensor 1 or DADF Size Sensor 2 failure or a
DADF Ram Test failure after switching the power on or placing the originals in the Entrance
Tray.
Refer to BSDs 5.3 for the following procedure.
Initial Actions
Initial Actions
Ensure that the Document Handler is free of any paper or debris.
Contamination on the DADF Duplex Sensor.
PWB and DADF Exit Sensor and there are no obvious crimped or broken wires.
Control PWB and DADF Size Sensors 1 and 2, and there are no obvious crimped or broken wires.
Procedure
Procedure
Enter dC330 005-150 #1 Size Sensor. Press Start. Block DADF Size Sensor 1. The display
changed from H to L.
Y
N
With the sensor blocked, less than +1 VDC is measured at P/J599-8 on the DADF
Control PWB.
Y
N
With the sensor blocked, less than +1 VDC is measured at P/J582-2 on DADF
Size Sensor 1.
Y
N
There is +5 VDC between P/J582-1 and P/J582-3 on the DADF Size Sensor 1.
Y
N
Go to Flag 6 on BSD 5.3 and check the wires for an open circuit. If the
wires are good, replace the DADF Control PWB (PL 12.3).
Enter dC330 005-119 Dup Sensor. Press Start. The display is L.

Y
N
Y
N
good, replace the DADF Duplex Sensor (PL 12.7).
The problem appears to be intermittent. Replace the DADF Duplex Sensor (PL 12.7). If the
problem continues, replace the DADF Control PWB (PL 12.3).
Replace the DADF Size Sensor 1 (Rear) (PL 12.5).

Go to Flag 3 on BSD 5.3 and check the wire for an open circuit.
Y
N
Control PWB.
Y
N
With the sensor blocked, less than +1 VDC is measured at P/J583-2 on the
DADF Size Sensor 2.
Y
N
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
2-47
D
5-199 DADF Duplex Sensor Static Jam RAP, 5-274
D
Replace the DADF Size Sensor 2 (Front) (PL 12.5).
5-275 DADF RAM Check Fail RAP
The Control Logic has detected a DADF Size Sensor 1 or DADF Size Sensor 2 failure or a
DADF Ram Test failure after switching the power on or placing the originals in the Entrance
Tray.
Initial Actions
Procedure
Y
N
Control PWB.
Y
N
Size Sensor 1.
Y
N
Y
N
Y
N
Control PWB.
Y
N
DADF Size Sensor 2.
Y
N
Y
N
A
5-274 Original Size Sensor Fail RAP, 5-275 DADF
1/05
2-48
D
Reissue
DocuColor 12/DCCS50
D
5-301 Top Cover Open RAP
The DADF Control PWB detected a signal from the Top Cover Front and/or Rear Interlock
Switches indicating that the DADF Top Cover is open at the start of print or during print run.
Initial Actions
The magnetic latches or actuators for the top cover are not damaged or loose.
The magnet plate on the top cover fully contacts the magnetic latches.
Procedure
Open the Top Cover. Enter dC330 005-301 Top Cover Interlock Switch. Actuate both Top
Cover Switches. The display changes. from H to L
Y
N
Go to BSD 5.1. Check both Interlock Switches with a meter. Ensure that there is continuity
across the switch contacts when the switches are closed. Replace any defective switches
(PL 12.2). If the switches are good, go to Flag 1, Flag 2, Flag 3, and Flag 4 on BSD 5.1,
and check the wires for an open circuit. If the wires are good, replace the DADF Control
PWB (PL 12.3).
Check that the Top Cover Interlock Switches are correctly installed. If the problem continues,
replace both interlock switches (PL 12.2).
Reissue
DocuColor 12/DCCS50
1/05
2-49
5-275 DADF RAM Check Fail RAP, 5-301 Top Cover
5-500 DADF No Originals RAP
5-501 DADF Document Size Irregular RAP
The DADF Control PWB detected that the original was removed from the Entrance Tray after
the DADF started operating.
The Control Logic has detected that a automatically-detected size of the original was irregular.
Initial Actions
Initial Actions
Return the removed originals to the Entrance Tray and attempt to run the job again. If no originals were removed, proceed with this RAP.
The Side Guide can be properly adjusted against the stack.
Contamination on the DADF Document Sensor.
PWB and DADF Document Sensor and there are no obvious crimped or broken wires.
Procedure
Y
N
Control PWB.
Y
N
Size Sensor 1.
Y
N
Y
N
Procedure
Enter dC330 005-102 Document Sensor. Press Start. Block the DADF Document Sensor.
The display changes from H to L.
Y
N
Less than +1 VDC is measured at P/J599-5 on the DADF Control PWB.
Y
N
+5 VDC is measured between P/J581-1 and P/J581-3 on the DADF Document
Sensor.
Y
N
Go to Flag 5 on BSD 5.2 and check the wires for an open circuit. If the harness
and connectors are OK, replace the DADF Control PWB (PL 12.3).
replace the DADF Document Sensor (PL 12.5).
Replace the DADF Document Sensor (PL 12.5). If the problem continues, replace the DADF
Control PWB (PL 12.3).
Y
N
Control PWB.
Y
N
DADF Size Sensor 2.
Y
N
Y
N
A
5-500 DADF No Originals RAP, 5-501 DADF Document
1/05
2-50
C
Reissue
DocuColor 12/DCCS50
C
5-503 Miss Doc Reset RAP
The Missing Document Reset fault code (05-503) is displayed when the Control Logic has
detected that after counting and returning the originals, there is a mismatch between the number of pages counted and the actual number of pages.
Replace the following until the problem is resolved
DADF Control PWB (PL 12.3).
DADF Size Sensor 1 (Rear) (PL 12.5)
Procedure
DADF Size Sensor 2 (Front) (PL 12.5).
Remove and reinsert the originals in the DADF Entrance Tray.
Run the job again.
Reissue
DocuColor 12/DCCS50
1/05
2-51
5-501 DADF Document Size Irregular RAP, 5-503
5-999 ADF Document Misfeed RAP
OF5-1 DADF Jam Recovery RAP
A document misfeed occurred during or after ADF Jam Recovery.
Jam Recovery problems occur when a jam clearance activity results in the complete re-copying
of a set of documents, instead of resuming the copy job at the point where the jam occurred.
Procedure
Check the set of originals for torn or damaged documents. Replace or recreate the original as required.
Remove and reinsert the originals in the ADF.
Run the job again.
5-999 ADF Document Misfeed RAP, OF5-1 DADF Jam
Procedure
Check the Tag Matrix for TAG P19. If the Tag is not marked off, install the Tag 19 DADF Software Upgrade to V2.2 Kit, by replacing U2 on the DADF Control PWB (PL 12.3) with the
EProm contained in the kit.
1/05
2-52
Reissue
DocuColor 12/DCCS50
6-275 Angle Sensor Fail RAP

The Control Logic has detected the Platen Angle Sensor is not in the correct state for the Job
Programed.
Refer to BSD 6.2 and BSD 6.7 in the following procedure.
Check the Document Handler for dirt or debris.
Check that the Document Handler Cover opens and closes without binding.
C
Go to Flag 2 on 6.2 and check the wires for an open or short circuit. If the wires are
OK, replace the Platen Angle Sensor (PL 3.2).
+5VDC is measured between P/J515-4 and GND on the Pre IPS PWB.
Y
N
Go to Flag 1 on BSD 6.2 and check the wires for an open or short circuit. If the wires
are OK, replace the PRE IPS PWB (PL 3.5).
Initial Actions
Clean and check the Platen Angle Sensor for damage. If the problem continues, replace
the Platen Angle Sensor (PL 3.2).
Procedure
Clean and check the Platen Angle Sensor for damage. If the problem continues, replace the
Platen Angle Sensor (PL 3.2)
Close the Document Handler Cover. Enter dC330 006-301 Angle Sensor. Press Start. The
Display is HIGH.
Y
N
Open the Document Handler Cover. The Display is Low.
Y
N
+5VDC is measured between P/J531-1 and P/J531-3 on the Platen Angle Sensor.
Y
N
+5VDC is measured between P/J515-6 and P/J515-2 on the Pre IPS PWB.
Y
N
Go to Flag 2 on BSD 6.2 and check the wires for an open or short circuit. If
the wires are OK, replace the Pre IPS PWB. (PL 3.5).
Go to Flag 2 on BSD 6.2 and check the wires for an open or short circuit. If the
wires are OK, replace the Platen Angle Sensor (PL 3.2).
+5VDC is measured between P/J515-4 to GND on the Pre IPS PWB.
Y
N
Go to Flag 3 on BSD 6.2 and check the wire for an open or short. If the wire is
OK, replace the Pre IPS PWB (PL 3.5).
Clean and check the Platen Angle Sensor for damage. If the problem continues,
replace the Platen Angle Sensor (PL 3.2).
Block and unblock the Platen Angle Sensor. The Display changes.
Y
N
Go to Flag 3 on BSD 6.2 and check the wire for an open or short circuit.
Clean and check the Platen Angle Sensor for damage. If the problem continues, replace
the Platen Angle Sensor (PL 3.2)
Open the Document Handler Cover. The Display is Low.
Y
N
+5VDC is measured between P/J531-1 and P/J531-3 on the Platen Angle Sensor.
Y
N
+5VDC is measured between P/J515-6 and P/J515-2 on the Pre IPS PWB.
Y
N
wires are OK, replace the PRE IPS PWB (PL 3.5).
A
B
C
Reissue
DocuColor 12/DCCS50
1/05
2-53
6-275 Angle Sensor Fail RAP
6-277 IISS - DADF Communications Fault RAP
6-300 Platen Cover Open RAP
The Pre IPS PWB detected a communication fault between the DADF Control PWB and the
Pre IPS PWB.
A fault code for Platen Cover Open appears even when the Platen Cover is physically closed.
Initial Actions
Initial Actions
Refer to BSD 3.3 in the following procedure.
Ensure that P/J551 on the DADF Control PWB is firmly seated.
Ensure that J543B on the communication line is firmly seated.
+5VDC is measured between P/J550-5 and P/J550-6 on the DADF Control PWB.
Y
N
Go to the +5VDC Power (IOT LVPS) RAP.
Reconnect P/J530. Open the Platen Cover. The voltage at P/J515-3 goes to less
than +1 VDC.
Y
N
Go to Flag 4, Flag 5, and Flag 6 on BSD 6.2 and check the wires for an open
circuit. If the wires are good, replace the Platen Open Switch (PL 3.2).
Go to Flag 1 on BSD 3.3 and check the wiring for an open circuit. If the wiring is OK, then
replace the DADF Control PWB (PL 12.3). If the problem continues, replace the following:
Pre IPS PWB (PL 3.5)

MEM SYS PWB (PL 3.5)
Post IPS PWB (PL 3.5)
Check that the Platen Cover closes properly.
Close the Platen Cover. Enter dC330 006-300 Platen Interlock Switch (IISS). Press Start.
The Display is H.
Y
N
Manually actuate the Platen Open Switch. The display changes.
Y
N
Disconnect P/J530. +5VDC is measured between P/J515-3 and GND on the
Pre IPS PWB.
Y
N
Replace the Pre IPS PWB (PL 3.5)
PO/PO the machine. The Fault Code is still declared.

Y
N
Inspect the PRE IPS PWB the MEM SYS PWB, the POST IPS PWB for loose connections or any obvious electrical/mechanical cause for malfunction.
Procedure
Procedure
Check the Platen Open Switch for intermittent operation. If the switch is good,
replace the Pre IPS PWB (PL 3.5). If the problem continues, replace the Platen
Open Switch (PL 3.2).
Check the Platen Open Switch for alignment and /or damage. If the Fault continues,
replace the Platen Open Switch (PL 3.2).
Open the Platen Cover The display is L
Y
N
Check the Platen Open Switch for alignment and /or damage. If the Fault continues,
replace the Platen Open Switch (PL 3.2).
Check the Platen Open Switch for alignment and /or damage. Go to Flag 4, Flag 5, on BSD 6.2
and check the wires for an open or short circuit. If the wires are OK, replace the Platen Open
Switch (PL 3.2).
6-277 IISS - DADF Communications Fault RAP, 6-300
1/05
2-54
Reissue
DocuColor 12/DCCS50
6-312 Memory Hotline Fail RAP
6-340 Pre IPS RAM Test Error RAP
The Control Logic has detected a communication error between the POST IPS PWB and the
MEM SYS PWB.
The Pre IPS PWB Ram Test detected a failure at power on.
Initial Actions
Refer to BSD 6.7 in this procedure:
Refer to BSD 3.2 and BSD 6.7 in the following procedure:
Check that P/J560 and P/J561 on the MEM SYS PWB are seated.
Ensure that the PRE IPS PWB, the MEM SYS PWB and the Post IPS PWB are firmly
seated.
Check that the Option Memory PWBs are fully seated on the MEM SYS PWB.
Initial Actions
Procedure
PO/PO the machine. The fault code is still declared.
Y
N
Procedure
PO/PO the machine. The fault code is still declared.
Y
N
Replace the following:
Option Memory PWBs (PL 3.5) on at a time.
MEM SYS PWB (PL 3.5).
POST IPS PWB (PL 3.5).
Pre IPS PWB (PL 3.5).
Reissue
DocuColor 12/DCCS50
1/05
2-55
Replace the MEM SYS PWB (PL 3.5).
Replace the Post IPS PWB (PL 3.5).
6-312 Memory Hotline Fail RAP, 6-340 Pre IPS RAM
6-345 Pre IPS EEPROM Failure RAP
6-355 IPS Fan Fail RAP
A Failure was detected when writing to the NVM and a communication failure with the
EEPROM when writing into the Pre IPS PWB NVM.
The IIT Driver PWB detected a control error caused by an IPS Fan failure. This error is not
detected during document scan.
Initial Actions
Initial Actions
Refer to BSD 3.3 PWB Communications (DADF) in this procedure:
Ensure that P/J551 on the DADF Control PWB is firmly seated.
Procedure
Procedure
Enter dC330 006-013 Cooling Fan High Speed. Press Start. The IPS Fan rotates.
Y
N
Press Stop. Enter dC330 006-003 Cooling Fan Low Speed. Press Start. The IPS Fan
rotates.
Y
N
+3.5VDC is measured between P/J524-4 and GND on the IIT Driver PWB.
Y
N
Go to Flag 5 on the BSD 6.1 and check the wire for an open or short circuit. If
the wire is OK, replace the Pre IPS PWB (PL 3.5).

Y
N
+24VDC is pulsed between P/J523-2 and P/J523-4 on the IIT Drive PWB.
Y
N
Press Stop. Select [06013]. Press Start. +5VDC is measured between P/J524-3
and GND on the IIT Driver PWB.
Y
N
Go to Flag 6 on the BSD 6.1 and check the wire for an open or short circuit. If
the wire is OK, replace the Pre IPS PWB (PL 3.5).
+24VDC is measure between P/J523-1 and P/J523-4 on the IIT Driver PWB.
Y
N
are OK, replace the IPS Fan (PL 3.2).
Press Stop. Select [06-013]. Press Start. +5VDC is measured between P/J524-3 and
GND on the IIT Driver PWB.
Y
N
Go to Flag 6 on the BSD 6.1 and check the wire for an open or short circuit. If the
wire is OK, replace the IPS PWB (PL 3.5).
+24VDC is measured between P/J523-1 and P/J523-4 on the IIT Driver PWB.
Y
N
Go to Flag 2 on BSD 6.1 and check the wires for an open or short circuit. If the wires are
OK, replace the IPS Fan (PL 3.2).
+5VDC is measured between P/J515-16 and GND on the Pre IPS PWB.
6-345 Pre IPS EEPROM Failure RAP, 6-355 IPS Fan
1/05
2-56
Reissue
DocuColor 12/DCCS50
6-360 Carriage Position Failure RAP
N
Replace the Pre IPS PWB (PL 3.5).
The Control Logic detected the Carriage out of position during Carriage Initialization
+ 5VDC is measured at P/J523-3 and GND on the Driver PWB.

Y
N
Go to Flag 4 on BSD 6.1 and check the wire for an open or short. If the wire is OK, replace
the IPS Fan (PL 3.2).
Initial Actions
Go to Flag 4 on BSD 6.1 and check the wires for an open or short circuit. If the wires are OK,
replace the IIT Driver PWB (PL 3.2).
Check the Carriage assembly for wear, dirt and debris, and misalignment of the components.
Verify that the IIT Regi Sensor is correctly aligned and free from contamination.
Verify that the Carriage and Carriage Cable are installed correctly and free of damage.
Procedure
Go to the 6-361 Scan Initialize Regi Sensor Failure RAP.
Reissue
DocuColor 12/DCCS50
1/05
2-57
6-355 IPS Fan Fail RAP, 6-360 Carriage Position
6-361 Scan Initialize Regi Sensor Failure RAP
The IIT Driver PWB detected an inability to control the Carriage during carriage during initialization.
N
Go to Flag 3 on BSD 6.3 and check the wires for an open circuit or short circuit. If the
wires are OK, replace the Pre IPS PWB (PL 3.5).
+5VDC is measured between P/J520-1,4,5,6,3 and GND on the IIT Driver PWB.
Y
N
Initial Actions
Refer to BSD 6.3 and BSD 6.7 in the following procedure
Check the Carriage assembly for wear, dirt, debris, and misalignment of the components.
Verify that the IIT Registration Sensor is correctly aligned and free from contamination.
Verify that the Carriage and Carriage Cable are installed properly and free from damage.
Go to Flag 4 on BSD 6.3 and check the wires for an open circuit or short circuit. If the
wires are OK, replace the Carriage Motor (PL 3.3).
Continue to run the Carriage through the full range of travel using dC330 006-005 IIT Scan
Motor (Scan) and 006-006 IIT Scan Motor (Return). Observe the motion and listen for any
abnormal sounds in the Carriage motor and assembly. The Carriage motor and assembly
appear to be defect free.
Y
N
Inspect the assembly for damage, misalignment, dirt, or debris. Verify that the Carriage
Cables are properly installed and free from damage. Repair or replace as required.
Procedure
Enter dC330 006-212 Registration Sensor. Press Start. Manually move the Full Rate Carriage from the full left position to the full right position and back full left. The display changes
from L to H then back to L.
Y
N
Actuate the IIT Regi Sensor with a piece of paper. The display is L.
Y
N
Disconnect P/J532 on the IIT Registration Sensor. The display is H.
Y
N
wires are OK, replace the Pre-IPS PWB (PL 3.5).
Go to Flag 1, Flag 2, Flag 3, and Flag 4 on BSD 6.3 and check the wires for an open or short
circuit. If the wires are OK, replace the following:
Replace the IIT Registration Sensor (PL 3.2).
Carriage Motor (PL 3.3)
IIT Driver PWB (PL 3.2)
Deactuate the IIT Registration Sensor. The display is H.

Y
N
+5 VDC is measured between P/J532-2 and GND on the IIT Registration Sensor.
Y
N
Go to Flag 1 on BSD 6.3 and check the wire for an open or short circuit. If the
wire is OK, replace the Pre IPS PWB (PL 3.5)
There is +5 VDC between P/J532-1 and P/J532-3 on the IIT Regi Sensor.
Y
N
wires are OK, replace the Pre IPS PWB (PL 3.5).
Clean and align the IIT Regi Sensor. If the problem continues, replace the IOT PWB
(PL 9.2).
Clean the IIT Regi Sensor and check for damaged and proper aligned. If the problem continues, replace the IIT Regi Sensor (PL 3.2).
Enter dC330 006-005 IIT Scan Motor (Scan) and 006-006 IIT Scan Motor (Return).
Carriage moves Right [06-005] and Left [06-006].
Y
N
+5VDC is measured between P/J524-12 and P/J524-8 on the IIT Driver PWB
A
6-361 Scan Initialize Regi Sensor Failure RAP
The
1/05
2-58
Reissue
DocuColor 12/DCCS50
6-371 Exposure Lamp Fail RAP
6-389 Carriage Overrun Fail (Scan End) RAP
The IIT Driver PWB detected a control error caused by an Exposure Lamp power failure.
The IIT Regi (Registration) Sensor detected an overrun during Full Rate Carriage scanning.
Initial Actions
Procedure
Procedure
Enter dC330 006-002 ITT Exposure Lamp. Press Start. The Exposure Lamp lights.
Y
N
+5VDC is measured between P/J524 -1 and GND on the IIT Driver PWB.
Y
N
Go to Flag 7 on BSD 6.1 and check the wire. If the wire is OK, replace the Pre IPS
PWB (PL 3.5).
0 VDC is measured between P/J534-3 and P/J534-2 on the Lamp Ballast.
Y
N
are OK, replace the IIT Driver PWB
Set the DMM to max recording mode (+ peak hold). +5VDC is measured between P/
J524-2 and GND on the IIT Driver PWB.
Y
N
are OK, replace the Pre IPS PWB (PL 3.5).
Set the DMM to max recording mode (+ peak hold). +5VDC is measured between P/
J534-6 and P/J534-2 on the Lamp Ballast PWB.
Y
N
Go to Flag 10 on BSD 6.1 and check the wire for an open or short circuit. If the wire
is OK, replace the IIT Driver PWB (PL 3.2).
+24VDC is measured between P/J534-5 and P/J534-2 on the Lamp Ballast PWB.
Y
N
wires are OK, replace the IIT Driver PWB (PL 3.2).
Replace the Flash Lamp Ballast PWB (PL 3.4) if the problem continues, replace the
Exposure Lamp (PL 3.4).
If the Fault continues, perform the following:
Ensure that the connectors are fully seated.
Go to Flag 7, Flag 8, Flag 9 and Flag 10 on BSD 6.1 and check the wires for damage.
Replace the following in order:
Exposure Lamp (PL 3.4)
Lamp Ballast PWB (PL 3.4)
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6-371 Exposure Lamp Fail RAP, 6-389 Carriage
6-390 Carriage Overrun Fail (Home End) RAP
6 391 Scan Initialize Failure RAP
The IIT Regi (Registration) Sensor detected an overrun during Full Rate return.
The IIT Regi (Registration) Sensor Changed to high when the Carriage Initialization Started.
Initial Actions
Initial Actions
Verify that the IIT Regi Sensor is correctly aligned and free from contamination.
Verify that the Full Rate Carriage and Carriage Cables are installed correctly.
Check the Full Rate Carriage Assembly for wear, foreign matter, and alignment of the
components.
Refer to BSD 6.3 and 6.7 in the following procedure:
Ensure that P/J515 on the Pre IPS PWB is firmly seated.
Ensure that P/J532 on the IIT Regi Sensor is firmly seated.
Procedure
Enter dC330 006-212 Registration Sensor. Press Start. Move the Full Rate Carriage from the
Home position to the full left position. The display changes from High to Low.
Y
N
Procedure
Move the Full Rate Carriage to the Home Position. The display changes to High.
Y
N
6-390 Carriage Overrun Fail (Home End) RAP, 6 391
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DocuColor 12/DCCS50
6-500 Lamp Not Ready RAP
6-615 b* Failure RAP
The Control Logic has detected that the Exposure Lamp Light did not reach the specified value
at Start.
The Control Logic has detected that the measured b* is out of the specific range.
Initial Actions
Initial Actions
Procedure
Ensure that the PRE IPS PWB, CCD PWB, MEM SYS PWB and the POST IPS PWB and
their connectors are seated properly.
Check that the Option Memory PWBs are fully seated on the MEM SYS PWB.
PO/PO the machine. If the fault continues go to the 6-371 Exposure Lamp Fail RAP.
Procedure
PO/PO the machine. If the fault continues go to Flag 1 on BSD 6.2 and check the wires for an
open or short circuit. If the fault continues, replace the following:
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CCD PWB (PL 3.2).
Pre IPS PWB (PL 3.5).
MEM SYS PWB (PL 3.5).
POST IPS PWB (PL 3.5).
6-500 Lamp Not Ready RAP, 6-615 b* Failure RAP
6-620 Reflection Rate Failure RAP

The Control Logic has detected that the measured reflective rate for each color is out of the
specific range.
Initial Actions
Ensure that the Exposure Lamp Light Path is not blocked or dirty.
Procedure
PO/PO the machine. If the Fault continues go to the 6-371 Exposure Lamp Fail RAP.
6-620 Reflection Rate Failure RAP
1/05
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Reissue
DocuColor 12/DCCS50
7-281 Tray 1 Lift Motor Failure RAP
Enter dC330 008-008 Tray 1 Feed/Lift Motor (Feed) Tray1 Feed/Lift Motor. Press Start and
Stop several times. The Feed/Lift Motor energizes and deenergizes.
Y
N
+24 VDC is measured between P/J414A-14 on the IOT Drive PWB and GND.
Y
N
Check the fuse on the Tray PWB. Fuse is OK.
Y
N
Replace fuse (PL 9.3).
The Tray 1 Stack Height Sensor failed to change state within the specified time after Tray 1
Feed/Lift Motor was energized.
Initial Actions
Refer to BSD 7.5 and BSD 7.10 for the following procedure.
Ensure there is paper loaded in the Tray 1.
Ensure connector P/J414A on the IOT Drive PWB is properly seated (PL 9.2).
Check for crimped or broken wires to connectors on the IOT Drive PWB (PL 9.2).
Pull out Paper Tray 1.
Open the Lower Left Door (PL 2.8).
Remove the Screw and open the Tray 1 Feed Assembly (PL 2.2).
+24 VDC is measured between P/J23-3 on the IOT LVPS and GND.
Y
N
+24 VDC is measured between P/J414A-A15 on the IOT Drive PWB and GND.
Y
N
Y
N
Procedure
Cheat the L/H Cover INTLK Switch. Remove the Tray 1 Feed Assembly without disconnecting
P/J791. Enter dC330 008-221 Tray 1 Level Sensor. Press Start. Manually actuate the Tray 1
Stack Height Sensor. The display changed from H to L.
Y
N
+0 VDC is measured at P/J414A-10 on the IOT Drive PWB.
Y
N
+5 VDC is measured at P/J130-2 on the Tray 1 Stack Height Sensor.
Y
N
Go to Flag 5 and Flag 6 on BSD 7.5 and check the harness and connectors. If
the harness and connectors are OK, replace the IOT Drive PWB.
Y
N
Go to Flag 3 on BSD 7.5 and check the harness and connectors. If the harness and
connectors are OK, replace the Tray 1 Feed/Lift Motor (PL 2.2).
Go to Flag 3 and Flag 4 on BSD 7.5 and check the wires for an open or a short circuit. If
the wires are OK replace the IOT Drive PWB (PL 9.2). If the problem continues, replace
the Tray 1 Feed/Lift Motor (PL 2.6).
+5 VDC is measured between P/J130-1 and P/J130-3 on the Tray 1 Stack

Height Sensor.
Y
N
+5 VDC is measured between P/J21-1 and P/J21-5 on the IOT LVPS.
Y
N
Enter dC330 008-231 Tray 1 No Paper Sensor. Press Start. Manually actuate the Tray 1 No
Paper Sensor. The display changed from H to L.
Y
N
Y
N
+5 VDC is measured at P/J129-2 on the Tray 1 No Paper Sensor.
Y
N
+5 VDC is measured between P/J414A-11 on the Tray PWB and P/J21-5

on the IOT LVPS.
Y
N
Go to Flag 5 on BSD 7.5 and check wires for an open circuit. If the wires are
OK, replace the IOT Drive PWB (PL 9.2).
+5VDC is measured between P/J129-1 and P/J129-3 on the Tray 1 No Paper

Sensor.
Y
N
Y
N
Push the Tray in. Enter dC330 008-007 Tray 1 Feed/Lift Motor (Lift) Tray1 Feed/Lift Motor.
Press Start and Stop several times.
OK, replace the IOT Drive PWB (PL 9.2)
Check that the mechanical flag on the Tray 1 Stack Height Sensor is not bent. If the
sensor flag is OK, replace the Tray 1 Stack Height Sensor (PL 2.5).
A
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C
C
Replace the Tray 1 No Paper Sensor (PL 2.5).
The Tray 2 Stack Height Sensor failed to change state within the specified time after Tray 2 Lift/
Feed Motor was energized.
Initial Actions
Check/replace the following parts in the order listed until the problem is resolved. Replace any
parts that are worn, broken, binding, or missing.
Tray 1 Paper Feed Assembly (PL 2.4)
Tray 1 Assembly (PL 2.1)
Wiring Harness
Ensure connector P/J803 on the Tray PWB is properly seated (PL 9.3).
Procedure
Y
N
+0 VDC is measured at P/J415A-15 on the IOT Drive PWB and GND.
Y
N
Y
N
Height Sensor.
Y
N
Y
N
+5 VDC is measured between P/J803-A11 on the Tray PWB and P/J21-5
on the IOT LVPS.
Y
N
OK, replace the Tray PWB (PL 9.3).
Replace the Tray 2 Stack Height Sensor (PL 2.5).
Go to Flag 6 on BSD 7.6 and check the wire for an open or a short circuit. If the wire is
Push the Tray in. Enter dC330 008-012 Tray 2 Feed/Lift Motor (Lift), 008-013 Tray 2 Feed/
Lift Motor (Feed) Tray 2 Feed/Lift Motor. Press Start and Stop several times.
1/05
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A
CAUTION
C
Y
Do not operate the component control more than twice before resetting paper position. To
lower the paper from the feed position, pull out respective tray. If the tray is overdriven, it will be
hard to pull out and may cause component damage.
N
+5 VDC is measured between P/J803-A8 on the Tray PWB and P/J21-5 on

the IOT LVPS.
Y
N
The Feed/Lift Motor energizes and deenergizes.

Y
N
+24 VDC is measured between P/J803-A14 on the Tray PWB and GND.
Y
N
Y
N
Y
N
Go to Flag 1 on BSD 7.6 and check the wire for an open or a short circuit. If the wire is
+24 VDC is measured between P/J803-A15 and GND on the IOT Drive PWB.
Y
N
Y
N
Wiring Harness
+24 VDC is measured between P/J23-3 and GND on the IOT LVPS and P/J803A15 on the IOT Drive PWB.
Y
N
Go to Flag 3 and Flag 4 on BSD 7.6 and check the harness and connectors. If the
harness and connectors are OK, replace the Tray PWB (PL 9.3). If the problem continues, replace the Tray 2 Feed/Lift Motor (PL 2.6).
Go to Flag 3 and Flag 4 on BSD 7.6 and check the harness and connectors. If the harness and connectors are OK, replace the IOT Drive PWB (PL 9.2)
Y
N
+0 VDC is measured at P/J415A-A16 on the IOT Drive PWB and GND.
Y
N
Y
N
+5 VDC is measured between P/J129-1 and P/J129-3 on the Tray 2 No Paper
Sensor.
Y
N
A
B
C
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CAUTION
The Tray 3 Stack Height Sensor (PL 2.5) failed to change state within the specified time after
Tray 3 Feed/Lift Motor was energized.

Y
N
+24 VDC is measured between P/J803B-14 and GND on the Tray PWB.
Y
N
Y
N
Initial Actions
+24 VDC is measured between P/J23-3 and GND on the IOT LVPS.
Y
N
Procedure
Y
N
Y
N
Y
N
+24 VDC is measured between P/J803B-15 and GND on the Tray PWB.
Y
N
Y
N
Y
N

Height Sensor.
Y
N
Y
N
Go to Flag 3 on BSD 7.7 and check the wires and connectors. If the wires and connectors are OK, replace the Tray 3 Feed/Lift Motor (PL 2.6).
Go to Flag 3 and Flag 4 on BSD 7.7 and check the wires and connectors. If the wires and
connectors are OK, replace the Tray 3 Feed/Lift Motor (PL 2.6). If the problem continue
place the Tray PWB (PL 9.2).
+5 VDC is measured between P/J803B-11 on the Tray PWB and P/J21-5

on the IOT LVPS.
Y
N
Y
N
+0 VDC is measured at P/J803B-7 on the IOT Drive PWB and GND.
Y
N
Y
N
Go to Flag 6 on BSD 7.7 and check wires for an open circuit. If the wires are OK, replace
the IOT Drive PWB (PL 9.2).

Sensor.
Y
N
Enter dC330 008-017 Tray 3 Feed/Lift Motor (Lift), 008-018 Tray 3 Feed/Lift Motor (Feed)]
Tray 3 Feed/Lift Motor. Press Start and Stop several times.
A
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C
Reissue
DocuColor 12/DCCS50
C
Y
N
The Tray 4 Stack Height Sensor failed to change state within the specified time after Tray 4
Feed/Lift Motor was energized.
+5 VDC is measured between P/J803B-8 on the Tray PWB and P/J21-5 on

the IOT LVPS.
Y
N
Initial Actions
Go to Flag 5 on BSD 7.7 and check wires for an open circuit. If the wires are OK, replace
Wiring Harness
Procedure
Y
N
Y
N
Y
N
Height Sensor.
Y
N
Y
N
Go to the +5VDC Power (IOT LVPS) RAP.
+5 VDC is measured between P/J804-11 on the Tray PWB and P/J21-5 on
the IOT Drive PWB.
Y
N
Go to Flag 6 on BSD 7.8 and check the harness and connectors. If the harness and connectors are OK, replace the IOT Drive PWB (PL 9.2).
Push in the Tray. Enter dC330 008-022 Tray 4 Feed/Lift Motor (Lift), 008-023 Tray 4 Feed/
Lift Motor (Feed) Tray 4 Feed/Lift Motor. Press Start and Stop several times.
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A
CAUTION
C
Y
N
+5 VDC is measured between P/J804-6 on the Tray PWB and P/J21-5 on

the IOT LVPS.
Y
N

Y
N
+24 VDC is measured between P/J804-14 and GND on the Tray PWB.
Y
N
Y
N
Y
N
Go to Flag 2 on BSD 7.8 and check the harness and connectors. If the harness and connectors are OK, replace the IOT Drive PWB (PL 9.2).
+24 VDC is measured between P/J804-15 and GND on the Tray PWB.
Y
N
Y
N
Wiring Harness
Y
N
Go to Flag 3 and Flag 4 on BSD 7.7 and check the wires and connectors. If the wires and
connectors are OK, replace the Tray 3 Feed/Lift Motor (PL 2.6). If the problem continue
place the Tray PWB (PL 9.2).
Y
N
Y
N
Y
N
Sensor.
Y
N
A
B
C
1/05
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DocuColor 12/DCCS50
7-286 Tray 5 Broken (UP) RAP
The Tray 5 Stack Up Sensor failed to change state within 3 seconds after the Tray 5 Feed/Lift
Motor Up was energized.
Initial Actions
Ensure the Tray 5 top cover is closed.
Ensure connector P/J416A on the IOT Drive PWB is properly seated.
Check for crimped or broken wires to connectors on the IOT Drive PWB.
+5 VDC is measured between P/J147-1 and P/J147-3 on the Tray 5 Down Sensor.
Y
N
Y
N
+5 VDC is measured between P/J416B-5 and P/J21-5 on the IOT Drive
PWB.
Y
N
Procedure
Cheat the Tray 5 Interlock Switch. Enter dC330 008-226 Tray 5 (Bypass) Level up Sensor.
Press Start. Manually actuate the Tray 5 Stack Up Sensor. The display changed from H to
L.
Y
N
+0 VDC is measured at P/J416B-6 on the IOT Drive PWB.
Y
N
+5 VDC is measured at P/J145-2 on the Tray 5 Stack Up Sensor.
Y
N
Go to Flag 3 on BSD 7.9 and check wires between P/J147 and P/J416 for an
open or short circuit. If the wires are OK, replace the Tray 5 Stack Down Sensor
(PL 2.12).
Replace the Tray 5 Stack Down Sensor (PL 2.12).
Go to Flag 4 on BSD 7.9 and check the wire for a short circuit. If the wire is OK, replace
+5 VDC is measured between P/J145-1 and P/J145-3 on the Tray 5 Stack Up

Sensor.
Y
N
Y
N
Enter dC330 [008-040 Tray 5 Lifter Motor CCW]. Press Start and Stop several times.
CAUTION
Y
N
Press Start. +24 VDC is measured between P/J416B-20 and GND on the IOT Drive
PWB.
Y
N
Y
N

PWB.
Y
N
open or short circuit. If the wires are OK, replace the Tray 5 Stack Up Sensor
(PL 2.11).
connectors are OK, replace the Tray 5 Lift Motor (PL 2.12). If the problem continues,
replace the IOT PWB (PL 9.2).
Replace the Tray 5 Stack Up Sensor (PL 2.11).

Go to Flag 5 on BSD and check the wires for an open circuit. If the wires are OK, replace
the Tray 5 Lift Motor (PL 2.12). If the problem continues, replace the IOT Drive PWB (PL
9.2).
Cheat the Tray 5 Switch. Enter dC330 008-227 Tray 5 (Bypass) Level Down Sensor. Press
Start. Manually actuate the Tray 5 Stack Down Sensor. The display changed from L to H.
Y
N
A
Reissue
DocuColor 12/DCCS50
N
+5 VDC is measured at P/J147-2 on the Tray 5 Stack Down Sensor.
Y
N
Enter dC330 008-042 Tray 5 Lifter Motor CW. Press Start and Stop several times.
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B
CAUTION
Wiring Harness

Y
N
Press Start. +24 VDC is measured between P/J416B-19 and GND on the IOT Drive
PWB.
Y
N
Y
N
connectors are OK, replace the Tray 5 Lift Motor (PL 2.12). If the problem continues,
Go to Flag 5 on BSD 7.9 and check the wires for an open circuit. If the wires are OK,
replace the Tray 5 Lift Motor (PL 2.12). If the problem continues, replace the IOT Drive
PWB (PL 9.2).
Enter dC330 008-236 Tray 5 Paper Sensor. Press Start. Manually actuate the Tray 5 Paper
Sensor. The display changed from H to L.
Y
N
Y
N
+5 VDC is measured at P/J146-2 on the Tray 5 Paper Sensor.
Y
N
+5 VDC is measured between P/J146-1 and P/J146-3 on the Tray 5 Paper Sensor.
Y
N
Y
N
PWB.
Y
N
open circuit. If the wires are OK, replace the IOT Drive PWB (PL 9.2).
Replace the Tray 5 Paper Sensor (PL 2.1).
B
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DocuColor 12/DCCS50
7-287 Tray 5 Broken (Down) RAP
The Tray 5 Stack Down Sensor failed to change state within 3 seconds after the Tray 5 Feed/
Lift Motor Down was energized.
+5 VDC is measured between P/J147-1 and P/J147-3 on the Tray 5 Stack Down
Sensor.
Y
N
Y
N
Initial Actions
Ensure the Tray 5 top cover is closed.
Ensure connector P/J416A on the IOT Drive PWB is properly seated (PL 9.2).
N
Go to Flag 4 on BSD 7.9 and check the harness and connectors. If the harness
and connectors are OK, replace the IOT Drive PWB.
+5 VDC is measured between P/J416B-5 on the IOT Drive PWB and P/

J21-5 on the IOT LVPS.
Y
N
Procedure
Cheat the Tray 5 Switch. Enter dC330 008-226 Tray 5 (Bypass) Level up Sensor. Press
Start. Manually actuate the Tray 5 Stack Up Sensor. The display changed from H to L.
Y
N
Y
N
+5 VDC is measured at P/J145-2 on the Tray 5 Stack Up Sensor.
Y
N
and connectors are OK, replace the IOT Drive PWB.
Enter dC330 008-042 Tray 5 Lifter Motor CW. Press Start and Stop several times.
CAUTION
+5 VDC is measured between P/J145-1 and P/J145-3 on the Tray 5 Stack Up

Sensor.
Y
N
Y
N
Y
N
+24 VDC is measured between P/J416B-20 and GND on the IOT Drive PWB.
Y
N
Y
N

Y
N
connectors are OK, replace the Tray 5 Lift Motor (PL 2.12).
Enter dC330 [008-040 Tray 5 Lifter Motor CCW]. Press Start and Stop several times.
CAUTION

Cheat the Tray 5 Switch. Enter dC330 008-227 Tray 5 (Bypass) Level Down Sensor. Press
Start. Manually actuate the Tray 5 Stack Down Sensor. The display changed from H to L.
Y
N
Y
N
+5 VDC is measured at P/J147-2 on the Tray 5 Stack Down Sensor.
A
B
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Y
N
Y
N
1/05
2-71
D
D
Y
7-340 All Tray Broken RAP
N
The IOT detected that all Paper Trays are not functional.
connectors are OK, replace the Tray 5 Lift Motor (PL 2.12).
Initial Actions

Enter dC330 008-236 Tray 5 Paper Sensor. Press Start. Manually actuate the Tray 5 Paper
Y
N
Y
N
+5 VDC is measured at P/J146-2 on the Tray 5 Paper Sensor.
Y
N
Check the fuses on the Distribution PWB (PL 9.3) to ensure they are good.
+5 VDC is measured between P/J420A-1 and P/J420A-2 on the IOT CPU PWB.
Y
N
+5 VDC is measured between P/J44-8 and GND on the Distribution PWB.
Y
N
Check the fuse on the Distribution PWB. Fuse is OK.
Y
N
Wiring Harness
Check the fuse on the Tray PWB (PL 9.3) to ensure it is good.
Check for crimped or broken wires to connectors on the Tray PWB (PL 9.3).
Go to Flag 4 on BSD 1.2 and check the harness for an open circuit. If the harness is
OK, replace the Distribution PWB (PL 9.3).

Y
N
Ensure connectors P/J801A, P/J802A and P/J802B on the Tray PWB are properly
seated (PL 9.3).
+5 VDC is measured between P/J800-3 and P/J800-4 on the Tray PWB.

Y
N
+5 VDC is measured between P/J44-9 and P/J44-13 on the Distribution PWB.
Y
N
Check the fuse on the Distribution PWB. Fuse is OK.
Y
N

Y
N
Ensure the L/H Cover is securely closed.
Procedure
+5 VDC is measured between P/J146-1 and P/J146-3 on the Tray 5 Paper Sensor.
Y
N
Y
N
+5VDC is measured between P/J21-1, 2, 3, or 4 and GND on the IOT LVPS.

Y
N
Go to +5 VDC Power (IOT LVPS) RAP
Go to Flag 4 on BSD 1.2 and check for an open or short circuit.
Go to Flag 5 on BSD 1.2 and check the harness for an open circuit. If the harness is OK,
replace the IOT CPU PWB (PL 9.3).
+24 VDC is measured between P/J800-1 and P/J800-2 on the Tray PWB.
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7-500 Tray out of position during Job RAP
N
Y
N
The machine detected that the Tray is out of position during the Job.
Initial Actions
Go to Flag 1 on BSD 1.2 and check for an open wiring. If the wiring is OK, replace the
Tray PWB (PL 9.3).
Refer to BSD 7.1 through BSD 7.3 for the following procedure.
Ensure the Tray attributes selected match the paper loaded in the Tray.
Ensure that the End Guides are properly adjusted to the paper in the Tray.
Ensure Connector PJ802 on the Tray PWB is seated properly for Trays 2,3,4.
Ensure that there are no obvious crimped or broken wires.
Procedure
Tray 2 was in use when the fault occurred.
Y
N
Y
N
Enter dC330 and Active Stack 008-250 Tray 4 size switch 1, 008-251 Tray 4 size
switch 2, 008-252 Tray 4 size switch 3, 008-253 Tray 4 size switch 4 for the Tray 4
Size Sensor and press Start. Open Tray 4. Check the state of the four Tray Sensors.
The four Tray Sensor States displayed corresponds with Table 3.
Y
N
Check for +XVDC (Refer to Table 3 for the DC Voltages) +XVDC is measured
at TP-8 on the Tray PWB.
Y
N
Check for +XVDC (Refer to Table 3 for the DC Voltages) +XVDC is measured at P/J415B-14 on the IOT PWB.
Y
N
Go to Flag 1 and Flag 2 on BSD 7.3 and check the harness and connectors. If the harness and connectors are OK, replace the Tray 4 Size Sensor (PL 2.1).
Check/Replace the following parts in the order listed until the problem is resolved.
Replace any parts that are worn, broken, binding, or slipping.
Tray 4 Assembly (PL 2.4).
Tray 4 Size Sensor (PL 2.1).
Enter dC330 and Active Stack 008-245 Tray 3 size switch 1, 008-246 Tray 3 size switch
2, 008-247 Tray 3 size switch 3, 008-248 Tray 3 size switch 4 for the Tray 3 Size Sensor
and press Start. Open Tray 3. Check the state of the four Tray Sensors. The four Tray
Sensor States displayed corresponds with Table 2.
Y
N
Check for +XVDC (Refer to Table 2 for the DC Voltages) +XVDC is measured at
TP-7 on the Tray PWB.
A
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B
B
Y
N
at P/J415B-14 on the IOT Drive PWB.
Y
N
Table 2 Tray Switch State to Voltage Values (Tray 3)
the harness and connectors are OK, replace the Tray 3 Size Sensor (PL 2.1).
Tray 3
XVDC at
008-245 008-246 008-247 008-248 Test
SW 1
SW 2
SW 3
SW4
Point
Open Tray
4.64
No Unit
5.0

Tray 4
XVDC at
008-250 008-251 008-252 008-253 Test
Point
SW 1
SW 2
SW 3
SW4
Open Tray
4.64
No Unit
5.0
Enter dC330 and Active Stack 008-240 Tray 2 size switch 1, 008-241 Tray 2 size switch 2,
008-242 Tray 2 size switch 3, 008-243 Tray 2 size switch 4 for the Tray 2 Size Sensor and
press Start. Open Tray 2. Check the state of the four Tray Sensors. The four Tray Sensor
States displayed corresponds with Table 1.
Y
N
Check for +XVDC (Refer to Table 1 for the DC Voltages) +XVDC is measured at TP-6
on the Tray PWB.
Y
N
Check for +XVDC (Refer to Table 1 for the DC Voltages) +XVDC is measured at P/
J415B-14 on the IOT Drive PWB.
Y
N
harness and connectors are OK, replace the Tray 2 Size Sensor (PL 2.1).
Check/Replace the following parts in the order listed until the problem is resolved. Replace any
parts that are worn, broken, binding, or slipping.
Tray 2
XVDC at
008-240 008-241 008-242 008-243 Test
SW 1
SW 2
SW 3
SW4
Point
Open Tray
4.64
No Unit
5.0
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DocuColor 12/DCCS50
7-501 Tray No Paper RAP
The machine detected no paper in the paper tray selected.

NOTE: This RAP should be used when the presence of paper is not detected in any of the
Paper Trays or if the paper tray selected ran out of paper and the Auto Tray Selection (ATS)
could not find paper of the same orientation from another tray to finish the job.

Initial Actions
Check/replace the following parts in the order listed until the problem is resolved. Replace
any parts that are worn, broken, binding, or missing.
Check the following items for dirt, binding, freedom of movement or excessive wear: Tray No
Paper Sensor, Tray Level Sensor, and Tray Nudger Solenoid.
Verify that the Trays are not jammed.
Ensure that all paper sizes are correct.
Ensure paper is properly loaded in the Trays.
Ensure all paper Trays are closed.
Select Tray 1 on the Control Panel while observing the UI. Paper is detected in Tray 1 and
the message Ready to Copy appears.
Y
N
Enter dC330 008-231 Tray 1 No Paper Sensor. Press Start. Manually actuate the Tray
1 No Paper Sensor. The display changed from L to H.
Y
N
Y
N
Y
N
Go to Flag 1 and Flag 2 on BSD 7.5 and check the harness and connectors. If the harness and connectors are OK, replace the IOT Drive PWB.
Wiring Harness
DocuColor 12/DCCS50
Wiring Harness
the message ready to copy appears.
Y
N
Enter dC330 008-234 Tray 4 No Paper Sensor. Press Start. Manually actuate the Tray 4
No Paper Sensor. The display changed from L to H.
Y
N
Y
N
Y
N
Y
N
Enter dC330 008-232 Tray 2 No Paper Sensor. Press Start. Manually actuate the Tray
2 No Paper Sensor. The display changed from L to H.
Y
N
Y
N
A
B
C
Reissue
Wiring Harness
Y
N
Enter dC330 008-233 Tray 3 No Paper Sensor. Press Start. Manually actuate the Tray 3
No Paper Sensor. The display changed from L to H.
Y
N
Y
N
Y
N
Procedure
N
D
1/05
2-75
G
G
7-502 Tray 5 Paper Size Mismatch (Width) RAP
The machine detected that the paper size width is not being detected correctly in Tray 5.
Initial Actions
Wiring Harness
Check the wire harnesses and connectors of all the Tray paper feed assemblies for an intermittent problem.
Perform ADJ 9.1.17.
Check for obstructions in the paper path.
Go to the Control Panel, ensure that Tray 5 Paper Size indicator is set to the correct paper
size loaded in Tray 5, and that the width guide is against the paper.
Ensure that the NVM location for the Market is the correct country code, 752-001 = 2
Procedure
The paper size being utilized for this procedure matches the paper size selected on the
Touch Screen.
Y
N
Voltage is measured at P/J146-B15 on the IOT PWB and GND on the Tray 5 Size
Sensor.
Y
N
+5 VDC is measured between P/J148-3 on the Tray 5 Paper Size Sensor and
GND.
Y
N
Go to Flag 2 on BSD 7.4 and check the harness for an open circuit or short to GND.
If the harness is OK, replace the Tray 5 Paper Size Sensor (PL 2.13).
Go to Flag 1 on BSD 7.4 and check the harness for an open circuit or short to GND. If the
harness is OK, replace the Tray 5 Paper Size Sensor (PL 2.13). If that does not correct
the problem, replace the IOT PWB (PL 9.2).
1/05
2-76
Spring (PL 2.13).
Link (PL 2.13).
Reissue
DocuColor 12/DCCS50
A
parts that are worn, binding, or missing.
Tray 5 Feed Clutch (PL 2.9)
7-503 Tray 5 Paper Size Mismatch (Length) RAP

The machine detected that the paper size length is not being detected correctly for Tray 5.
Initial Actions
Perform ADJ 9.1.17.
Go to the Control Panel, ensure that Tray 5 Paper Size indicator is set to the correct paper
size loaded in Tray 5.
Tray 5 Retard Roll (PL 2.12)
Tray 5 Feed Roll (PL 2.9)
Tray 5 Lifter Motor (PL 2.12)
Procedure
Touch Screen.
Y
N
Sensor.
Y
N
+5 VDC is measured at P/J148-2 on the Tray 5 Size Sensor.
Y
N
+5 VDC is measured between P/J148-1 and P/J148-3 on the Tray 5 Size Sensor.
Y
N
Y
N
+5 VDC is measured between P/J416B-B4 and P/J21-5 on the IOT Drive
PWB.
Y
N
Replace the Tray 5 Size Sensor (PL 2.13).
Go to Flag 1 on BSD 7.4 and check the harness for an open circuit or short to GND. If the
harness is OK, replace the Tray 5 Size Sensor (PL 2.4). If that does not correct the problem, replace the IOT PWB (PL 9.2).
Enter dC330 008-155 Registration Sensor. Press Start. Manually actuate the Registration
Y
N
Go to Flag 5 and Flag 6 on BSD 8.8 and check the harness for an open circuit or short to
GND. If the harness is OK, replace the Registration Sensor (PL 2.15).
A
Reissue
DocuColor 12/DCCS50
1/05
2-77
7-504 Tray Size Change during Job RAP
The machine detected that the paper size changed during the Job.
Initial Actions
Refer to BSD 7.1 through BSD 7.4 for the following procedure.
Ensure the Tray attributes selected match the paper loaded in the Tray.
Ensure that the End Guides are properly adjusted to the paper in the Tray.
Ensure Connector PJ802 on the Tray PWB is seated properly for Trays 2,3,4.
Ensure that there are no obvious crimped or broken wires.
If 12x18 paper is being used in Trays 2,3,or 4 go to ADJ 9.1.19.
and connectors are OK, replace the Tray 3 Size Sensor (PL 2.1).
Procedure

Y
N
Y
N
Enter dC330 and Active Stack 008-250 Tray 4 size switch 1, 008-251 Tray 4 size
switch 2, 008-252 Tray 4 size switch 3, 008-253 Tray 4 size switch 4 for the Tray 4
four
Size Sensor and press Start. Check the state of the four Tray Sensors. The
Tray Sensor States displayed corresponds to the paper size loaded in Tray 4.
(Refer to Table 3 for the correct Tray Sensor States for the matching paper
size).
Y
N
at TP-8 on the Tray PWB.
Y
N
Check for +XVDC (Refer to Table 3 for the DC Voltages) +XVDC is measured at P/J415B-14 on the IOT PWB.
Y
N
Check/Replace the following parts in the order listed until the PROBLEM is resolved. Replace
any parts that are worn, broken, binding, or slipping.

Enter [DC330] and Active Stack 008-245 Tray 3 size switch 1, 008-246 Tray 3 size
switch 2, 008-247 Tray 3 size switch 3, 008-248 Tray 3 size switch 4 for the Tray 3 Size
Sensor and press Start. Check the state of the four Tray Sensors. The four Tray Sensor
States displayed corresponds to the paper size loaded in Tray 3. (Refer to Table 2
for the correct Tray Sensor States for the matching paper size).
A
Check/Replace the following parts in the order listed until the PROBLEM is resolved.
connectors are OK, replace the Tray 2 Size Sensor (PL 2.1).
Enter dC330 and Active Stack 008-240 Tray 2 size switch 1, 008-241 Tray 2 size switch 2,
008-242 Tray 2 size switch 3, 008-243 Tray 2 size switch 4 for the Tray 2 Size Sensor and
press Start. Check the state of the four Tray Sensors. The four Tray Sensor States displayed corresponds to the paper size loaded in Tray 2. (Refer to Table 3 for the correct
Tray Sensor States for the matching paper size).
Y
N
Check for +XVDC (Refer to Table 1 for the DC Voltages) +XVDC is measured at TP-6
on the Tray PWB.
Y
N
Check for +XVDC (Refer to Table 1 for the DC Voltages) +XVDC is measured at P/
J415B-14 on the IOT Drive PWB.
Y
N
Go to Flag 3 on BSD 7.3 and check the harness and connectors. If the
harness and connectors are OK, replace the Tray 4 Size Sensor (PL 2.1).
N
Check for +XVDC (Refer to Table 2 for the DC Voltages) +XVDC is measured at
TP-7 on the Tray PWB.
Y
N
Y
N
Paper Size
1/05
2-78
Paper Size
XVDC at
008-240 008-241 008-242 008-243 Test
SW 1
SW 2
SW 3
SW4
Point
8.5 x 13 SEF 215.9 x 330.2 L
8.5 x 10 LEF
254 x 203
2.74
Reissue
DocuColor 12/DCCS50
Paper Size
Paper Size
XVDC at
008-250 008-251 008-252 008-253 Test
SW 1
SW 2
SW 3
SW4
Point
8.5 x 14 SEF 215.9 x 355.6 L
3.99
A3 SEF
297 x 420
A3 SEF
297 x 420
3.37
B4 SEF
257 x 364
B4 SEF
257 x 364
11 x 17 SEF
279.4 x 431.8 L
4.31
11 x 17 SEF
279.4 x 431.8 L
4.31
A4 SEF
210 x 297
2.14
A4 SEF
210 x 297
2.14
B5 LEF
257 x 182
B5 LEF
257 x 182
B4 SEF
257 x 364
B4 SEF
257 x 364
8.5 x 11 SEF
8.5 x 11 SEF
1.51
8.5 x 11 SEF
8.5 x 11 SEF
1.51
A4 LEF
279 x 210
0.91
A4 LEF
279 x 210
0.91
8.5 x 11 LEF
279.4 x 215.9 H
0.61
8.5 x 11 LEF
279.4 x 215.9 H
0.61
Open Tray
949
4.64
Open Tray
949
4.64
No Unit
255
5.0
No Unit
255
5.0
Paper Size
Paper Size
XVDC at
008-240 008-241 008-242 008-243 Test
SW 1
SW 2
SW 3
SW4
Point
3.37
Paper Size
Paper Size
XVDC at
008-245 008-246 008-247 008-248 Test
Point
SW 1
SW 2
SW 3
SW4
8.5 x 13 SEF 215.9 x 330.2 L
8.5 x 10 LEF
8.5 x 14 SEF 215.9 x 355.6 L
3.99
A3 SEF
297 x 420
3.37
B4 SEF
257 x 364
11 x 17 SEF
279.4 x 431.8 L
4.31
A4 SEF
210 x 297
2.14
B5 LEF
257 x 182
B4 SEF
257 x 364
8.5 x 11 SEF
8.5 x 11 SEF
1.51
A4 LEF
279 x 210
0.91
8.5 x 11 LEF
279.4 x 215.9 H
0.61
Open Tray
949
4.64
No Unit
255
5.0
254 x 203
2.74
Paper Size
Paper Size
XVDC at
008-250 008-251 008-252 008-253 Test
SW 1
SW 2
SW 3
SW4
Point
8.5 x 13 SEF 215.9 x 330.2 L
8.5 x 10 LEF
8.5 x 14 SEF 215.9 x 355.6 L
254 x 203
Reissue
DocuColor 12/DCCS50
2.74
3.99
1/05
2-79
7-600 Tray 5 Adjustment Side Guide out of specified Range

RAP
The machine detected that Tray 5 Side Guide was outside the specified range.
Initial Actions
Go to the Control Panel, ensure that Tray 5 Tray Paper Size icon is set to the correct paper
size that is loaded in Tray 5.
Procedure
Touch Screen.
Y
N
Sensor.
Y
N
+5 VDC between J703B-7 on the Tray 5 Paper Size Sensor and GND.
Y
N
Go to Flag 1 and Flag 2 on BSD 7.4 and check the harness for an open circuit or
short to GND. If the harness is OK, replace the Tray 5 Size Sensor (PL 2.13).
Go to Flag 2 and Flag 3 on BSD 7.4 and check the harnesses for an open circuit or short
to GND. If the harness is OK, replace the IOT Drive PWB (PL 9.2).
parts that are worn, binding, or missing.
Spring (PL 2.5)
Link (PL 2.5)
1/05
2-80
Reissue
DocuColor 12/DCCS50
8-104 Tray 1 Prefeed Sensor On Jam RAP

The Tray 1 Prefeed Sensor did not detect paper within the specified time after the prefeed
started.
Initial Actions
Ensure that the No Paper Sensor is properly installed in the Paper Tray Feed Head.
Refer to BSD 8.1, BSD 7.5, and BSD 8.10 for the following procedure.
Check for any obstructions in the paper path.
Open the Tray 1 Feeder (PL 2.4).
B
There is +24 VDC at P/J414A-A2 on the IOT Drive PWB.
Y
N
good, replace the Tray 1 Nudger Solenoid (PL 2.5).
Press the Start button. The voltage at P/J414A-A2 goes to less than +2.0 VDC.
Y
N
Replace the Tray 1 Nudger Solenoid (PL 2.5).
Check/replace the Tray 1 Feeder Assembly. Replace any components that are worn, broken,
binding, or slipping (PL 2.4).
Procedure
Cheat the L/H Cover Interlock Switch. Enter dC330 008-104 Tray 1 Pre feed Sensor. Press
Start. Block the Tray 1 Prefeed Sensor with a sheet of paper. The display changes from H
to L.
Y
N
The display indicates a constant H.
Y
N
Go to Flag 1 on BSD 8.1 and check the harness for a short circuit. If the harness is
good, replace the Tray 1 Prefeed Sensor (PL 2.5).
Connect the meter from P/J414A-A4 on the IOT Drive PWB to machine frame. Block the
Tray 1 Prefeed Sensor with a sheet of paper. The voltage at P/J414A-A4 goes from +5
VDC when the sensor is not blocked, to less than +1.0 VDC when the senor is
blocked.
Y
N
There is +5 VDC between P/J414A-A5 and P/J414A-A3 on the IOT Drive PWB.
Y
N
Go to Flag 2 on BSD 8.1 and check the harness for a short circuit. If the harness is good, replace the IOT Drive PWB (PL 9.2).
Go to Flag 1 and Flag 2 on BSD 8.1 and check the harness for an open circuit. If the
harness is OK, replace the Tray 1 Prefeed Sensor (PL 2.5). If the problem continues,
replace the IOT Drive PWB (PL 9.2).
Press Stop. Enter dC330 008-008 Tray 1 Feed/Lift Motor (Feed). Press Start and Stop several times. The Tray 1 Feed/Lift Motor energizes and deenergizes.
Y
N
Go to the 7-281 Tray 1 Lift Motor Failure RAP.
Press Stop. Enter dC330 008-006 Tray 1 Nudger Roll Solenoid. Press Start and Stop several times. The Tray 1 Nudger Solenoid energizes.
Y
N
Press the Stop button. There is +24 VDC at P/J414A-A1 on the IOT Drive PWB.
Y
N
A
B
Reissue
1/05
DocuColor 12/DCCS50
2-81
8-105 Tray 1 Feed Out Sensor On Jam RAP
The Tray 1 Feed Out Sensor did not detect paper within the specified time after the prefeed
started.
Press the Start button. The voltage at P/J414B-B12 goes to less than +2.0 VDC.
Y
N
Initial Actions
N
good, replace the Tray 1 Takeaway Feed Clutch (PL 1.5).
Replace the Tray 1 Takeaway Feed Clutch (PL 1.5).

Check/replace the following components until the problem is resolved. Replace any components that are worn, broken, binding, or slipping.
Pinch Rolls and Springs in the Left Cover (PL 2.8)
Procedure
Cheat the L/H Cover Interlock Switch. Enter dC330 008-105 Tray 1 feed out Sensor and
press Start. Block the Tray 1 Feed Out Sensor with a sheet of paper. The display changes
from H to L.
Y
N
Y
N
good, replace the Tray 1 Feed Out Sensor (PL 2.8).
Tray 1 Feeder Assembly (PL 2.4)
Connect the meter from P/J420A-B8 on the IOT Drive PWB to machine frame. Block the
Tray 1 Feed Out Sensor with a sheet of paper. The voltage at J420-B8 goes from +5
VDC when the sensor is unblocked, to less than +1.0 VDC when the sensor is
blocked.
Y
N
There is +5 VDC between P/J420A-B9 and P/J420A-B7 on the IOT Drive PWB.
Y
N
harness is OK, replace the Tray 1 Feed Out Sensor (PL 2.8). If the problem continues, replace the IOT Drive PWB (PL 9.2)
Enter dC330 008-043 Main Motor 2. Press Start. The Main Motor 2 energizes.
Y
N
Go to the Main Motor 2 RAP.
Enter dC330 008-009 Tray 1 Take Away Feed Clutch. Press Start. The Tray 1 Takeaway
Feed Clutch energizes.
Y
N
Press the Stop button. There is +24 VDC at P/J414B-B11 on the IOT Drive PWB.
Y
N
There is +24 VDC at P/J414B-B12 on the IOT Drive PWB.
A
1/05
2-82
Reissue
DocuColor 12/DCCS50
8-107 Tray 1 Feed Out Sensor On RAP
The Tray 1 Feed Out Sensor detected paper when closing the Front Cover or when power was
switched on.
started.
Initial Actions
Initial Actions
Procedure
Pull out Paper Tray 2
Enter dC330 008-105 Tray 1 feed out Sensor and press Start. The display indicates H.
Y
N
Go to Flag 3 on BSD 8.1 and check the harness for a short circuit. If the harness is good,
replace the Tray 1 Feed Out Sensor (PL 2.8).
If the fault code is present and can not be cleared, replace the IOT Drive PWB (PL 9.2). If the
fault code is not present and is occurring intermittently, go to Flag 3 on BSD 8.1 and check the
harness for an intermittent short circuit. If the harness is OK, replace the Tray 1 Feed Out Sensor (PL 2.8). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Cheat the L/H Cover Interlock Switch. Enter dC330 008-109 Tray 2 Pre feed Sensor and
press Start. Block the Tray 2 Prefeed Sensor with a sheet of paper. The display changes
from H to L.
Y
N
Y
N
Procedure
Connect the meter from P/J415A-14 on the IOT Drive PWB to machine frame. Block the
Tray 2 Prefeed Sensor with a sheet of paper. The voltage at P/J415A-14 goes from +5
VDC when the sensor is not blocked, to less than +1.0VDC when the senor is
blocked.
Y
N
There is +5 VDC between P/J803-5 and P/J803-3 on the Tray PWB.
Y
N
Go to Flag 2 on BSD 8.2 and check the harness for a short circuit. If the harness is good, replace the Tray PWB (PL 9.3).
replace the Tray PWB (PL 9.3).
Enter dC330 008-013 Tray 2 Feed/Lift Motor (Feed). Press Start and Stop several times.
The Tray 2 Feed/Lift Motor energizes and deenergizes.
Y
N
Go to the 7-282 Tray 2 Lift Motor Failure RAP
Reissue
Enter dC330 008-011 Tray 2 Nudger Roll Solenoid. Press Start and Stop several times.
The Tray 2 Nudger Solenoid energizes.
Y
N
Press the Stop button. There is +24 VDC at P/J803-1 on the Tray PWB.
Y
N
A
B
1/05
DocuColor 12/DCCS50
2-83
8-107 Tray 1 Feed Out Sensor On RAP, 8-109 Tray
B
There is +24 VDC at P/J803-2 on the Tray PWB.
Y
N

started.
Initial Actions
Press Start. The voltage at P/J803-2 goes to approximately 0 VDC.

Y
N
Press Start. There is +5 VDC at P/J801B-11 of the Tray PWB.
Y
N
Go to Flag 8 on BSD 7.6 and check the harness for an open or short circuit. If
the harness is good, replace the IOT Drive PWB (PL 9.2).
Procedure
press Start. Actuate the Tray 2 Feed Out Sensor. The display changes from L to H.
Y
N
Y
N

Enter dC330 008-014 Tray 2 Take Away Feed Clutch. Press Start and Stop several times.
The Tray 2 Takeaway Feed Clutch energizes.
Y
N
Press the Stop button. There is +24 VDC at P/J802B-14 on the Tray PWB.
Y
N
Connect the meter from P/J415A-7 on the IOT Drive PWB to machine frame. Actuate the
Tray 2 Feed Out Sensor. The voltage at P/J415A-7 goes from less than +1.0 VDC
when the sensor is not actuated, to +5.0 VDC when the sensor is actuated.
Y
N
There is +5 VDC between P/J802A-9 and P/J802A-7 on the Tray PWB.
Y
N
There is +24 VDC at P/J802B-13 on the Tray PWB.

Y
N
good, replace the Tray 2 Takeaway Feed Clutch (PL 2.7A).
Press the Start button. The voltage at P/J802B-13 goes to approximately 0 VDC.
Y
N
Y
N
Go to Flag 6 on BSD 8.2 and check the harness for an open circuit. If the harness is good, replace the IOT Drive PWB (PL 9.2).
harness is OK, replace the Tray 2 Feed Out Sensor (PL 2.8). If the problem continues, replace the Tray PWB (PL 9.3). If the problem continues, replace the IOT Drive
PWB (PL 9.2).
Y
N
Press the Stop button. There is +24 VDC between P/J802B-14 on the Tray PWB and
GND.
Y
N
Replace the Tray 2 Takeaway Feed Clutch (PL 2.7A).

Check/replace the Tray 2 Feeder Assembly (PL 2.4). Replace any components that are worn,
broken, binding, or slipping.
There is +24 VDC between P/J802B-13 on the Tray PWB and GND.
Y
N
A
8-109 Tray 2 Prefeed Sensor On Jam RAP, 8-110 Tray
1/05
2-84
Reissue
DocuColor 12/DCCS50
A
Y
N
Y
N
switched on.
Initial Actions

Enter dC330 008-025 Take Away Motor. Press Start. The Takeaway Motor energizes.
Y
N
Go to the Takeaway Motor RAP
Reissue
Check the actuator for the Tray 2 Feed Out Sensor.
Enter dC330 008-110 Tray 2 feed out Sensor. Press Start. The display indicates L.
Y
N
Go to Flag 3 and Flag 4 on BSD 8.2 and check the harness for an open circuit. If the harness is good, replace the Tray 2 Feed Out Sensor (PL 2.8).
DocuColor 12/DCCS50
Procedure
If the fault code is present and can not be cleared, replace the Tray PWB (PL 9.3). If the fault
code is not present and is occurring intermittently, go to Flag 3 on BSD 8.2 and check the harness for an intermittent short circuit. If the harness is OK, replace the Tray 2 Feed Out Sensor
(PL 2.8). If the problem continues, replace the Tray PWB (PL 9.3).
1/05
2-85
8-110 Tray 2 Feed Out Sensor On Jam RAP, 8-112

started.
Initial Actions
Pull out Paper Tray 3
Procedure
Cheat the L/H Cover Interlock Switch. Enter dC330 008-114 Tray 3 Pre feed Sensor and
press Start. Block the Tray 3 Prefeed Sensor with a sheet of paper. The display changes
from H to L.
Y
N
Y
N
VDC when the sensor is not blocked, to less than +1.0 VDC when the sensor is
blocked.
Y
N
There is +5 VDC between P/J803B-5 and P/J803B-3 on the Tray PWB.
Y
N
B
Y
N
Press Start. The voltage at P/J803B-2 goes to approximately 0 VDC.
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Go to Flag 6 on BSD 8.3 and check the harness for an open circuit. If the harness is good, replace the IOT Drive PWB.
Y
N
Y
N
Y
N
A
B
1/05
2-86
Reissue
DocuColor 12/DCCS50
started.
Initial Actions
N
Y
N

Enter dC330 008-025 Take Away Motor. Press the Start button. The Takeaway Motor energizes.
Y
N
Go to the Takeaway Motor RAP.
Procedure
press Start. Actuate the Tray 3 Feed Out Sensor. The display changes from L to H.
Y
N
Y
N
Y
N
Y
N
PWB (PL 9.2).
Y
N
GND.
Y
N
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
2-87
switched on.
started.
Initial Actions
Initial Actions
Procedure
Y
N
code is not present and is occurring intermittently, go to Flag 3 on BSD 8.3 and check the harness for an intermittent short circuit. If the harness is OK, ensure that the sensor actuator
moves freely. If the actuator is OK, replace the Tray 3 Feed Out Sensor (PL 2.8). If the problem
continues, replace the Tray PWB (PL 9.3).
Cheat the L/H Cover Interlock Switch. Enter dC330 008-119 Tray 4 Pre feed Sensor. Press
Start. Block the Tray 4 Prefeed Sensor with a sheet of paper. The display changes from H
to L.
Y
N
Y
N
Procedure
VDC when the sensor is not blocked, to less than +1.0 VDC when the sensor is
blocked.
Y
N
There is +5 VDC between P/J804-5 and P/J804-3 on the Tray PWB.
Y
N
Y
N
8-117 Tray 3 Feed Out Sensor On RAP, 8-119 Tray 4
Y
N
Press the Stop button. There is +24 VDC at P/J804-1 on the Tray PWB.
Y
N
A
B
Reissue
1/05
2-88
DocuColor 12/DCCS50
B
There is +24 VDC at P/J804-2 on the Tray PWB.
Y
N

started
Initial Actions
Press Start. The voltage at P/J804-2 goes to approximately 0 VDC.

Y
N
Y
N
Procedure
Cheat the L/H Cover Interlock Switch. Enter dC330 008-120 Tray 4 feed out Sensor. Press
Start. Actuate the Tray 4 Feed Out Sensor. The display changes from L to H.
Y
N
Y
N

Y
N
Press Stop. There is +24 VDC at P/J802B-10 on the Tray PWB.
Y
N
Y
N
Y
N

Y
N
Y
N
Y
N
PWB (PL 9.2).
Y
N
GND.
Y
N

Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
2-89
8-119 Tray 4 Prefeed Sensor On Jam RAP, 8-120
A
Y
N
Y
N
Go to Flag 6 on BSD 8.4 and check the harness for an open circuit. If the harness is good, replace the IOT Drive PWB
switched on.
Initial Actions

code is not present and is occurring intermittently, go to Flag 3 on BSD 8.4 and check the harness for an intermittent short circuit. If the harness is OK, ensure that the sensor actuator
moves freely. If the actuator is OK, replace the Tray 4 Feed Out Sensor (PL 2.8). If the problem
continues, replace the Tray PWB (PL 9.3).
Y
N
8-120 Tray 4 Feed Out Sensor On Jam RAP, 8-122
Procedure
Enter dC330 008-025 Take Away Motor. Press the Start button. The Takeaway Motor energizes.
Y
N
1/05
2-90
Reissue
DocuColor 12/DCCS50

The Tray 5 Feed Sensor did not detect paper within the specified time after the feed started
Initial Actions
Refer to BSD 7.9, BSD 8.5 and BSD 8.10 for the following procedure.
Remove the Tray 5 Upper Cover (PL 2.10).
C
Press the Start button to energize the Tray 5 Feed Clutch. The voltage at
J414B-B8 goes to approximately 0 VDC.
Y
N
P/
Replace the Tray 5 Feed Clutch (PL 2.9).

Tray 5 Feed Roll and related components (PL 2.9)
Procedure
Takeaway Pinch Roll, Pinch Roll, and Springs (PL 2.10)
Ensure there is paper in Tray 5. Attempt to feed a single sheet of paper from Tray 5. The
sheet of paper attempts to feed.
Y
N
Enter dC330 008-043 Main Motor 2. Press the Start button. Main Motor 2 energizes.
Y
N
Tray 5 Nudger Roll, Tray 5 Feed Roll, and related components (PL 2.11)
Enter dC330 008-135 Tray 5 Feed Sensor. Press Start. Actuate the Tray 5 Feed Sensor.
The display changes from L to H.
Y
N
Y
N
good, replace the Tray 5 Feed Sensor (PL 2.10).
Press the Stop button. Enter dC330 008-039 Tray 5 Nudger Solenoid. Press the Start
button. The Tray 5 Nudger Solenoid energizes.
Y
N
Press the Stop button. +24 VDC is measured at P/J416B-17 on the IOT Drive
PWB.
Y
N
Connect the meter from P/J416B-7 on the IOT Drive PWB to machine frame. Actuate the
Tray 5 Feed Sensor. The voltage at P/J416B-7 goes from less than +1.0 VDC when
the sensor is not actuated, to +5.0 VDC when the sensor is actuated.
Y
N
There is +5 VDC between P/J416B-5 and P/J416B-3 on the IOT Drive PWB.
Y
N

Y
N
Go to Flag 8 on BSD 7.9 and check the harness for an open circuit. If the harness is good, replace the Tray 5 Nudger Solenoid (PL 2.11).
harness is OK, replace the Tray 5 Feed Sensor (PL 2.10). If the problem continues,
Press the Start button. The voltage at P/J416B-18 goes to approximately 0

VDC.
Y
N
Tray 5 Feed Roll and related components (PL 2.9)
Enter dC330 008-037 Tray 5 Feed Clutch. Press Start. The Tray 5 Feed Clutch energizes.
Y
N
Press the Stop button. +24 VDC is measured at P/J414B-B7 on the IOT Drive
PWB.
Y
N
Takeaway Pinch Roll, Pinch Roll, and Springs (PL 2.10)
Tray 5 Nudger Roll, Tray 5 Feed Roll, and related components (PL 2.11)
+24 VDC is measured at P/J414B-B8 on the IOT Drive PWB.

Y
N
Go to Flag 3 on BSD 8.5 and check the harness for an open circuit. If the harness is good, replace the Tray 5 Feed Clutch (PL 2.9).
A
B
C
Reissue
DocuColor 12/DCCS50
1/05
2-91
8-147 Tray 1 Takeaway Sensor On Jam RAP
The Tray 5 Feed Sensor detects paper at all times.
The Takeaway Sensor did not actuate within 0 - 80 msec after the Tray 1 feed started.
Initial Actions
Initial Actions
Open the Tray 5 Assembly.
Open the Tray 5 Upper Assembly (REP 2.11.1).
Check the Actuator for the Tray 5 Feed Out Sensor.
Procedure
Procedure
Cheat the L/H Cover Interlock Switch. Enter dC330 008-150 Take Away Sensor. Press Start.
Block the Takeaway Sensor with a sheet of paper. The display changes from H to L.
Y
N
Y
N
good, replace the Takeaway Sensor (PL 2.8).
Enter dC330 008-135 Tray 5 Feed Sensor. Press Start. The display indicates L.
Y
N
replace the Tray 5 Feed Sensor (PL 2.10).
harness for an intermittent open circuit. If the harness is OK, replace the Tray 5 Feed Sensor
(PL 2.10). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Takeaway Sensor with a sheet of paper. The voltage at P/J420A-B5 goes from +5
blocked.
Y
N
Y
N
harness is OK, replace the Takeaway Sensor (PL 2.8). If the problem continues,
Enter dC330 008-043 Main Motor 2. Press Start. Main Motor 2 energizes.
Y
N
Y
N
Press Stop. There is +24 VDC between P/J414B-11 on the IOT Drive PWB and GND.
Y
N
There is +24 VDC between P/J414B-12 on the IOT Drive PWB and GND.
Y
N
good, replace the Tray 1 Takeaway Feed Clutch (PL 1.5).
A
8-139 Tray 5 Feed Out Sensor On RAP, 8-147 Tray 1
1/05
2-92
B
Reissue
DocuColor 12/DCCS50
B
Press the Start button. The voltage at P/J414B-12 goes to less than +2.0 VDC.
Y
N
Replace the Tray 1 Takeaway Feed Clutch (PL 1.5).
Initial Actions
Pinch Rolls and Springs (PL 2.8)
Check for burrs on the Baffle (PL 2.8).
Procedure
Y
N
Y
N
blocked.
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
2-93
B
8-147 Tray 1 Takeaway Sensor On Jam RAP, 8-148
B
Y
N
connectors are good, replace the Tray PWB (PL 9.3).

Initial Actions
Y
N
good, replace the IOT Drive PWB
Check for burrs on the Baffle (PL 2.8)

Gears in the Takeaway Drive Assembly (PL 2.7A)
Y
N
Y
N
Procedure
blocked.
Y
N
Y
N
Y
N
Y
N
Press Stop. There is +24 VDC between P/J802B-12 on the Tray PWB and GND.
Y
N
Y
N
A
1/05
2-94
B
Reissue
DocuColor 12/DCCS50
B
Y
N
Y
N

Initial Actions
Procedure
Y
N
Y
N
blocked.
Y
N
Y
N
Y
N
Go to the Takeaway Motor RAP
Y
N
Press Stop. There is +24 VDC between P/J802B-10 on the Tray PWB and GND.
Y
N
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
2-95
B
B
Y
N
Y
N
8-152 Takeaway Sensor On RAP

The Takeaway Sensor detected paper when closing the Front Cover or when power was
switched on.
Initial Actions

Procedure
Cheat the L/H Cover Interlock Switch. Enter dC330 008-150 Take Away Sensor. Press the
Start button. The display indicates H.
Y
N
Go to Flag 1 on BSD 8.6 and check the harness for a short circuit. If the harness is OK,
replace the Takeaway Sensor (PL 2.8).
harness for an intermittent short circuit. If the harness is OK, replace the Takeaway Sensor (PL
2.8). If the problem continues, replace the IOT Drive PWB (PL 9.2).
1/05
2-96
Reissue
DocuColor 12/DCCS50
8-154 Pre Registration Sensor On RAP
8-157 Registration Sensor On Jam RAP
The Pre Registration Sensor detected paper when closing the Front Cover or when power was
switched on.
The Registration Sensor detected paper when closing the Front Cover or when power was
switched on.
Initial Actions
Initial Actions
Procedure
Procedure
Enter dC330 008-153 Pre Registration Sensor. Press Start. The display indicates H.
Y
N
replace the Pre Registration Sensor (PL 2.16).
Enter dC330 008-155 Registration Sensor. Press Start. The display indicates H.
Y
N
replace the Registration Sensor (PL 2.15).
harness for an intermittent short circuit. If the harness is OK, replace the Pre Registration Sensor (PL 2.16). If the problem continues, replace the IOT Drive PWB (PL 9.2).
harness for an intermittent short circuit. If the harness is OK, replace the Registration Sensor
Reissue
DocuColor 12/DCCS50
1/05
2-97
8-154 Pre Registration Sensor On RAP, 8-157 Reg-
8-158 Pre IBT Sensor On Jam RAP
8-163 Pre IBT Sensor On Jam RAP
The Pre IBT Sensor detected paper when closing the Front Cover or when power was switched
on.
The Pre IBT Sensor did not actuate within the specified time after the Registration Feed
started:
Initial Actions
Initial Actions
Procedure
Procedure
Enter dC330 008-163 Pre IBT Sensor. Press Start. The display indicates H.
Y
N
replace the Pre IBT Sensor (PL 7.10).
Enter dC330 008-163 Pre IBT Sensor. Press Start. The display is H.
Y
N
+5 VDC is measure between P/J420A-A8 on the IOT Drive and GND.
Y
N
good, replace the Pre IBT Sensor (PL 7.10).
harness for an intermittent short circuit. If the harness is OK, replace the Pre IBT Sensor (PL

Cheat the Front Door Interlock. Open the Drawer and block the Pre IBT Sensor with a sheet of
paper. Carefully close the drawer. Enter dC330 008-163 Pre IBT Sensor. Press Start. The
display is L.
Y
N
There is +5 VDC between P/J420A-A9 and P/J420A-A7 on the IOT Drive PWB.
Y
N
good, replace the IOT Drive PWB (PL 9.2).
Go to Flag 3 and Flag 4 on BSD 8.8 and check the harness for an open circuit. If the harness is OK, replace the Pre IBT Sensor (PL 7.10). If the problem continues, replace the
IOT Drive PWB (PL 9.2).
Enter dC330 008-054 Registration Motor. Press Start. The Registration Motor energizes.
Y
N
Go to the Registration Motor RAP.
Gears on the 2nd BTR (PL 7.10)
8-158 Pre IBT Sensor On Jam RAP, 8-163 Pre IBT Sen-
1/05
2-98
Check for burrs on the Inlet Plate (PL 7.10)
2nd BTR Assembly (PL 7.9)
Reissue
DocuColor 12/DCCS50
8-171 Tray 1 Pre Registration Sensor On Jam RAP
The Pre Registration Sensor did not actuate with 80 - 180 msec after the feed started from Tray
1.
The Pre Registration Sensor did not actuate with 320 - 420 msec after the feed started from
Tray 2.
Initial Actions
Initial Actions
Procedure
Procedure
Enter dC330 008-153 Pre Registration Sensor. Press Start. The display is H.
Y
N
+5 VDC is measure between P/J419A-13 on the IOT Drive and GND.
Y
N
good, replace the Pre Registration Sensor (PL 2.16).
Y
N
Y
N
Cheat the Front Door Interlock. Open the Drawer and block the Pre Registration Sensor with a
sheet of paper. Carefully close the drawer. Enter dC330 008-153 Pre Registration Sensor
and press Start. The display is L.
Y
N
There is +5 VDC between P/J419A-14 and P/J419A-12 on the IOT Drive PWB.
Y
N
Y
N
Y
N
Go to Flag 1 and Flag 2 on BSD 8.8 and check the harness for an open circuit. If the harness is OK, replace the Pre Registration Sensor (PL 2.16). If the problem continues,
Y
N
Y
N
Pre Registration Roller and Bearings (PL 2.16)
Rollers and Springs (PL 2.16)
Check for burrs on the Chute and Upper Chute in the Pre Registration Assembly (PL
2.16).
2.16).
All components in the Main Motor 2 Assembly (PL 1.5)
Pinch Rolls and Springs in the Lower Left Cover (PL 2.8)
Reissue
DocuColor 12/DCCS50
1/05
2-99
8-171 Tray 1 Pre Registration Sensor On Jam RAP,
Tray 3.
Tray 4.
Initial Actions
Initial Actions
Procedure
Procedure
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
2.16)
2.16)
8-173 Tray 3 Pre Registration Sensor On Jam RAP, 8-
1/05
2-100
Reissue
DocuColor 12/DCCS50
8-175 Tray 5 Registration Sensor On Jam RAP
The Registration Sensor did not actuate with 562 - 1010 msec after the feed started from Tray
5.
The Registration Sensor did not actuate with 316 - 416 msec after the feed started from Tray 1.
Initial Actions
Initial Actions
Procedure
Procedure
Enter dC330 008-155 Registration Sensor. Press Start. The display is H.
Y
N
Y
N
good, replace the Registration Sensor (PL 2.15).

Y
N
Y
N

Cheat the Front Door Interlock. Open the Drawer and block the Registration Sensor with a
sheet of paper. Carefully close the drawer. Enter dC330 008-155 Registration Sensor and
press Start. The display is L.
Y
N
Y
N
sheet of paper. Carefully close the drawer. dC330 008-155 Registration Sensor and press
Start. The display is L.
Y
N
Y
N
Go to Flag 5 and Flag 6 on BSD 8.8 and check the harness for an open circuit. If the harness is OK, replace the Registration Sensor (PL 2.15). If the problem continues, replace
Y
N
Y
N
Registration Roller and Roller, Springs, and Bearings in the Registration Assembly (PL
2.15)
Gear in the Registration Assembly (PL 2.15)
Check for burrs on the Upper Chute and Chute in the Registration Assembly (PL 2.15).
Reissue
DocuColor 12/DCCS50
2.15)
1/05
2-101
8-175 Tray 5 Registration Sensor On Jam RAP, 8-
Initial Actions
Initial Actions
Procedure
Procedure

Y
N
Y
N

Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
2.15)
2.15)
8-177 Tray 2 Registration Sensor On Jam RAP, 8-178
1/05
2-102
Reissue
DocuColor 12/DCCS50
8-305 Tray 5 Interlock Open RAP
The Registration Sensor did not actuate with 956 - 1056 msec after the feed started from Tray
4.
The Tray 5 Interlock is detected open.
Initial Actions
Initial Actions
Procedure
Procedure
Y
N
Y
N
Y
N
Y
N
Enter dC330 008-305 Tray 5 Interlock Switch. Press Start. Actuate, then deactuate, the Tray
5 Interlock Switch. The display changes from L when the switch is actuated to H when
the switch is deactuated.
Y
N
Connect the meter from P/J416B-9 on the IOT Drive PWB to machine frame. Actuate,
then deactuate, the Tray 5 Interlock Switch. The voltage at P/J416B-9 goes from less
than +1.0 VDC when the switch is actuated, to +5.0 VDC when the switch is deactuated.
Y
N
good, replace the Tray 5 Switch (PL 2.12).
harness for an intermittent open circuit. If the harness is OK, replace the Tray 5 Switch (PL
Y
N
2.15)
Reissue
DocuColor 12/DCCS50
1/05
2-103
8-179 Tray 4 Registration Sensor On Jam RAP, 8-
8-306 Drawer Interlock Open RAP
Main Motor 2 RAP
The Drawer Interlock is detected open.
Main Motor 2 is inoperative.
Initial Actions
Initial Actions
Procedure
Procedure
Enter dC330 008-306 Drawer Interlock Switch. Press Start. Open, then close, the Drawer.
The display changes from H when the Drawer is open to L when the Drawer is closed.
Y
N
Connect the meter from P/J419B-18 on the IOT Drive PWB to machine frame. Open,
then close, the Drawer. The voltage at P/J419B-18 goes from +5 VDC when the
Drawer is open to less than +1.0 VDC when the Drawer is closed.
Y
N
Connect the meter from P/J11A-3 on the AC Driver PWB to machine frame. Open,
then close, the Drawer. The voltage at P/J11A-3 goes from +5 VDC when the
Drawer is open to less than +1.0 VDC when the Drawer is closed.
Y
N
Connect the meter from P/J14-8 on the AC Driver PWB to machine frame.
Open, then close, the Drawer. The voltage at P/J14-8 goes from less than
1.0 VDC when the Drawer is open to +5.0 VDC when the Drawer is closed.
Y
N
There is + 5 VDC from P/J19-4 on the AC Drive PWB to machine
frame.
Y
N
Go to Flag 7 on BSD 1.4 and check the harness for an open circuit. If the
harness is good, replace the Drawer Interlock Switch (PL 2.18).
Enter dC330 008-043 Main Motor 2. Press Start and Stop several times. Main Motor 2 energizes and deenergizes.
Y
N
Press Stop. +24 VDC is measured between P/J414B-3, 4, 5, 6 on the IOT Drive PWB
and machine frame.
Y
N
+24 VDC is measured between P/J414B-1 on the IOT Drive PWB and machine
frame.
Y
N
harness and connectors are OK, replace Main Motor 2 (PL 1.5).
Press Start. The voltage at P/J414B-3, 4, 5, 6 on the IOT Drive PWB goes to approximately +23 VDC.
Y
N
Replace Main Motor 2 Motor (PL 1.5).
If the problem is occurring intermittently, go to Flag 1 and Flag 2 on BSD 8.9 and check the harness for an intermittent open circuit. If the harness is good, replace the Main Motor 2 (PL 1.5).
If the problem continues, replace Main Motor 2 (PL 1.5). If the problem still continues, replace
Go to Flag 6 on BSD 1.4 and check the harness for an open circuit.
harness for an intermittent open circuit. If the harness is OK, go to Flag 7 on BSD 1.4 and
check the wire for an intermittent open or short circuit. If the harness is good, replace the
Drawer Interlock Switch (PL 2.18). If the problem continues, replace the AC Driver PWB (PL
9.3). If the problem still continues, replace the IOT Drive PWB (PL 9.2).
8-306 Drawer Interlock Open RAP, Main Motor 2 RAP
1/05
2-104
Reissue
DocuColor 12/DCCS50
Takeaway Motor RAP
Registration Motor RAP
The Takeaway Motor is inoperative.
The Registration Motor is inoperative.
Initial Actions
Initial Actions
Procedure
Procedure
Y
N
Press the Stop button. Connect the meter from P/J801B-5 on the Tray PWB to machine
frame. Press the Start button. The voltage at P/J801B-5 goes from +5 VDC to less
than +1.0 VDC when the Start button is pressed.
Y
N
Enter dC330 008-054 Registration Motor. Press Start and Stop several times. The Registration Motor energizes and deenergizes.
Y
N
Press the Stop button. +24 VDC is measured between P/J419A-3, 4, 5, 6 on the IOT
Drive PWB and machine frame.
Y
N
+24 VDC is measured between P/J419A-1 on the IOT Drive PWB and machine
frame.
Y
N
The voltage at P/J802B-6 on the Tray PWB is less than +1.0 VDC.
Y
N
harness and connectors are OK, replace the Registration Motor (PL 2.15).
Check the following:
Check if the drives for Takeaway Motor Assembly are binding (PL 2.7A). Replace
any damaged gears.
If the harness is good, replace the Takeaway Motor (PL 2.7A)
If the problem continues, replace the Tray PWB (PL 9.3)
Replace the Registration Motor (PL 2.15).
If the problem is occurring intermittently, go to Flag 1 and Flag 2 on BSD 8.7 and check the harness for an intermittent open circuit. If the harness is good, replace the Takeaway Motor (PL
2.7A). If the problem continues, replace the Takeaway Motor Assembly (PL 2.7A). If the problem still continues, replace the Tray PWB (PL 9.3). If the problem still continues, replace the
Reissue
DocuColor 12/DCCS50
Press the Start button. The voltage at P/J419A-3, 4, 5, 6 on the IOT Drive PWB goes
to approximately +18 VDC.
Y
N
Replace the IOT Drive PWB (PL 9.2)
If the problem is occurring intermittently, go to Flag 3 and Flag 4 on BSD 8.9 and check the harness for an intermittent open circuit. If the harness is good, replace the Registration Motor (PL
2.15). If the problem still continues, replace the IOT Drive PWB (PL 9.2).
1/05
2-105
Takeaway Motor RAP, Registration Motor RAP
Takeaway Motor RAP, Registration Motor RAP
1/05
2-106
Reissue
DocuColor 12/DCCS50
9-271 Yellow Toner Empty RAP
9-272 Magenta Toner Empty RAP
Control Logic has detected that the Yellow dispenser is empty.
Control Logic has detected that the Magenta dispenser is empty.
Initial Actions
Initial Actions
This is a message fault only. An operator action is required
NOTE: If this code doesnt clear after the Toner cartridge is replaced, go into NVM 776-372
Toner Cartridge Y Empty and set the value to 0. Then, go into NVM 776-060 and set the value
to 0.
Toner Cartridge M Empty and set the value to 0. Then, go into NVM 776-061 and set the value
to 0.
Procedure
Procedure
This fault should not require any service action. If this fault causes a problem, use the 9-354
Yellow Toner Dispenser Broken RAP to troubleshoot the problem.
Magenta Toner Dispenser Broken RAP to troubleshoot the problem.
Reissue
DocuColor 12/DCCS50
1/05
2-107
9-271 Yellow Toner Empty RAP, 9-272 Magenta
9-273 Cyan Toner Empty RAP
9-274 Black Toner Empty RAP
Control Logic has detected that the Cyan dispenser is empty.
Control Logic has detected that the Black dispenser is empty.
Initial Actions
Initial Actions
Toner Cartridge C Empty and set the value to 0. Then, go into NVM 776-062 and set the value
to 0.
Toner Cartridge K Empty and set the value to 0. Then, go into NVM 776-063 and set the value
to 0.
Procedure
Procedure
Cyan Toner Dispenser Broken RAP to troubleshoot the problem.
Black Toner Dispenser Broken RAP to troubleshoot the problem.
9-273 Cyan Toner Empty RAP, 9-274 Black Toner
1/05
2-108
Reissue
DocuColor 12/DCCS50
9-311 Xerographic CRU (Drum) Type Mismatch RAP
9-342/9-432 2nd BTR Contact Fail RAP
Xerographic CRU (Drum) Type Mismatch. The Control Logic detected that the Xerographic
CRU (Drum) that is installed in the machine is not the correct type for this product.
The Control Logic has detected that the 2nd BTR failed to contact the IBT.
Initial Actions
Initial Actions
Ensure that P/J422B on the IOT Drive PWB, P/J713 and P/J704 on the EP ROM PWB
are connected before beginning this RAP.
Refer to BSD 9.10 and 9.15 for the following procedure.
Ensure that P/J421A and P/J414A on the IOT Drive PWB (PL 9.2), P/J255 on the 2nd
BTR Retract Clutch (PL 1.4), and P/J159 on the 2nd BTR Retract Home Position Sensor
(PL 7.9) are connected before beginning this RAP.
Procedure
Procedure
Check the Type of Xerographic CRU (Drum) that is installed in the machine, NVM 774-056
Drum Unit Type. The Xerographic CRU (Drum) is the approved type.
Y
N
Install an approved Xerographic CRU (Drum).
Stack the codes dC330 004-007 Main Motor and 009-058 2ND Belt Transfer Roll Contact.
Press Start. The Main Motor energizes.
Y
N
Go to the OF4-001 Main Motor RAP.
Go to Flag 8 on BSD 9.1. Check the harness for an open circuit or a short circuit. If the harness
is good, replace the Xerographic CRU (Drum). If the problem continues, replace the IOT Drive
PWB (PL 9.2).
Enter dC330 009-215 2nd BTR H/Position Sensor. Press Start. The Display is (H)
Y
N
Press Stop for the codes dC330 004-007 Main Motor and 009-058 2ND Belt Transfer Roll
Contact. Rotate the Indicator (Item 3 PL 7.9) to block the 2nd BTR Retract Home Position
Sensor. The display changes to (H)
Y
N
+5 VDC is measured between P/J421A-2 and GND on the IOT Drive PWB.
Y
N
+5 VDC is measured between P/J421A-3 and P/J421A-1 on the IOT Drive
PWB.
Y
N
Go to the +5 VDC (IOT) Wirenet and check the wires between P/J21-1 on
the IOT LVPS and P/J421A-3 on the IOT Drive PWB. Go to the DC COM
(IOT) Wirenet and check the wires between P/J21-5 on the IOT LVPS and
P/J421A-1 on the IOT Drive PWB.
Go to Flag 1 on BSD 9.10 and check the wire for a short circuit to ground. Go to
Flag 3 on BSD 9.10. Check the wires for an open circuit. If the wires are good,
replace the 2nd BTR Retract Home Position Sensor (PL 7.9).
Check the 2nd BTR Retract Home Position Sensor for intermittent operation. If the
sensor is good, replace the IOT Drive PWB (PL 9.2).
Stack the codes dC330 004-007 Main Motor and 009-058 2ND Belt Transfer Roll Contact. The 2nd BTR raises to the contact position.
Y
N
Press Stop for the codes dC330 004-007 Main Motor and 009-058 2ND Belt Transfer Roll Contact. +24 VDC is measured at P/J414B-10 on the IOT Drive PWB.
Y
N
Y
N
Go to the +24 VDC Wirenet and check the fuse F1 on the AC Drive PWB.
If the fuse is good, check the wires between P/J24-2 on the IOT LVPS
and P/J414B-9 on the IOT Drive PWB.
A
Reissue
DocuColor 12/DCCS50
1/05
2-109
D
9-311 Xerographic CRU (Drum) Type Mismatch
D
Go to Flag 2 on BSD 9.10. Check the wires for an open circuit or a short circuit.
If the wires are good, replace the IOT Drive PWB (PL 9.2). If the problem continues, replace the 2nd BTR Retract Clutch (PL 1.4).
Enter dC330 009-058 2ND Belt Transfer Roll Contact. There is less than +1 VDC
Y
N
Check the 2nd BTR Retract Clutch for slipping, binding or intermittent operation.
Check for mechanical damage in the 2nd BTR components (PL 7.10), gears and
drives.
Check the 2nd BTR Retract Clutch for binding or intermittent operation. If the 2nd BTR
Retract Clutch is good, replace the 2nd BTR Retract Home Position Sensor (PL 7.9). If
the problem continues, replace the 2nd BTR Retract Clutch (PL 1.4).
Check the Main Motor for slow or intermittent operation. Refer to the OF4-001 Main Motor
RAP.
Check the 2nd BTR Retract Home Position Sensor (PL 7.9) for intermittent operation. If the
sensor is good, replace the IOT Drive PWB (PL 9.2).
9-343/9-433 2nd BTR Retract Fail RAP

The Control Logic has detected that the 2nd BTR failed to retract.
Initial Actions
Ensure that P/J421A and P/J414A on the IOT Drive PWB (PL 9.2), P/J255 on the 2nd
BTR Retract Clutch (PL 1.4), and P/J159 on the 2nd BTR Retract Home Position Sensor
(PL 7.9) are connected before beginning this RAP.
Procedure
Enter dC330 009-215 2nd BTR H/Position Sensor. Press Start. The Display is (L).
Y
N
Stack the codes dC330 004-007 Main Motor and 009-058 2ND Belt Transfer Roll Contact.
Press Start. The Main Motor energizes.
Y
N
Go to the OF4-001 Main Motor RAP.
Enter dC330 009-215 2nd BTR H/Position Sensor. Press Start. The Display is (L).
Y
N
less than +1 VDC is measured between P/J421A-2 and GND on the IOT Drive
PWB.
Y
N
PWB.
Y
N
Go to Flag 1 and Flag 3 on BSD 9.10 and check the wire for an open circuit. If
the wires are good, replace the 2nd BTR Retract Home Position Sensor (PL
7.9).
Check the 2nd BTR Retract Clutch (PL 1.4) for binding, slipping, or intermittent operation.
If the 2nd BTR Retract Clutch is good, replace the 2nd BTR Retract Home Position Sensor (PL 7.9). If the problem continues, replace the 2nd BTR Retract Clutch (PL 1.4).
Check the Main Motor for slow or intermittent operation. Refer to the OF4-001 Main Motor
RAP.
Check the 2nd BTR Retract Clutch (PL 1.4) for slipping, binding or intermittent operation.
Check for mechanical damage in the 2nd BTR components (PL 7.10), gears and drives. If the
2nd BTR Retract Clutch is good, replace the 2nd BTR Retract Home Position Sensor (PL 7.9).
If the problem continues, replace the 2nd BTR Retract Clutch (PL 1.4). If the problem continues, replace the IOT Drive PWB (PL 9.2).
9-342/9-432 2nd BTR Contact Fail RAP, 9-343/9-433
1/05
2-110
Reissue
DocuColor 12/DCCS50
9-344/9-434 IBT Cleaner Contact Fail RAP
C
good, replace the Cleaner Retract Clutch (PL 1.3).
The Control Logic has detected that the IBT Cleaner failed to contact the IBT.
Check the Cleaner Retract Clutch for binding or intermittent operation. If the Cleaner
Retract Clutch is good, replace the IBT Clean Blade Home Position Sensor (PL 7.3). If the
problem continues, replace the Cleaner Retract Clutch (PL 1.3).
Initial Actions
Ensure that P/J417A and P/J418B on the IOT Drive PWB, P/J252 on the Cleaner
Retract Clutch, and P/J111 on the IBT Clean Blade Home Position Sensor are connected
before beginning this RAP.
Procedure
Stack the codes dC330 004-007 Main Motor and 009-066 IBT Cleaner Contact.
Enter dC330 009-216 IBT Cleaner Retract Home Sensor. Press Start. The Display is (H)
Y
N
Remove the IBT REP 7.1.1 (Reinstall IBT after test is completed). Manually block the IBT
Clean Home Position Sensor. The display changes to (H)
Y
N
Y
N
+5 VDC is measured between P/J418B-6 and P/J418B-4 on the IOT Drive
PWB.
Y
N
Go to the +5 VDC (IOT) Wirenet and check the wires between P/J21 -1
on the IOT LVPS and P/J418B8-6 on the IOT Drive PWB. Go to the DC
COM (IOT) Wirenet and check the wires between P/J21-5 on the IOT
LVPS and P/J418B-4 on the IOT Drive PWB.
Flag 3 on BSD 9.11. Check the wires for an open circuit. If the wires are good,
replace the IBT Clean Blade Home Position Sensor (PL 7.3).
Enter dC330 009-059 2ND Belt Transfer Roll Retract. Press Start. Enter dC330 009-067
IBT Cleaner Retract. Press Start. The Cleaner Retract Clutch energizes.
Y
N
PWB.
Y
N
+24 VDC is measured between P/J417A-9 and GND on the IOT Drive
PWB.
Y
N
Go to the +24 VDC-4 Wirenet and check the wires between P/J24-2 on
the IOT LVPS and P/J417A-9 on the IOT Drive PWB.
If the wires are good, replace the IOT Drive PWB (PL 9.2). If the problem continues, replace the Cleaner Retract Clutch (PL 1.3).
A
B
C
Reissue
DocuColor 12/DCCS50
1/05
2-111
9-344/9-434 IBT Cleaner Contact Fail RAP
9-345/9-435 IBT Cleaner Retract Fail RAP
9-354 Yellow Toner Dispenser Broken RAP
The Control Logic has detected that the IBT Clean Blade failed to retract from the IBT.
This fault code appears when any one of the following conditions occurs: the Low Toner Sensor
detects that there is no toner for a period of 2 seconds; the low toner sensor detects that there
is no toner for a period of 500 seconds (approximately 8 minutes); or when the toner dispense
motor remains energized.
Initial Actions
Ensure that P/J417A and P/J418B on the IOT Drive PWB, P/J252 on the Cleaner
Retract Clutch, and P/J111 on the IBT Clean Blade Home Position Sensor are connected
Procedure
Stack the dC330 codes 4-007 and 9-067. Enter dC330 009-216 IBT Cleaner Retract Home
Sensor. Press Start. The Display is (L)
Y
N
Remove the IBT REP 7.1.1 (Reinstall IBT after test is completed). Manually unblock the
IBT Clean Home Position Sensor. The display changes to (L)
Y
N
Y
N
+5 VDC is measured between P/J418B6 and P/J418B-4 on the IOT Drive
PWB.
Y
N
Go to the +5 VDC-3 Wirenet and check the wires between P/J21-1 on the
IOT LVPS and P/J418B-6 on the IOT Drive PWB. Go to the DC COM (+5
V Ret.)-3 Wirenet and check the wires between P/J21-5 on the IOT LVPS
and P/J418B-4 on the IOT Drive PWB.
Initial Actions
Refer to BSD 9.4, 9.6 and BSD 9.15 for the following procedure.
Ensure that P/J432, P/J433B, and P/J434 on the Dispense PWB, P/J421B on the IOT Drive
PWB, P/J214 on the Yellow Cartridge Motor and P/J118 on the Yellow Low Toner Sensor are
connected before beginning this RAP.
NOTE: If the code doesnt clear and the auger isnt broken, go to NVM 776-060 and set the
value to 0. Then, go to NVM 776-372 Toner Cartridge Y Empty and set the value to 0.
Procedure
Check the Yellow Toner Cartridge. The toner cartridge is empty.
Y
N
NOTE: The Cartridge Motor is only energized for 10 seconds each time Start is pressed.
The display will indicate Off when the 10 seconds have expired. Pressing Start will energize the Cartridge Motor for another 10 seconds. Press Start as often as necessary to get
an accurate reading.
Remove the Yellow Toner Cartridge to see the Toner Cartridge Coupling (PL 6.3). Cheat
the Front Door Interlock. Enter dC330 009-012 Cartridge Motor Y. Press Start. The Yellow Toner Cartridge Coupling rotates.
Y
N
Press Start. The Yellow Cartridge Motor operates.
Y
N
+12 VDC is measured at P/J433B-9 and at P/J433B-7 on the Dispense
PWB.
Y
N
+24 VDC is measured between P/J431-2 and P/J431-1 on the Dispense PWB.
Y
N
Go to +24VDC Wirenets and check the wires between P/J24-2 on
the IOT LVPS and P/J431-2 on the Dispense PWB.
Go to DC COM (24V RET) Wirenets and check the wires between
P/J23-4 on the IOT LVPS and P/J431-1 on the Dispense PWB.
Go to Flag 1 on BSD 9.11 and check the wire for an open circuit. Go to Flag 3
on BSD 9.11. Check the wires for an open circuit. If the wires are good, replace
the IBT Clean Blade Home Position Sensor (PL 7.3).
Enter dC330 009-059 2ND Belt Transfer Roll Retract. Press Start. Enter dC330 009-067
IBT Cleaner Retract. Press Start. The Cleaner Retract Clutch de-energizes.
Y
N
Y
N
If the wires are good, replace the IOT Drive PWB (PL 9.2). If the problem continues, replace the Cleaner Retract Clutch (PL 1.3).
+5VDC is measured between P/J421B-4 and GND on the IOT Drive

PWB when the display indicates Off.
Y
N
Go to Flag 4 on BSD 9.4. Check the wire for an open or a short circuit. If the wire is good, replace the Dispense PWB (PL 6.4). If the
problem continues, replace the IOT Drive PWB (PL 9.2).
Replace the Cleaner Retract Clutch (PL 1.3).

Check the Cleaner Retract Clutch for binding or intermittent operation. If the Cleaner
Retract Clutch is good, replace the IBT Clean Blade Home Position Sensor (PL 7.3). If the
problem continues, replace the Cleaner Retract Clutch (PL 1.3).
Press Start. The voltage momentarily goes to less than +1 VDC.

A
9-345/9-435 IBT Cleaner Retract Fail RAP, 9-354 Yel-
1/05
2-112
D
Reissue
DocuColor 12/DCCS50
A
Y
N
E
Y
Replace the Dispense PWB (PL 6.4)

the wires are good, replace the Cartridge Motor (Y). (PL 6.3).
Vacuum the Yellow Dispense Housing. Reinstall the Yellow Toner Cartridge. Enter
dC330 and stack the codes 009-032 Dispense Motor Y and [009-257 Low Toner
Sensor Y]. The sensor changes state as toner is dispensed.
Y
N
Connect the DVM from J 432 pin 3 to GND. +5 VDC is measured between P/
J433A-6 and P/J433A-4.
Y
N
Go to+5VDC Wirenets (Figure 1) and check the wires between P/J21-1
on the IOT LVPS and P/J118-1 on the Low Toner Sensor (Y).
Go to DC COM (+5V RET) Wirenets and check the wires between P/J215 on the IOT LVPS and P/J118-3 on the Low Toner Sensor (Y).
Check the Coupling and Spring (PL 6.3) for damage or contamination. Clean, repair
or replace as required.
NOTE: The Dispense Motor is only energized for 10 seconds each time Start is pressed.
The display will indicate Off when the 10 seconds have expired. Pressing Start will energize the Dispense Motor for another 10 seconds. Press Start as often as necessary to get
Enter dC330 009-032 Dispense Motor Y. Press Start. Watch the Dispense and Conveyor
Gears to see if they rotate. The Toner Dispense Motor (Y) operates.
Y
N
+12 VDC is measured at P/J434-6 and at P/J434-5 on the Dispense PWB.
Y
N
+24 VDC is measured between P/J431-2 and P/J431-1 on the Dispense
PWB.
Y
N
Go to the ++24VDC Wirenets and check the wires between P/J24-2 on
Go to DC COM (24V RET) Wirenets and check the wires between P/J234 on the IOT LVPS and P/J431-1 on the Dispense PWB.
+5VDC is measured between P/J421B-3 and GND on the IOT Drive PWB
when the display indicates Off.
Y
N
Go to Flag 3 on BSD 9.6. Check the wire for an open or a short circuit. If
the wire is good, replace the Dispense PWB (PL 6.4). If the problem continues, replace the IOT Drive PWB (PL 9.2)
N
Go to Flag 6 on BSD 9.4 and check the wire for an open circuit or a short circuit
to ground. If the wire is good, replace the Low Toner (M) Sensor (PL 6.3). If the
Go to Flag 6 on BSD 9.4 and check the wire for a short circuit to ground. Check
the wires between P/J118-1and P/J433A-6 and between P/J118-3 and P/
J433A-4 for an open circuit. If the wires are good, replace the Low Toner (Y)
Sensor (PL 6.3).
This should resolve the problem. Ensure that there is no blockage in the dispense
area. Check the machine for proper operation.
The sensor indicates that toner is present in the Toner Dispense Housing and is being dispensed. Replace the IOT Drive PWB (PL 9.2).
Replace the Yellow Toner Cartridge (Section 6, Machine Consumables).

Y
N
check the toner dispense gears (PL 6.3) and (PL 6.4) for damage. If the gears are
OK, replace the Toner Dispense Motor Y (PL 6.3). If the problem continues, replace
the Toner Dispense Assembly Y (PL 6.4).
Reinstall the Yellow Toner Cartridge. Enter dC330. Stack the codes [009-032 Dispense
Motor Y] and [009-257 Low Toner Sensor Y]. The sensor changes state as toner is
dispensed.
Y
N
Connect the DVM from J 432 pin 3 to GND. The meter reads a constant +5 VDC.
A
E
Reissue
DocuColor 12/DCCS50
1/05
2-113
9-354 Yellow Toner Dispenser Broken RAP
9-355 Magenta Toner Dispenser Broken RAP
D
Y
This fault code appears when any one of the following conditions occurs: the Low Toner Sensor
detects that there is no toner for a period of 2 seconds; the Low Toner Sensor detects that
there is no toner for a period of 500 seconds (approximately 8 minutes); or when the toner dispense motor remains energized.
N

the wires are good, replace the Cartridge Motor (M). (PL 6.3)
Initial Actions
Check the Coupling and Spring (PL 6.3) for damage or contamination. Clean, repair
or replace as required.
Ensure that P/J432, P/J433B, and P/J434 on the Dispense PWB, P/J421B on the IOT
DRIVE PWB, P/J215 on the Magenta Cartridge Motor and P/J119 on the Magenta Low Toner
Sensor are connected before beginning this RAP.
value to 0. Then, go to NVM 776-373 Toner Cartridge M Empty and set the value to 0.
Enter dC330 009-033 Dispense Motor M. Press Start. Watch the Dispense and Conveyor
Gears to see if they rotate. The Toner Dispense Motor (M) operates.
Y
N
Y
N
PWB.
Y
N
Go to +24VDC Wirenets and check the wires between P/J24-2 on the IOT
LVPS and P/J431-2 on the Dispense PWB.
Procedure
Check the Magenta Toner Cartridge. The toner cartridge is empty.
Y
N
Remove the Magenta Toner Cartridge to see the Toner Cartridge Coupling. Cheat the
Front Door Interlock. Enter dC330 009-013 Cartridge Motor M. Press Start. The
Magenta Toner Cartridge Coupling rotates.
Y
N
Press Start. The Magenta Cartridge Motor operates.
Y
N
+12 VDC is measured at P/J433B-6 and at P/J433B-4 on the Dispense
PWB.
Y
N
+24 VDC is measured between P/J431-2 and P/J431-1 on the Dispense PWB.
Y
N
Go to +24VDC Wirenets and check the wires between P/J24-2 on
Go to DC COM (24V RET) Wirenets and check the wires between
P/J23-4 on the IOT LVPS and P/J431-1 on the Dispense PWB.
Y
N
Y
N
OK, replace the Toner Dispense Motor M (PL 6.3). If the problem continues, replace
the Toner Dispense Assembly M (PL 6.4).
+5VDC is measured between P/J421B-6 and GND on the IOT Drive

PWB when the display indicates Off.
Y
N
Go to Flag 1 on BSD 9.5. Check the wire for an open or a short circuit. If the wire is good, replace the Dispense PWB (PL 6.4). If the
problem continues, replace the IOT Drive PWB (PL 9.2)
Reinstall the Magenta Toner Cartridge. Enter dC330. Stack the codes [009-033 Dispense
Motor M] and [009-258 Low Toner Sensor M]. The sensor changes state as toner is
dispensed.
Press Start. The voltage momentarily goes to less than +1 VDC

A
B
C
D
9-355 Magenta Toner Dispenser Broken RAP
A
1/05
2-114
Reissue
DocuColor 12/DCCS50
A
Y
N
Connect the meter between P/J432-2 and GND. The meter reads a constant +5
VDC.
Y
N
Vacuum the Magenta Dispense Housing. Reinstall the Magenta Toner Cartridge.
Enter dC330. Stack the codes [009-033 Dispense Motor M] and [009-258 Low Toner
Sensor M]. The sensor changes state as toner is dispensed.
Y
N
+5 VDC is measured between P/J433A-9 and P/J433A-7.
Y
N
Go to +5VDC Wirenets (Figure 1) and check the wires between P/J21-1
on the IOT LVPS and P/J119-1 on the Low Toner Sensor (M).
Go to DC COM (+5V RET) Wirenets and check the wires between P/J215 on the IOT LVPS and P/J119-3 on the Low Toner Sensor (M).
J433A-7 for an open circuit. If the wires are good, replace the Low Toner (M)
Sensor (PL 6.3).
9-356 Cyan Toner Dispenser Broken RAP

This fault code appears when any one of the following conditions occurs: the low toner sensor
Initial Actions
Ensure that P/J432, P/J433B, and P/J434 on the Dispense PWB, P P/J421B on the IOT
DRIVE PWB, P/J216 on the Cyan Cartridge Motor and P/J120 on the Cyan Low Toner Sensor
value to 0. Then, go to NVM 776-374 Toner Cartridge C Empty and set the value to 0.
Procedure
Check the Cyan Toner Cartridge. The toner cartridge is empty.
Y
N
Remove the Cyan Toner Cartridge to see the Toner Cartridge Coupling. Cheat the Front
Door Interlock. Enter dC330 [009-014 Cartridge Motor C]. Press Start. The Toner Cartridge Motor C operates.
Y
N
+12 VDC is measured at P/J433B-3 and at P/J433B-1 on the Dispense PWB.
Y
N
PWB.
Y
N
Replace the Magenta Toner Cartridge (Section 6, Machine Consumables).
Y
N
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
2-115
C
9-355 Magenta Toner Dispenser Broken RAP, 9-356
C
Go to Flag 5 on BSD 9.5. Check the wires for an open circuit or a short circuit. If the
wires are good, replace the Cartridge Motor (C). (PL 6.3)
Enter dC330 009-034 Dispense Motor C. Press Start. Watch the Dispense and Conveyor
Gears to see if they rotate. The Toner Dispense Motor (C) operates.
Y
N
Y
N
PWB.
Y
N
Y
N
E
Vacuum the Cyan Dispense Housing. Reinstall the Cyan Toner Cartridge. Enter
dC330. Stack the codes [009-034 Dispense Motor C] and [009-259 Low Toner Sensor C]. The sensor changes state as toner is dispensed.
Y
N
Y
N
Go to+5VDC Wirenets (Figure 1) and check the wires between P/J21-1
on the IOT LVPS and P/J120-1 on the Low Toner Sensor (C).
Go to DC COM (+5V RET) Wirenets and check the wires between P/J215 on the IOT LVPS and P/J120-3 on the Low Toner Sensor (C).
J433A-10 for an open circuit. If the wires are good, replace the Low Toner (C)
Sensor (PL 6.3).
Replace the Cyan Toner Cartridge (Section 6, Machine Consumables).

Y
N
OK, replace the Toner Dispense Motor C (PL 6.3). If the problem continues, replace
the Toner Dispense Assembly C (PL 6.4).
Reinstall the Cyan Toner Cartridge. Enter dC330. Stack the codes [009-034 Dispense
Motor C] and [009-259 Low Toner Sensor C]. The sensor changes state as toner is
dispensed.
Y
N
VDC.
Y
N
A
D
E
9-356 Cyan Toner Dispenser Broken RAP
1/05
2-116
Reissue
DocuColor 12/DCCS50
9-357 Black Toner Dispenser Broken RAP

Fault code appears when any one of the following conditions occurs: the low toner sensor
C
Go to Flag 2 on BSD 9.4. Check the wires for an open circuit or a short circuit. If the
wires are good, replace the Cartridge Motor (K). (PL 6.3)
Initial Actions
Enter dC330 009-031 Dispense Motor K. Press Start. Watch the Dispense and Conveyor
Gears to see if they rotate. The Toner Dispense Motor (K) operates.
Y
N
Y
N
PWB.
Y
N
Ensure that P/J432 and P/J433B on the Dispense PWB, P/J421B on the IOT DRIVE PWB, P/
P/J213 on the Black Cartridge Motor, and P/J117 on the Black Low Toner Sensor are connected before beginning this RAP.
value to 0. Then, go to NVM 776-371 Toner Cartridge K Empty and set the value to 0.
Procedure
Check the Black Toner Cartridge. The toner cartridge is empty.
Y
N
Y
N
Remove the Black Toner Cartridge to see the Toner Cartridge Coupling. Cheat the Front
Door Interlock. Enter dC330 009-011 Cartridge Motor K. Press Start. The Toner Cartridge Motor K operates.
Y
N
+12 VDC is measured at P/J433B-12 and at P/J433B-10 on the Dispense PWB.
Y
N
PWB.
Y
N

Y
N
OK, replace the Toner Dispense Motor K (PL 6.3). If the problem continues, replace
the Toner Dispense Assembly K (PL 6.4).
Reinstall the Black Toner Cartridge. Enter dC330. Stack the codes [009-031 Dispense
Motor K] and [009-255 Low Toner Sensor K]. The sensor changes state as toner is
dispensed.
Y
N
VDC.
Y
N
to ground. If the wire is good, replace the Low Toner (K) Sensor (PL 6.3). If the
Y
N
Y
N
A
B
C
Reissue
DocuColor 12/DCCS50
A
1/05
2-117
E
9-357 Black Toner Dispenser Broken RAP
E
Vacuum the Black Dispense Housing. Reinstall the Black Toner Cartridge. Enter
dC330. Stack the codes [009-031 Dispense Motor K] and [009-255 Low Toner Sensor K]. The sensor changes state as toner is dispensed.
Y
N
Y
N
Go to +5VDC Wirenets (Figure 1) and check the wires between P/J21-1
on the IOT LVPS and P/J117-1 on the Low Toner Sensor (K).
Go to DC COM (+5V RET) Wirenets and check the wires between P/J215 on the IOT LVPS and P/J117-3 on the Low Toner Sensor (K).
J433A-1 for an open circuit. If the wires are good, replace the Low Toner (K)
Sensor (PL 6.3).
Replace the Black Toner Cartridge (Section 6, Machine Consumables).
9-358 Cleaning Auger Full RAP

The Control Logic has determined that 130 copies have been made since the Cleaning Auger
Stopped.
Initial Actions
Ensure that P/J418B on the IOT Drive PWB and P/J115 0n the Auger Sensor are connected.
Check that the Auger sensor is clean and properly installed.
Procedure
Enter dC330 009-248 Waste Auger Rotate Sensor. Press Start. The Display is (H)
Y
N
Check the Auger Sensor for intermittent operation. If there is intermittent operation,
replace the Auger Sensor (PL 5.5). If the problem continues, replace the IOT Drive PWB
(PL 9.2).
The Waste Bottle is full
Y
N
The Waste Toner Junction is packed with toner
Y
N
Y
N
+5 VDC is measured between P/J418B-3 and P/J418B-1 on the IOT Drive
PWB.
Y
N
Go to the +5 VDC (IOT) Wirenet and check the wires between P/J21-1 on the
IOT LVPS and P/J418B-3 on the IOT Drive PWB. Go to the DC COM (IOT)
Wirenet and check the wires between P/J21-5 on the IOT LVPS and P/J418B1 on the IOT Drive PWB.
replace the Auger Sensor (PL 5.5).
Clean the Waste Toner Junction. If large particle of fused toner are present, replace the
Waste Toner Junction (PL 5.5).
Replace the Waste Toner Bottle and clean the Waste Toner Junction (Section 6, Machine Consumables).
9-357 Black Toner Dispenser Broken RAP, 9-358
1/05
2-118
Reissue
DocuColor 12/DCCS50
9-363 Rotary Home Position Fail RAP

Control Logic detected that the Rotary did not reach the Home position
Initial Actions
Refer to BSD 9.2 and BSD 9.15 for the following procedure
Ensure that P/J420A, P/J418A and P/J412A on the IOT Drive PWB, P/J260, P/J261,
and P/J262 on the Rotary PWB, and P/J110 on the Rotary Home Position Sensor are
connected.
Verify that the Xerographic CRU (Drum) unit is firmly seated and secured.
Adjust the Rotary Home Position Sensor (ADJ 6.1.1).
Press Start again. Visually inspect the Rotary Assembly. Ensure smooth operation of the
Rotary Motor. The Rotary Assembly goes to the Y, M, C, K, positions and then to the
Home position without binding.
Y
N
Replace the Rotary PWB (PL 6.1).
Go to Flag 6 on BSD 9.2. Check for an open circuit. If the wires are OK, check the Rotary
Drive Components (PL 6.1) and (PL 6.5) for contamination and or binding. Check the
Rotary Home Position Sensor for contamination. If the problem continues, replace the
Rotary Home Position Sensor (PL 6.1).
If erratic operation or intermittent faults continue, perform dC301 NVM Initialization.
Procedure
The fault is declared after long runs of black-and-white prints or copies
Y
N
Enter dC330 009-220 Rotary Home Position Sensor. Press Start. Ensure that the Rotary
is in the home position The Display indicates (H).
Y
N
Y
N
Go to Flag 3 on BSD 9.2. Check the wire for a short circuit to ground. If the wire
is good, replace the Rotary Home Position Sensor (PL 6.1).
B
Enter DC920. Select Home Position and press Start. The Rotary returns to the Home
position.
Y
N
Check the Rotary Drive Components (PL 6.1) and (PL 6.6) for contamination and or
binding. If the problem continues, replace the Rotary Motor (PL 6.1).
Remove the Black Development Housing. If binding is present, replace the Black Developer
(REP 6.6.2).
Perform the following NVM modification to resolve the problem:
Enter dC131 from the machine UI.
Change the value in location 776-066 to 300.
Change the value in location 776-480 to 300.
Exit UI diagnostics.
Enter DC920. Select Yellow Position and press Start. The Rotary goes to the Yellow
Developer position
Y
N
Check the Fuses on the Rotary PWB. One or both of the fuses are open
Y
N
+24 VDC is measured between P/J14-11 on the AC Driver PWB and P/J244 on the IOT LVPS.
Y
N
Y
N
Go to the +24 VDC wirenet, and check the fuse F5 on the AC Drive PWB.
If the fuse is good, check the wire and circuit between P/J14-11 on the AC
Driver PWB and P/J24-2 on the IOT LVPS for an open circuit.
Go to Flag 4 on BSD 9.2. Check the wires for an open or a short circuit. If the
wires are good, replace the Rotary PWB (PL 6.1). If the problem continues,
Replace the Rotary Motor (PL 6.1). If the problem continues, replace the IOT
Drive PWB (PL 9.2).
Replace the Fuses. If the fuses become open again, replace the Rotary Motor (PL
6.1).
A
B
Reissue
DocuColor 12/DCCS50
1/05
2-119
9-363 Rotary Home Position Fail RAP
9-365/9-450 Toner Dispenser Near Broken Yellow RAP
9-366/9-451 Toner Dispenser Near Broken Magenta RAP
Control Logic has detected that the Yellow dispenser is almost empty.
Control Logic has detected that the Magenta dispenser is almost empty.
Initial Actions
Initial Actions
Procedure
Procedure
9-365/9-450 Toner Dispenser Near Broken Yellow
1/05
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DocuColor 12/DCCS50
9-367/9-452 Toner Dispenser Near Broken Cyan RAP
9-368/9-453 Toner Dispenser Near Broken Black RAP
Control Logic has detected that the Cyan dispenser is empty.
Control Logic has detected that the Black dispenser is almost empty.
Initial Actions
Initial Actions
Procedure
Procedure
Black Toner Dispenser Broken RAP to troubleshoot the problem.
Reissue
DocuColor 12/DCCS50
1/05
2-121
9-367/9-452 Toner Dispenser Near Broken Cyan
A
9-369 Rotary Lock Fail RAP

The Control Logic has detected that the Rotary Latch Solenoid failed to lock
Initial Actions
Ensure that P/J412A and P/J418A on the IOT Drive PWB, P/J272 on the Rotary Latch Solenoid, and P/J116 on the Rotary Latch Sensor are connected before beginning this RAP.
Procedure
Enter dC330 009-237 Rotary Lock Mech Sensor. Press Start. The Display is (H)
Y
N
Actuate the Rotary Latch Sensor. The display changes to (H)
Y
N
Y
N
PWB.
Y
N
the +5 VDC (IOT) Wirenet and check the wires between P/J116-1 on the
Rotary Latch Sensor and P/J418A-5 on the IOT Drive PWB. Go to the DC
COM (IOT) Wirenet and check the wires between P/J116-3 on the Rotary
Latch Sensor and P/J418A-3 on the IOT Drive PWB. If the wires are good,
replace the Rotary Latch Sensor (PL 6.1).
Enter dC330 009-018 Rotary Lock Mech Latch. Press Start. The Rotary Latch Solenoid Latches
Y
N
PWB.
Y
N
the wires are good, replace the IOT Drive PWB (PL 9.2). If the problem continues, replace the Rotary Latch Solenoid (PL 6.1).
good, replace the Rotary Latch Solenoid (PL 6.1).
Check the Rotary Latch Solenoid for binding or intermittent operation. If the Rotary Latch
Solenoid is good, replace the Rotary Latch Sensor (PL 6.1). If the problem continues,
replace the Rotary Latch Solenoid(PL 6.1).
A
9-369 Rotary Lock Fail RAP
1/05
2-122
Reissue
DocuColor 12/DCCS50
A
9-370 Rotary Release Fail RAP

The Control Logic has detected that the Rotary Latch Solenoid failed to unlock
Initial Actions
Ensure that P/J412A and P/J418A on the IOT Drive PWB, P/J272 on the Rotary Latch Solenoid, and P/J116 on the Rotary Latch Sensor are connected before beginning this RAP.
Procedure
Enter dC330 009-237 Rotary Lock Mech Sensor. Press Start. The Display is (L)
Y
N
Deactuate the Rotary Latch Sensor. The display changes to (L)
Y
N
Y
N
PWB.
Y
N
Go to Flag 5 on BSD 9.2 and check the wire for an open. Go to the +5 VDC
(IOT) Wirenet and check the wires between P/J116-1 on the Rotary Latch Sensor and P/J418A-5 on the IOT Drive PWB. Go to the DC COM (IOT) Wirenet
and check the wires between P/J116-3 on the Rotary Latch Sensor and P/
J418A-3 on the IOT Drive PWB. If the wires are good, replace the Rotary Latch
Sensor (PL 6.1).
Enter dC330 009-018 Rotary Lock Mech Latch. Press Start. The Rotary Latch Solenoid releases.
Y
N
PWB.
Y
N
the wires are good, replace the IOT Drive PWB (PL 9.2). If the problem continues, replace the Rotary Latch Solenoid (PL 6.1).
good, replace the Rotary Latch Solenoid (PL 6.1).
Check the Rotary Latch Solenoid for binding or intermittent operation. If the Rotary Latch
Solenoid is good, replace the Rotary Latch Sensor (PL 6.1). If the problem continues,
replace the Rotary Latch Solenoid(PL 6.1).
A
Reissue
DocuColor 12/DCCS50
1/05
2-123
9-370 Rotary Release Fail RAP
9-372 Xerographic CRU (Drum) Not In Position RAP
9-374 Waste Bottle Not In Position RAP
Xerographic CRU (Drum) not in Position. The Control Logic detected that the Xerographic CRU
(Drum) is not installed in the machine.
This status code is declared when the sensor detects the there is no Waste Bottle, or that the
Waste Bottle has been improperly installed.
Initial Actions
Initial Actions
Ensure that P/J422A on the IOT Drive PWB and P/J713 are connected and that the Xerographic CRU (Drum) is properly installed before beginning this RAP.
Check that the Waste Bottle is in place, and that the actuator is not deformed. Check the Waste
Toner Bottle Sensor for dirt or foreign matter.
Procedure
Procedure
Go to Flag 8 on BSD 9.1. Check the harness for an open or a short circuit. If the harness is
good, replace the Xerographic CRU (Drum).
Enter dC330 009-249 Waste Bottle Position Sensor. Press Start. The Display is (L)
Y
N
Check the Waste Toner Bottle Sensor for intermittent operation. If there is intermittent
operation, replace the Waste Toner Bottle Sensor (PL 5.2). If the problem continues,
If the problem continues, replace the IOT Drive PWB (PL 9.2).
NOTE: Check GP 15 Setting the Machine for a Time & Materials (T & M) Account, to ensure
that the CRU is compatible with the machine service contract.
Less than +1 VDC is measured between P/J413-B4 and GND on the IOT Drive PWB.
Y
N
Go to Flag 2 on BSD 9.13. Check the wire for a short circuit to ground. If the wire is good,
replace the Waste Toner Bottle Sensor (PL 5.2).
9-372 Xerographic CRU (Drum) Not In Position RAP,
1/05
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DocuColor 12/DCCS50
9-376 Waste Bottle Full RAP
9-378 Xerographic CRU (Drum) Change RAP
Waste Bottle Full. This status code is declared when the number of copies reach a specific
count after the Waste Toner Full Sensor has detected a full toner bottle.
Control Logic has detected that the count in the Xerographic CRU (Drum) Eprom has reached
40k.
NOTE: The specified count is programmable in NVM location 774-020 Bottle Full The default
value of 300 may cause overfilling of the Waste Toner Bottle if many high coverage prints are
made after detection. If this occurs, set the value to a lower number.
Initial Actions
Initial Actions
Procedure
Refer to BSD 9.13and BSD 9.15 for the following procedure.
Check the Waste Toner Full Sensor for dirt or foreign matter
This fault should not require any service action. The Xerographic CRU (Drum) is specified as a
Customer Replaceable Unit.
This is a message fault only. An operator action is required.
Check that the / P/J114 on the Waste Toner Full Sensor, and P/J413B on the IOT Drive PWB
are firmly connected.
Procedure
The Waste Toner Bottle is full.
Y
N
Enter dC330 009-250 Waste Bottle Full Sensor. Press Start. The Display is (H)
Y
N
Check the Waste Toner Full Sensor for intermittent operation. If there is intermittent
operation, replace the Waste Toner Full Sensor (PL 5.2). If the problem continues,
Y
N
+5 VDC is measured between P/J413B-8 and P/J413B-6.
Y
N
Go to the +5 VDC (IOT) Wirenet and check the wires between P/J21-1 on the IOT
LVPS and P/J413B-8 on the Waste Toner Full Sensor. Go to the DC COM (IOT)
Wirenet and check the wires between P/J21-3 on the IOT LVPS and P/J413B-6 on
the Waste Toner Full Sensor.
Go to Flag 4 and Flag 6 on BSD 9.13. Check the wires for an open circuit. If the wires are
good, replace the Waste Toner Full Sensor (PL 5.2).
. Replace the Waste Toner Bottle (Section 6, Machine Consumables).
Reissue
DocuColor 12/DCCS50
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9-376 Waste Bottle Full RAP, 9-378 Xerographic
9-379 Trickle Bottle Full RAP
9-400 Black Toner Near Empty RAP
Trickle Bottle Full. This status code is declared when the number of copies reach a specific
count after the Trickle Toner Full Sensor has detected a full trickle bottle.
Control Logic has detected that the Black dispenser is almost empty.
Initial Actions
Initial Actions
Check the Trickle Toner Full Sensor for dirt or foreign matter
Procedure
Check that the P/J122 on the Trickle Toner Full Sensor, and P/J417A on the IOT Drive PWB
Procedure
The Trickle Toner Bottle is full.
Y
N
Enter dC330 009-251 Trickle Bottle Sensor. Press Start. The Display is (H)
Y
N
Check the Trickle Toner Full Sensor for intermittent operation. If the sensor appears
to be good, replace the IOT Drive PWB (PL 9.2). If the problem continues, replace
the Trickle Toner Full Sensor (PL 6.5).
Y
N
+24 VDC is Measured between P/J417A-1 and P/J417A-3 on the IOT Drive PWB.
Y
N
Go to the +24 VDC (IOT) Wirenet and check the wires between P/J23-1 on the IOT
LVPS and P/J417A-1 on the IOT Drive PWB for an open circuit. Go to the DC COM
(24 VRET) Wirenet and check the wires between P/J23-4 on the IOT LVPS and P/
J417A-3 on the IOT Drive PWB for an open circuit.
Go to Flag 2 on BSD 9.3. Check the wire for an open circuit. Check the wires between P/
J122-1 of the Trickle Toner Full Sensor and P/J417A-1 of the IOT Drive PWB and
between P/J122-3 of the Trickle Toner Full Sensor and P/J417A-3 of the IOT Drive PWB
for an open circuit. If the wires are good, replace the Trickle Toner Full Sensor (PL 6.5).
Replace the Trickle Toner Bottle (Section 6, Machine Consumables).
9-379 Trickle Bottle Full RAP, 9-400 Black Toner Near
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9-402 Yellow Toner Near Empty RAP
9-403 Magenta Toner Near Empty RAP
Control Logic has detected that the Yellow dispenser is almost empty.
Control Logic has detected that the Magenta dispenser is almost empty.
Initial Actions
Initial Actions
Procedure
Procedure
Reissue
DocuColor 12/DCCS50
1/05
2-127
9-402 Yellow Toner Near Empty RAP, 9-403 Magen-
9-404 Cyan Toner Near Empty RAP
9-410 Xerographic CRU (Drum) Change Soon RAP
Control Logic has detected that the Cyan dispenser is almost empty.
Control Logic has detected that the Xerographic CRU (Drum) is almost at the end of life.
Initial Actions
Initial Actions
Procedure
Procedure
This fault should not require any service action.
9-404 Cyan Toner Near Empty RAP, 9-410 Xerograph-
1/05
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DocuColor 12/DCCS50
9-420 Waste Bottle Near Full RAP
9-423 Trickle Bottle Near Full RAP
Control Logic has detected that the Waste Bottle is almost full.
Control Logic has detected that the Trickle Bottle is almost full.
Initial Actions
Initial Actions
Procedure
Procedure
Waste Bottle Full RAP to troubleshoot the problem.
Trickle Bottle Full RAP to troubleshoot the problem.
Reissue
DocuColor 12/DCCS50
1/05
2-129
9-420 Waste Bottle Near Full RAP, 9-423 Trickle
9-424 Cleaning Auger Near Full RAP
9-601 Humidity Out Of Range RAP
Control Logic has detected that the Cleaning Auger is almost full.
The measured humidity was out of the prescribed range.
Initial Actions
Initial Actions
Check the Temp Humidity Sensor (PL 7.1) for dirt or foreign matter
Procedure
Cleaning Auger Full RAP to troubleshoot the problem.
Check that the P/J142 on the Temp Humidity Sensor, and P/J422A on the IOT Drive PWB
Procedure
+5 VDC is measured between P/J422B-2 and P/J422A-3 on the IOT Drive PWB.
Y
N
Go to Flag 1 and Flag 2 on BSD 9.14. Check the wires for an open circuit or a short circuit. If
the wires are good, replace the Temp Humidity Sensor (PL 7.1). If the problem continues,
9-424 Cleaning Auger Near Full RAP, 9-601 Humidity
1/05
2-130
Reissue
DocuColor 12/DCCS50
9-610 VPatch Out Of Range RAP
9-612 TRC RADC Out Of Range RAP
The measured toned ADC patch was to light.
The measured toned TRC patch density is out of range.
Initial Actions
Initial Actions
Clean the ADC Sensor.
Clean the IBT Belt.
Clean the IBT Belt.
Check that P/J139 on the ADC Sensor PWB, IBT connector J702A, J702B and P/
J416A on the IOT Drive PWB are firmly connected.
Check that the P/J139 on the ADC Sensor PWB, IBT connector J702A, J702B and P/
Procedure
Procedure
Perform the following in the order listed.
Go to the IQ 38 Charge Corotron HVPS RAP and check the Charge Corotron HVPS for
proper operation.
proper operation.
Ensure that the Charge Corotron Wire and Grid are in good condition.
Go to the IQ 37 Developer Bias HVPS RAP and check the Developer Power Supply for
proper operation.
Go to the IQ 37 Developer Bias HVPS RAP and check the Developer Power Supply for
proper operation.
Go to Flag 7 and Flag 8 on BSD 9.8. Check the wires for an open circuit or a short circuit.
If the wires are good, replace the ADC Sensor (PL 7.5). If the problem continues, replace
Replace the Xerographic CRU (Drum) (Section 6, Machine Consumables).
Reissue
DocuColor 12/DCCS50
1/05
2-131
9-610 VPatch Out Of Range RAP, 9-612 TRC RADC
9-614 VClean Out Of Range RAP
9-619 VClean TRC Out Of Range RAP
The measured untoned ADC patch was out of range.
The measured untoned TRC patch density was out of range.
Initial Actions
Initial Actions
Clean the IBT Belt.
Clean the IBT Belt.
Procedure
Procedure
proper operation.
proper operation.
9-614 VClean Out Of Range RAP, 9-619 VClean TRC
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Reissue
DocuColor 12/DCCS50
9-634 ADC Out Of Range RAP
9-662 LD Out Of Range RAP
The selected gain for ADC was out of range.
The selected LD value was out of range.
Initial Actions
Initial Actions
Refer to BSD 9.1and BSD 9.15 for the following procedure.
Clean the ESV Sensor.
Clean the IBT Belt.
Check that P/J141 on the ESV Sensor, and P/J422A on the IOT Drive PWB are firmly
connected.
Procedure
Procedure
Go to Flag 7 and Flag 8 on BSD 9.8. Check the wires for an open circuit or a short circuit. If the
wires are good, replace the ADC Sensor (PL 7.5). If the problem continues, replace the IOT
Drive PWB (PL 9.2).
proper operation.
If the wires are good, replace the ESV Sensor (PL 5.1). If the problem continues, replace
Reissue
DocuColor 12/DCCS50
1/05
2-133
9-634 ADC Out Of Range RAP, 9-662 LD Out Of
9-667 VH/VM Out Of Range RAP

The selected LD value was out of range.
Initial Actions
Clean the ESV Sensor.
Check that P/J141 on the ESV Sensor, and P/J422A on the IOT Drive PWB are firmly
connected.
Procedure
proper operation.
If the wires are good, replace the ESV Sensor (PL 5.1). If the problem continues, replace
If the fault was declared during the VH portion of dC933, replace the Xerographic Module
(Drum CRU) (Machine Consumables, Section 6).
If the fault was declared during the VM portion of dC933, replace the ROS Assembly (PL
4.1).
9-667 VH/VM Out Of Range RAP
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DocuColor 12/DCCS50
10-102 Pre Fuser Sensor On Jam RAP
10-103 Pre Fuser Sensor On RAP
The Pre Fuser Sensor did not actuate within the specified time after the Pre IBT Sensor actuated.
The Pre Fuser Sensor detected paper when closing the Front Cover or when power was
switched on.
Initial Actions
Initial Actions
Clean the Pre Fuser and Pre IBT Sensor.
Check for paper on the Pre Fuser Sensor
Skewed sheets with LE corner damage.
Clean the Pre Fuser Sensor
Obstructions in the paper path or damage on lead edge of sheets
Contamination on the 2nd BTR Roll and/or Vacuum Transport.
Ensure that connectors P/J420 and P/J157 are seated correctly on the IOT Drive PWB
and the Pre Fuser Sensor, and there are no obvious crimped or broken wires.
and the Pre Fuser Sensor, and there are no obvious crimped or broken wires.
Ensure the Front Cover is closed. Switch the power Off then On.
Procedure
Procedure
Enter dC330 010-100 Pre Fuser Sensor. Press Start. Open the Drawer and block the Pre
Fuser Sensor with a sheet of paper. Close the Drawer. The display changes from H to L.
Y
N
Y
N
good, replace the Pre Fuser Sensor (PL 7.10).
Enter dC330 010-100 Pre Fuser Sensor. Press Start. The display indicates H.
Y
N
replace the Pre Fuser Sensor (PL 7.10).
harness for an intermittent short circuit. If the harness is OK, replace the Pre Fuser Sensor (PL
Open the Drawer (the paper should still be blocking the sensor). Connect the meter from
P/J420-A11 on the IOT Drive PWB to GND. Close the drawer. The voltage at P/J420A11 goes from +5 VDC when the drawer is open, to less than +1.0 VDC when the
drawer is closed.
Y
N
There is +5 VDC between P/J420-A12 and P/J420-A10 on the IOT Drive PWB.
Y
N
Go to Flag 1 and Flag 2 on BSD 10.1 and check the harness for an open circuit. If
the harness is good, replace the Pre Fuser Sensor (PL 7.10). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Check/replace the following components until the problem is resolved. Replace any components that are worn, broken, binding, or slipping:
Drives for the 2nd BTR Roll (PL 7.10)
2nd BTR Roll (PL 7.10)
Guide (PL 7.10)
Reissue
DocuColor 12/DCCS50
1/05
2-135
10-102 Pre Fuser Sensor On Jam RAP, 10-103 Pre
10-105 Fuser Exit Sensor On Jam RAP

The Fuser Exit Sensor did not actuate within the specified time after the IBT Entrance Sensor
actuated.
Initial Actions
Ensure that 605K91060 Pressure Roll Finger Assembly Kit, Tag 11, is installed.
A
Enter dC330 004-009 Fuser Motor. Press Start and Stop several times. The Fuser Motor
energizes and deenergizes.
Y
N
Press Stop. + 5 VDC is measured between P/J417B-11 and GND on the IOT Drive
PWB.
Y
N
Y
N
Replace the Distribution PWB (PL 9.3).
NOTE: This problem is common when heavyweight paper is fed from the tray long-edge first.
All heavyweight and extra-heavyweight paper should be fed from the tray short-edge first.
Go to Flag 1 and Flag 4 on BSD 10.4 and check the harnesses for an open circuit. If
the harnesses are good, replace the Fuser Motor (PL 1.6)
Clean the Fuser Exit Sensor
Cheat the Front Door Interlock and remove the Oil Bottle. Visually observe the paper on
the Vacuum Transport to see that it stays down. If not, orient the paper so it feeds from the
tray short-edge first. If the problem remains, ensure that the Fuser Nip is cammed in
before the sheet arrives.
Ensure that the Fuser Inlet Baffle is correctly positioned
Contamination on the Vacuum Transport
Press Start. The voltage a P/J417B-11 go to less than +1.0 VDC.

Y
N
+24 VDC is measured between P/J42-6 on the Distribution PWB and GND.
Y
N
Go to Flag 2 and Flag 3 on BSD 10.4 and check the harnesses for an open circuit. If the
harnesses are good, replace the Fuser Motor (PL 1.6). If the problem continues, replace
Damage to Vacuum Transport Drive Gears
Ensure that connectors P/J413A, P/J417B, P/J418B and P/J168 are seated correctly
on the IOT Drive PWB and the Fuser Exit Sensor, and there are no obvious crimped or
broken wires.
Procedure
Enter dC330 010-105 Fuser Exit Sensor. Press Start. Block the Fuser Exit Sensor with a
sheet of paper. The display changes from H to L.
Y
N
Y
N
good, replace the Fuser Exit Sensor (PL 8.10).
Check/replace the following components until the problem is resolved. Replace any component that is worn, broken, bent, deformed, binding or slipping:
Heat Roll Stripper Fingers (PL 8.3) and Pressure Roll Stripper Fingers (PL 8.10)
Heat Roll Finger Assembly (PL 8.3) and the Pressure Roll Finger Assembly (PL 8.10)
Gears and shafts on the Fuser Exit Drive Assembly (PL 1.6)
Ensure that the rubber sleeve on the Exit Roll (shaft) (located under the Fuser Exit Sensor) is
not torn, damaged or contaminated with Fuser Oil. Clean the sleeve or repair it by replacing the
Exit Roll (shaft) (PL 8.10).
Connect the meter from P/J413A-4 on the IOT Drive PWB to GND. Block the Fuser Exit
Sensor with a sheet of paper. The voltage at P/J413A-4 goes from +5 VDC when the
sensor is not blocked, to less than +1.0 VDC when the sensor is blocked.
Y
N
There is +5 VDC between P/J413A-14 and GND on the on the IOT Drive PWB.
Y
N
the harness is good, replace the Fuser Exit Sensor (PL 8.10). If the problem continues, replace the IOT Drive PWB (PL 9.2).
A
10-105 Fuser Exit Sensor On Jam RAP
1/05
2-136
Reissue
DocuColor 12/DCCS50
10-106 Fuser Exit Sensor Off Jam RAP

The Fuser Exit Sensor did not deactuate within the specified time after the Registration Feed
started.
Replace the Inverter Gate Solenoid (PL 2.25).

Contamination on the Regi Roll, 2 nd BTR or Vacuum Transport.
Ensure that connectors P/J412B, P/J413A, P/J418B and P/J168 are seated correctly
on the IOT Drive PWB and the Fuser Exit Sensor, and there are no obvious crimped or
broken wires.
Enter dC330 010-006 Inverter Gate Solenoid (Invert). Press Start. The Inverter Gate Solenoid energizes.
Y
N
+24 VDC is measured between P/J412B-7 and GND.
Y
N
good, replace the Inverter Gate Solenoid (PL 2.25).
Press Start. The voltage at P/J412B-7 momentarily goes to less than +1.0 VDC.
Y
N
Procedure
Y
N
Y
N
Y
N
Y
N

Enter dC330 010-033 Oil Pump. Press Start and Stop several times. The Exit Motor energizes and deenergizes.
Y
N
Press Stop. Approximately +7 VDC is measured between P/J418B-17 on the IOT
Drive PWB and GND.
Y
N
the harness is good, replace the Exit Motor (PL 1.6).
Press Start. The voltage at P/J418B-17 goes to less than +1.0 VDC.
Y
N
Y
N

Enter dC330 010-005 Inverter Gate Solenoid (Exit). Press Start. The Inverter Gate Solenoid energizes.
Y
N
Y
N
Y
N
A
B
C
Reissue
DocuColor 12/DCCS50
C
Y
N
Initial Actions
good, replace the Exit Motor (PL 1.6). If the problem continues, replace the IOT Drive
PWB (PL 9.2).
Check for obvious damage, missing and/or broken Fuser Exit Drive gear assemblies and drive
belts that would cause the paper to be slow to leave the Fuser Exit Sensor (PL 1.6). Also,
cheat the Front Door Interlock and remove the Oil Bottle. Visually observe the paper as it feeds
into and through the Fuser. Ensure that the Fuser Nip stays engaged until the trail edge of the
sheet exits the Fuser.
Ensure that the rubber sleeve on the Exit Roll (shaft) (located under the Fuser Exit Sensor) is
not torn, damaged or contaminated with Fuser Oil. Clean the sleeve or repair it by replacing the
Exit Roll (shaft) (PL 8.10).
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10-106 Fuser Exit Sensor Off Jam RAP
10-107 Fuser Exit Sensor On RAP
10-110 Machine Exit Sensor On Jam RAP
The Fuser Exit Sensor detected paper when closing the Front Cover or when power was
switched on.
The Machine Exit Sensor did not actuate within the specified time after the Fuser Exit Sensor
actuated.
Initial Actions
Initial Actions
Refer to BSD 10.7, 10.9, and 10.12 for the following procedure.
Check for paper on the Fuser Exit Sensor.
Contamination on the Fuser Exit Roll and/or M/C Exit Roll.
Ensure that connectors P/J413A and P/J168 are seated correctly on the IOT Drive PWB
and the Fuser Exit Sensor, and there are no obvious crimped or broken wires.
Ensure the Front Cover is closed. Switch the power Off then On.
Ensure that connectors P/J412B, P/J418B, and P/J149 are seated correctly on the IOT
Drive PWB and the Machine Exit Sensor, and there are no obvious crimped or broken
wires.
Open the Inverter Door (PL 2.23) and clean the Machine Exit Sensor. Also, ensure that
the sensor actuator is not bent or damaged; that it does not contact the harness or baffles;
and that it is seated in the bracket correctly.
Clean the Fuser Exit Sensor.
Cheat the Front Door Interlock and observe the paper as it feeds out of the Fuser Exit
Assembly and into the Inverter Top Chute Assembly. Ensure that the lead edge is not
catching on the baffles or cutouts.
Procedure
Enter dC330 010-105 Fuser Exit Sensor. Press Start. The display indicates H.
Y
N
replace the Fuser Exit Sensor (PL 8.10).
harness for an intermittent short circuit. If the harness is OK, replace the Fuser Exit Sensor (PL
Procedure
Enter dC330 010-110 Machine Exit Sensor. Press Start. Actuate the Machine Exit Sensor
actuator. The display changes from L to H.
Y
N
The display is a constant H.
Y
N
Go to Flag 7 on BSD 10.7 and check the harness for an short circuit. If the harness is
good, replace the Machine Exit Sensor (PL 2.25).
Connect the meter from P/J412B-5 on the IOT Drive PWB to GND. Actuate the Machine
Exit Sensor actuator. The voltage at P/J412B-5 goes from less than +1.0 VDC when
the sensor is deactuated, to +5 VDC when the sensor is actuated.
Y
N
Y
N
the harness is good, replace the Machine Exit Sensor (PL 2.25). If the problem continues, replace the IOT Drive PWB (PL 9.2).
10-107 Fuser Exit Sensor On RAP, 10-110 Machine
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DocuColor 12/DCCS50
N
Y
N
Y
N
Y
N
A
Y
N
Drive PWB and GND.
Y
N
Y
N
Y
N
PWB (PL 9.2).

Y
N
Y
N
Y
N
Check for obvious damage, missing and/or broken Fuser Exit Drive gear assemblies and drive
belts that would cause the paper to be slow to actuate the Machine Exit Sensor (PL 1.6).
Y
N
Enter dC330 010-006 Inverter Gate Solenoid (Invert). Press Start. The Inverter Gate Solenoid energizes.
Y
N
Y
N
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
2-139
10-110 Machine Exit Sensor On Jam RAP
10-111 Machine Exit Sensor Off Jam RAP
When using either the inversion path or exit path, the Machine Exit Sensor did not deactuate
within the specified time after it actuated.
Initial Actions
the harness is good, replace the Machine Exit Sensor (PL 2.25). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Make ONE single-sided set of 10 or more originals. (This causes the copies to go through the
inversion path and exit the machine face down.) Repeat this job several times. Next, make
TWO single-sided sets of 10 or more originals. (This causes the copies to bypass the inversion
path and exit the machine face up.) Repeat this job several times. If a fault occurs ONLY when
the copies exit the machine face down, replace the Exit Roll Assembly (PL 2.26) as follows:
with Tag 23 install the Tag 23 Exit Roll Assembly, machines with an Offset Catch Tray install
the Offset Roller Kit, machines without an Offset Catch Tray install the Corrugation Mark Roller
Kit. If the fault occurs when the copies exit the machine face down AND face up, continue with
Initial Actions below:
Obstructions in the inverter and exit paper path
Equal Pinch-roll (PL 2.25) force at the Machine Exit Roll (PL 2.26) nips.
Binding of the Machine Exit Roll (PL 2.26) or Pinch Roll Shafts (PL 2.25).
N
Y
N

Y
N
Drive PWB and GND.
Y
N
Y
N
Ensure that the Inverter Pinch Rolls (PL 2.26) have proper nip pressure.
Remove the Inverter Door Cover (PL 2.25) and tape down the Exit Chute (PL 2.25) to prevent jamming. Look for skew along the lead edge of the paper as it inverts and exits the
machine. If skewing occurs, check for movement in the Door Latch area by pressing on
the door. If the door moves in, hold it closed at the latch area to see if feeding improves. If
feeding improves, check the (door) Lever (assembly) (PL 2.26) for loose or damaged
components. To minimize movement in the Inverter 2 Assembly, loosen the two screws
holding the white plastic latch and metal latch bracket. Move both parts to the right and
then tighten the screws.
Clean the Machine Exit and Inverter Rolls (PL 2.26).
Ensure that connectors P/J412B, P/J418B and P/J149 are seated correctly on the IOT
Drive PWB and the Machine Exit Sensor, and there are no obvious crimped or broken
wires.
Y
N
PWB (PL 9.2).
Check for binding, obvious damage, missing and/or broken Drive Motor gear assemblies and
drive belts that would cause the paper to be slow to leave the Machine Exit Sensor. If OK,
replace these components in the following order: Exit Roll (Assembly) (PL 2.26), Inverter 2
Upper Chute (PL 2.25), Inverter 2 Assembly (PL 2.23).
Procedure
Enter dC330 010-110 Machine Exit Sensor. Press Start. Actuate the Machine Exit Sensor
Y
N
Y
N
good, replace the Machine Exit Sensor (PL 2.25).
Connect the meter from P/J412B-5 on the IOT PWB to GND. Actuate the Machine Exit
Sensor actuator. The voltage at P/J412B-5 goes from less than +1.0 VDC when the
sensor is deactuated, to +5 VDC when the sensor is actuated.
A
10-111 Machine Exit Sensor Off Jam RAP
1/05
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Reissue
DocuColor 12/DCCS50
10-112 Machine Exit Sensor On RAP
10-115 Exit Path Sensor On Jam RAP
The Machine Exit Sensor detected paper when closing the Front Cover or when power was
switched on.
The Exit Path Sensor did not actuate within the specified time after the Fuser Exit Sensor actuated.
Initial Actions
Initial Actions
Obstructions in the paper path.
Ensure there is no paper on the Machine Exit Sensor.
Contamination on the Fuser Exit Roll.
Ensure that connectors P/J412B and P/J149 are seated correctly on the IOT Drive PWB
and the Machine Exit Sensor, and there are no obvious crimped or broken wires.
Ensure the Inverter is closed. Switch the power Off then On.
Cheat the Front Door Interlock and observe the paper as it feeds out of the Fuser Exit
Assembly and into the Inverter Top Chute Assembly. Ensure that the lead edge is not
catching on the Inverter 1 Baffle or Inverter Gate. Also, check the function and position of
the Inverter gate and Inverter Gate Solenoid dC330 010-005 Inverter Gate Solenoid (Exit)
and 010-006 Inverter Gate Solenoid (Invert).
Open the Inverter Door (PL 2.23) and clean the Exit Path Sensor. Also, ensure that the
sensor actuator moves freely.
Ensure that connectors P/J412B, P/J417A, and P/J164 are seated correctly on the IOT
Drive PWB and the Exit Path Sensor, and there are no obvious crimped or broken wires.
Ensure that the front Fuser Pin Bracket (PL 8.1) is installed and correctly positioned on
the semi-perfs.
Procedure
Enter dC330 010-110 Machine Exit Sensor. Press Start. The display indicates L.
Y
N
Go to Flag 7 and Flag 8 on BSD 10.7 and check the harness for an open circuit. If the harness is good, replace the Machine Exit Sensor (PL 2.25).
fault code is not present and is occurring intermittently, go to Flag 7 and Flag 8 on BSD 10.7
and check the harness for an intermittent open circuit. If the harness is OK, replace the
Machine Exit Sensor (PL 2.25). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Procedure
Enter dC330 010-115 Exit Path Sensor. Press Start. Actuate the Exit Path Sensor actuator.
The display changes from L to H.
Y
N
Y
N
good, replace the Exit Path Sensor (PL 2.25).
Connect the meter from P/J412B-2 on the IOT Drive PWB to GND. Actuate the Exit Path
Sensor actuator. The voltage at P/J412B-2 goes from less than +1.0 VDC when the
sensor is not actuated, to +5 VDC when the sensor is actuated.
Y
N
Y
N
the harness is good, replace the Exit Path Sensor (PL 2.25). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Enter dC330 004-009 Fuser Motor. Press Start and Stop several times. The Fuser Motor
energizes and deenergizes.
Reissue
DocuColor 12/DCCS50
1/05
2-141
10-112 Machine Exit Sensor On RAP, 10-115 Exit
N
Press Stop. + 5 VDC is measured between P/J417B-11 and GND on the IOT Drive
PWB.
Y
N
Y
N
Go to Flag 1 and Flag 4 on BSD 10.4 and check the harnesses for an open circuit. If
the harnesses are good, replace the Fuser Motor (PL 1.6)
Y
N
Y
N
Check for obvious damage, missing and/or broken Drive Motor gear assemblies and drive
belts that would cause the paper to be slow to actuate the Exit Path Sensor.
The Exit Path Sensor detected paper when closing the Inverter Cover or when the power was
switched on.
Initial Actions
Open the Inverter Door (PL 2.23) and clean the Exit Path Sensor. Also, ensure that the
sensor actuator is moving freely.
and the Exit Path Sensor, and there are no obvious crimped or broken wires.
Procedure
Go to Flag 2 and Flag 3 on BSD 10.4 and check the harnesses for an open circuit. If the
harnesses are good, replace the Fuser Motor (PL 1.6). If the problem continues, replace
10-115 Exit Path Sensor On Jam RAP, 10-117 Exit
10-117 Exit Path Sensor On Jam RAP
Enter dC330 010-115 Exit Path Sensor. Press Start. The display indicates L.
Y
N
Go to Flag 5 and Flag 6 on BSD 10.7 and check the harness for a open circuit. If the harness is good, replace the Exit Path Sensor (PL 2.25).
and check the harness for an intermittent open circuit. If the harness is OK, replace the Exit
Path Sensor (PL 2.25). If the problem continues, replace the IOT Drive PWB (PL 9.2).
1/05
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Reissue
DocuColor 12/DCCS50
10-120 Inverter Path Sensor On Jam RAP
The Inverter Path Sensor detected paper when closing the Inverter Cover or when the power
was switched on.
The Inverter Path Sensor did not actuate within the specified time after the Fuser Exit Sensor
actuated.
Initial Actions
Initial Actions
Clean the Inverter Path Sensor.
Obstructions in the paper path
and the Inverter Path Sensor, and there are no obvious crimped or broken wires.
Proper Nip Drive force on the Inverter Rolls
Cheat the Front Door Interlock and check the function and the position of the Inverter
Gate and Inverter Gate Solenoid dC330 010-005 Inverter Gate Solenoid (Exit) and 010006 Inverter Gate Solenoid (Invert).
Clean the Inverter Path Sensor and Inverter Roll 2. Also, ensure that the sensor actuator
moves freely.
Ensure that connectors P/J412A, P/J417A and P/J151 are seated correctly on the IOT
Drive PWB and the Inverter Path Sensor, and there are no obvious crimped or broken
wires.
Procedure
Enter dC330 010-125 Inverter Path Sensor. Press Start. The display indicates L.
Y
N
Go to Flag 1 and Flag 2 on BSD 10.8 and check the harness for a open circuit. If the harness is good, replace the Inverter Path Sensor (PL 2.24).
and check the harness for an intermittent open circuit. If the harness is OK, replace the Inverter
Path Sensor (PL 2.24). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Procedure
Enter dC330 010-125 Inverter Path Sensor. Press Start. Actuate the Inverter Path Sensor
Y
N
Y
N
good, replace the Inverter Path Sensor (PL 2.24).
Connect the meter from P/J412A-8 on the IOT Drive PWB to GND. Actuate the Inverter
Path Sensor actuator. The voltage at P/J412A-8 goes from less than +1.0 VDC when
the sensor is not actuated, to +5 VDC when the sensor is actuated.
Y
N
Y
N
the harness is good, replace the Inverter Path Sensor (PL 2.24). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Reissue
DocuColor 12/DCCS50
Enter dC330 010-025 Inverter Roll Solenoid Nip. Press Start. The Release Solenoid energizes.
Y
N
+24 VDC is measured between P/J412A-14 and GND.
Y
N
A
B
1/05
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10-120 Inverter Path Sensor On Jam RAP, 10-125
B
Y
C
belts that would cause the paper to be slow to actuate the Inverter Path Sensor.
N
good, replace the Release Solenoid (PL 2.24).
Press Start. The voltage at P/J412A-14 decreases momentarily then returns to +24
VDC.
Y
N
Replace the Release Solenoid (PL 2.24).
Enter dC330 010-026 Inverter Roll Release Solenoid (Release). Press Start. The Release
Solenoid energizes.
Y
N
Y
N
VDC.
Y
N
Enter dC330 010-020 Inverter Motor Forward. Press Start and Stop several times. The
Inverter Motor energizes and deenergizes.
Y
N
Press Stop. +24 VDC is measured between P/J417A-13, 14, 17, 18 on the IOT Drive
PWB and GND.
Y
N
Y
N
harness and connectors are OK, replace the Inverter Motor (PL 2.24).
Press Start. The voltage at P/J417A-13, 14, 17, 18 on the IOT Drive PWB goes to
approximately +18 VDC.
Y
N
Replace the Inverter Motor (PL 2.24).
Enter dC330 010-021 Inverter Motor Reverse. Press Start and Stop several times. The
Y
N
C
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Reissue
DocuColor 12/DCCS50

The Inverter Path Sensor did not deactuate within the specified time after the Fuser Exit Sensor deactuated.
C
VDC.
Y
N
Initial Actions
Refer to BSD 10.8, 10.9, 10.11 and 10.12 for the following procedure.
Proper Nip Drive force on the Inverter Roll
Obstructions in the paper path
Clean the Inverter Path Sensor and ensure that the sensor actuator moves freely.
Drive PWB and the Inverter Path Sensor, and there are no obvious crimped or broken
wires.
Enter dC330 010-026 Inverter Roll Solenoid Release. Press Start. The Release Solenoid
energizes.
Y
N
Y
N
Procedure
Enter dC330 010-125 Inverter Path Sensor. Press Start. Actuate the Inverter Path Sensor
Y
N
Y
N
good, replace the Inverter Path Sensor (PL 2.24).
Connect the meter from P/J412A-8 on the IOT Drive PWB to GND. Actuate the Inverter
Path Sensor actuator. The voltage at P/J412A-8 goes from less than +1.0 VDC when
the sensor is deactuated, to +5 VDC when the sensor is actuated.
Y
N
Y
N
VDC.
Y
N
Y
N
PWB and GND.
Y
N
Y
N
the harness is good, replace the Inverter Path Sensor (PL 2.24). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Y
N

Y
N
Y
N
Y
N

Y
N
belts that would cause the paper to be slow to actuate the Inverter Path Sensor.
A
B
C
Reissue
DocuColor 12/DCCS50
1/05
2-145
10-127 Duplex Registration Sensor On Jam RAP

The Registration Sensor did not actuate within the specified time after the start of Paper Feed
in Duplex Mode.
C
Y
N
Initial Actions
Contamination on the Regi Roll, 2nd BTR or Vacuum Transport.
Ensure that connectors P/J421A, P/J419A, P/J412A and P/J162 are seated correctly
on the IOT Drive PWB and the Registration Sensor, and there are no obvious crimped or
broken wires.
Clean the Registration Sensor.
Procedure
Enter dC330 008-054 Registration Motor. Press Start and Stop several times. The Registration Motor energizes and deenergizes.
Y
N
Press Stop. +24 VDC is measured between P/J419A-3, 4, 5, 6 on the IOT Drive PWB
and GND.
Y
N
Y
N
Enter dC330 008-155 Registration Sensor. Press Start. Block the Registration Sensor with a
sheet of paper The display changes from H to L.
Y
N
Y
N
Connect the meter from P/J421A-11 on the IOT Drive PWB to GND. Block the Registration Sensor with a sheet of paper. The voltage at P/J421A-11 goes from +5 VDC
when the sensor is not blocked, to less than +1.0 VDC when the sensor is blocked.
Y
N
There is +5 VDC between P/J421A-12 and P/J421A-10 on the on the IOT Drive
PWB.
Y
N
harness and connectors are OK, replace the Registration Motor (PL 2.15).
Press Start. The voltage at P/J419A-3, 4, 5, 6 on the IOT Drive PWB goes to approximately +18 VDC.
Y
N
Replace the Regi. Motor (PL 2.15).
belts that would cause the paper to be slow to actuate the Registration Sensor.
harness is good, replace the Registration Sensor (PL 2.15). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Y
N
There is +24 VDC between P/J412B-9 and GND.
Y
N
There is +24 VDC between P/J412B-8 and GND.
Y
N
A
B
C
10-127 Duplex Registration Sensor On Jam RAP
1/05
2-146
Reissue
DocuColor 12/DCCS50
10-128 Duplex Pre Regi. Sensor On Jam RAP
The Pre Registration Sensor did not actuate within the specified time after the start of Paper
Feed in Duplex Mode.
N
harness and connectors are OK, replace Main Motor 2 (PL 1.5).
Initial Actions
Press Start. The voltage at P/J414B-3, 4, 5, 6 on the IOT Drive PWB goes to approximately +23 VDC.
Y
N
Proper Nip Drive force.
Contamination on the Pre Regi Roll or 2 nd BTR.
Ensure that connectors P/J419A, P/J414B and P/J162 are seated correctly on the IOT
Drive PWB and the Pre Registration Sensor, and there are no obvious crimped or broken
wires.
Replace Main Motor 2 Motor (PL 1.5).

belts that would cause the paper to be slow to actuate the Pre Registration Sensor.
Procedure
Enter dC330 008-153 Pre Registration Sensor. Press Start. Open the Drawer. Insert a piece
of paper to black the Pre Registration Sensor. Close the Drawer. The display changes from
H to L.
Y
N
Y
N
Connect the meter from P/J419A-13 on the IOT Drive PWB to GND. Block the Pre Registration Sensor with a sheet of paper. The voltage at P/J419A-13 goes from +5 VDC
when the sensor is not blocked, to less than +1.0 VDC when the sensor is blocked.
Y
N
There is +5 VDC between P/J419A-14 and P/J419A-12 on the on the IOT Drive
PWB.
Y
N
harness is good, replace the Pre Registration Sensor (PL 2.16). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Enter dC330 008-043 Main Motor 2. Press Start and Stop several times. Main Motor 2 energizes and deenergizes.
Y
N
Press Stop. +24 VDC is measured between P/J414B-3, 4, 5, 6 on the IOT Drive PWB
and GND.
Y
N
+24 VDC is measured between P/J414B-1 on the IOT Drive PWB and GND.
A
B
Reissue
DocuColor 12/DCCS50
1/05
2-147
10-128 Duplex Pre Regi. Sensor On Jam RAP
10-130 Duplex In Sensor On Jam RAP
C
The Duplex In Sensor did not actuate within the specified time after the start of Reverse Feed.
Press Start. The voltage at P/J412A-14 momentarily goes to approximately +12 to
+15 VDC then returns to +24 VDC.
Y
N
Initial Actions
Ensure that the Upper Inverter Roll (PL 2.24) has proper nip pressure.
Drive PWB and the Duplex In Sensor, and there are no obvious crimped or broken wires.
Procedure
energizes.
Y
N
Y
N
NOTE: In the following step, to block the Duplex In Sensor, open the Inverter Door. Slide a
sheet of paper up, and under, the mylar guides at the bottom of the Inverter 1 Upper Chute.
Enter dC330 010-130 Duplex In Sensor. Press Start. Open the Inverter Cover and block the
Duplex In Sensor with a sheet of paper. The display changes from L to H.
Y
N
There display is a constant H.
Y
N
Go to Flag 3 on BSD 10.10 and check the harness for an short circuit. If the harness
is good, replace the Duplex In Sensor (PL 2.24).
Connect the meter from P/J412A-5 on the IOT PWB to GND. Block the Duplex In Sensor. The voltage at P/J412A-5 goes from less than +1.0 VDC when the sensor is not
blocked, to +5 VDC when the sensor is blocked.
Y
N
Y
N

Y
N
Y
N
PWB and GND.
Y
N
Y
N
the harness is good, replace the Duplex In Sensor (PL 2.24). If the problem continues, replace the IOT Drive PWB (PL 9.2).
approximately +18.5 VDC.
Y
N

Y
N
Y
N
Y
N
A
B
C

Y
N
belts that would cause the paper to be slow to actuate the Duplex In Sensor.
1/05
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Reissue
DocuColor 12/DCCS50
10-132 Duplex Path Sensor On Jam RAP

The Duplex Path Sensor did not actuate within the specified time after the start of Reverse
Feed.
C

Y
N
Initial Actions
Refer to BSD 10.8, 10.9, 10.10, and 10.12 for the following procedure.
Contamination on the Duplex In Roll (PL 2.21).
Ensure that connectors P/J412A, P/J417A, and P/J420 are seated correctly on the IOT
Drive PWB and there are no obvious crimped or broken wires.
Procedure
Enter dC330 010-132 Duplex Path Sensor. Ensure the Drawer is closed. Press Start. The
display indicates L.
Y
N
Connect the meter from P/J420-A2 on the IOT Drive PWB to GND. The meter indicates less than +1.0 VDC.
Y
N
Y
N
Go to Flag 8 on BSD 10.10. Check the harness for a short circuit. If the harness
is good, replace the IOT Drive PWB (PL 9.2).
Check the actuator for the Duplex Path Sensor. If it is good, go to Flag 7 and Flag 8
on BSD 10.10 and check the harness for an open circuit. If the harness is good,
replace the Duplex Path Sensor (PL 2.21). If the problem continues, replace the IOT
Drive PWB (PL 9.2).
deenergizes.
Y
N
Press Stop. +24 VDC is measured between P/J412A-12 and GND.
Y
N
Y
N
Y
N
PWB and GND.
Y
N
Y
N
NOTE: In the following step, to block the Duplex Path Sensor, open the Drawer then open the
baffle (Jam Clearance Lever 3) on the bottom of the Drawer. Place a sheet of paper on the baffle then close the baffle. CLose the Drawer.
Block the Duplex Path Sensor with a sheet of paper. The display indicates H.
Y
N
Go to Flag 7 on BSD 10.10. Check the harness for a short circuit. If the harness is good,
replace the Duplex Path Sensor (PL 2.21).
Y
N
Y
N
Y
N
Y
N
A
B
C
Reissue
DocuColor 12/DCCS50
Y
N
belts that would cause the paper to be slow to actuate the Duplex Path Sensor.
1/05
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10-132 Duplex Path Sensor On Jam RAP
10-133 Duplex Out Sensor On Jam RAP

The Duplex Out Sensor did not actuate within the specified time after the start of Reverse
Feed.

Proper Nip Drive force at Drive Rolls (Baffle latches properly).
C

Y
N
Initial Actions
Contamination on the Duplex Path Roll (PL 2.21).
Ensure that connectors P/J412A, P/J417A, and P/J420 are seated correctly on the IOT
Drive PWB and there are no obvious crimped or broken wires.
Procedure
Enter dC330 010-133 Duplex Out Sensor. Ensure the Drawer is closed. Press Start. The
display indicates L.
Y
N
Connect the meter from P/J420-A5 on the IOT Drive PWB to GND. The meter indicates less than +1.0 VDC.
Y
N
Y
N
Go to Flag 6 on BSD 10.10. Check the harness for a short circuit. If the harness
is good, replace the IOT Drive PWB (PL 9.2).
Check the actuator for the Duplex Out Sensor. If it is good, go to Flag 5 and Flag 6
on BSD 10.10 and check the harness for an open circuit. If the harness is good,
replace the Duplex Out Sensor (PL 2.21). If the problem continues, replace the IOT
Drive PWB (PL 9.2).
deenergizes.
Y
N
Y
N
Y
N
Y
N
PWB and GND.
Y
N
Y
N
NOTE: To block the Duplex Out Sensor, open the Drawer then open Jam Clearance Lever 3
on the bottom of the Drawer. Place a sheet of paper on the baffle, close the baffle and Drawer.
Block the Duplex Out Sensor with a sheet of paper. The display indicates H.
Y
N
Go to Flag 5 on BSD 10.10. Check the harness for a short circuit. If the harness is good,
replace the Duplex Out Sensor (PL 2.21).
Y
N
Y
N
Y
N
Y
N
A
B
C
Y
N
belts that would cause the paper to be slow to actuate the Duplex Out Sensor.
1/05
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Reissue
DocuColor 12/DCCS50
10-162 Duplex Path 1 Sensor On Jam RAP
Duplex In Sensor Paper Static Jam.
Duplex Path Sensor Paper Static Jam.
Initial Actions
Initial Actions
Clean the Duplex In Sensor (PL 2.24).
Clean the Duplex Path Sensor (PL 2.21).
Ensure that connectors P/J412A and P/J150 are seated correctly on the IOT Drive PWB
and the Duplex In Sensor, and there are no obvious crimped or broken wires.
and the Duplex Path Sensor, and there are no obvious crimped or broken wires.
Ensure the Drawer is closed. Switch the power Off then On.
Procedure
Procedure
Enter dC330 010-130 Duplex In Sensor. Press Start. The display indicates L.
Y
N
Go to Flag 3 and Flag 4 on BSD 10.10 and check the harness for a open circuit. If the harness is good, replace the Duplex In Sensor (PL 2.24).
Enter dC330 010-132 Duplex Path Sensor. Press Start. The display indicates L.
Y
N
Go to Flag 7 and Flag 8 on BSD 10.10 and check the harness for a open circuit. If the harness is good, replace the Duplex Path Sensor (PL 2.21).
and check the harness for an intermittent open circuit. If the harness is OK, replace the Duplex
In Sensor (PL 2.24). If the problem continues, replace the IOT Drive PWB (PL 9.2).
In Sensor (PL 2.21). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Reissue
DocuColor 12/DCCS50
1/05
2-151
10-160 Duplex In Sensor On Jam RAP, 10-162 Du-
10-280 OCT Offset Sensor Failure RAP
Duplex Out Sensor Paper Static Jam.
At initialization, the home position was not detected by the Offset Home Sensor after OCT
reversal.
Initial Actions
During offset, movement of the Stacker to the offset position was not detected by the Offset Home Sensor
During offset, movement of the Stacker to the home position was not detected by the Offset Home Sensor

Clean the Duplex Out Sensor (PL 2.21).
Initial Actions
and the Duplex Out Sensor, and there are no obvious crimped or broken wires.
Ensure the Drawer is closed. Switch the power Off then On.
Procedure
Enter dC330 010-133 Duplex Out Sensor. Press Start. The display indicates L.
Y
N
Go to Flag 5 and Flag 6 on BSD 10.10 and check the harness for a open circuit. If the harness is good, replace the Duplex Out Sensor (PL 2.21).
Out Sensor (PL 2.21). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Ensure that connectors P/J422A and P/J422B is seated correctly on the IOT Drive PWB
and there are no obvious crimped or broken wires.
Procedure
Manually move the OCT toward the front of the system (Home Position). Enter dC330 010-086
Offset Motor Forward. Press Start. The OCT moves toward the rear (offset position).
Y
N
good, replace the OCT Offset Motor (PL 14.1). If the problem continues, replace the IOT
Drive PWB (PL 9.2).
Press Stop. Less than +1 VDC is measured between P/J422B-12 and GND.
Y
N
Press Start. The voltage between P/J422B-12 and GND goes to +24 VDC.
Y
N
Enter dC330 010-085 Offset Motor Reverse. Press Start. The OCT moves toward the
front (Home Position).
Y
N
good, replace the OCT Offset Motor (PL 14.1). If the problem continues, replace the IOT
Drive PWB (PL 9.2).
Enter dC330 010-298 OCT Home Sensor. Press Start. Enter dC330 010-086 Offset Motor
disForward. Press Start. Enter dC330 010-085 Offset Motor Reverse. Press Start. The
play changes from H to L to H.
Y
N
Y
N
good, replace the OCT Offset Home Sensor (PL 14.1).
A
10-163 Duplex Out Sensor On Jam RAP, 10-280 OCT
1/05
2-152
B
Reissue
DocuColor 12/DCCS50
B
Connect the meter from P/J422A-9 on the IOT PWB to GND. Manually move the Stacker
Tray toward the rear until it stops, and then toward the front, until it stops. The voltage at
P/J422A-9 goes from than +5.0 VDC when the tray is to the front, to less than +1.0
VDC when the tray is moved off the front position.
Y
N
the harness is good, replace the OCT Offset Home Sensor (PL 14.1).
10-300 Inverter Cover Open RAP

The Inverter Cover is detected open.
Initial Actions

Enter dC330 010-299 OCT Position Sensor. Press Start. Enter dC330 010-086 Offset Motor
disForward. Press Start. Enter dC330 010-085 Offset Motor Reverse. Press Start. The
play changes from L to H to L.
Y
N
Y
N
good, replace the OCT Offset Position Sensor (PL 14.1).
Connect the meter from P/J422A-8 on the IOT PWB to GND. Manually move the Stacker
Tray toward the rear until it stops, and then toward the front, until it stops. The voltage at
P/J422A-8 goes from less than +1.0 VDC when the tray is to the front, to +5.0 VDC
when the tray is moved to the rear position.
Y
N
the harness is good, replace the OCT Offset Position Sensor (PL 14.1).
Open and close the Inverter Cover. While physically pushing on the Inverter Cover, switch
the power off then on. If the Fault Code does not appear, check Inverter Cover latch and
alignment for damaged parts.
Ensure that connectors P/J412A and P/J152 are seated correctly on the IOT Drive PWB,
and the Inverter Cover Switch and there are no obvious crimped or broken wires.
Procedure
Enter dC330 010-300 Inverter Cover Interlock. Open the Inverter Cover. Manually actuate the
Inverter Cover Switch. The display changes from H to L when the switch is actuated.
Y
N
Connect the meter from P/J412A-11 on the IOT Drive PWB to GND. Manually actuate the
Inverter Cover Switch. The voltage at P/J412A-11 goes from +5 VDC to less than +1.0
VDC when the switch is manually actuated.
Y
N
Go to Flag 3 on BSD 10.8. Check the harness for an open circuit. If the harness is
good, replace the Inverter Cover Switch (PL 2.24).

Check for obvious damage, missing and/or broken Offset Motor gear assemblies.
Reissue
DocuColor 12/DCCS50
harness for an intermittent open circuit. If the harness is OK, replace the Inverter Cover Switch
1/05
2-153
10-280 OCT Offset Sensor Failure RAP, 10-300 In-
10-341 Fuser Oil Empty RAP
10-342 Fuser Web Change RAP
Fuser Oil Empty. This status code is declared when approximately 2000 - 4000 pages (Prints
or Copies) have been made since Oil Near Empty Condition.
The Web Supply Roll is empty. The customer should install a new Web CRU.
NOTE: The Oil Near Empty Condition occurs when the sensor detects that the oil is low
(approximately 40k prints have been printed). The machine issues a warning when it detects
Fuser Oil Near Empty. When another 2000 to 4000 prints are printed out without servicing the
Fuser Oil, the machine issues a stop message and then stops printing.
NOTE: Oil usage varies depending on the types of images and paper being used. 30 - 40k
prints per bottle is typical. However, when an oil metering system (Metering Blade, Donor Roll,
etc.) is in need of service, it can use oil at two to three times the normal rate.
Initial Actions
NOTE: The Web Empty condition occurs when the web supply roll has been emptied. when
this occurs, two metal contacts touch the empty Web Supply Roll and complete a circuit. This
causes two things to happen: a 10-342 fault code is declared and a Replace Cleaning Web
message is displayed. The machine will not operate until a new Web is installed.
NOTE: This status code is stored in NVM location 777-077 and cannot be reset by Power Off/
On. Replacing the empty Web CRU with a new one will automatically reset NVM location 777077 Web Status from 2 to 0 and NVM location 777-078 Web Motor On Time from 17 to 0.
The Replace Cleaning Web Soon message will first appear when 777-075 Web Near Empty
changes from 0 to 1.
Initial Actions
Refer to BSD 10.5 (2 of 2) and 10.12 for the following procedure.
Refer to BSD 10.5 (1 of 2) and 10.12 for the following procedure.

1.
Open the Drawer.
Procedure
2.
Remove the Oil Cartridge (PL 8.1). Verify that there is oil in the bottle. If not, install a new
Oil Cartridge Machine Consumables.
3.
Close the Drawer.
4.
Switch the power Off and then On.
1.
Open the Drawer.
2.
Remove and inspect the Web CRU. The web supply roll should be empty and two metal
clips should be touching the metal supply roll. If it is, install a new Web CRU (Machine
Consumables) the fault code should disappear. If the web supply roll is not empty, install a
new Web CRU (Machine Consumables). If the fault codes is still displayed, replace the
Procedure
NOTE: This RAP assumes that there is fuser oil in the bottle and therefore is not a cause of the
10-341 Fault Code.
Enter dC330 010-222 Oil Empty Sensor. Press Start. The Oil Empty Sensor status is H.
Y
N
Press Stop. There is +5 VDC between P/J413A-3 on the IOT Drive PWB and GND.
Y
N
Go to Flag 1 on BSD 10.5 (2 of 2) and check the harness for an open circuit. If the
harness is good, replace the IOT Drive PWB (PL 9.2).
There is +5 VDC between P/J413A-14 on the IOT Drive PWB and P/J44-7 on the
Distribution PWB.
Y
N
Go to Flag 2 on BSD 10.5 (2 of 2) and check the harness for an open circuit. If the harness is good, replace the Oil Empty Sensor (PL 8.7). If the problem continues, replace the
10-341 Fuser Oil Empty RAP, 10-342 Fuser Web
1/05
2-154
Reissue
DocuColor 12/DCCS50
10-355 External Heat Roll Contact Failure RAP
The External Heat Roll Retract Sensor did not go L within 5 seconds after the External Heat
Roll Retract Motor started rotating.
Initial Actions
+5 VDC is measured between P/J413A-14 on the IOT Drive PWB and P/J44-7 on the
Distribution PWB.
Y
N

1.
Go to Flag 2 and Flag 3 on BSD 10.6 and check the harness for an open circuit. If the harness is good, go to Flag 7 on BSD 10.6 and check the harness for an open circuit. If the
harness is good, replace the External Heat Roll Retract Sensor (PL 8.4). If the problem
continues, replace the IOT Drive PWB.
Open the Drawer
2.
Remove the Oil Cartridge (PL 8.1)
3.
Remove the Front Cover (PL 8.1)
4.
Remove the Top Cover (PL 8.2)
5.
Close the Drawer.
6.
Switch the power off, then on.
N
Y
N
Enter dC330 010-221 External Heat Roll Retract Sensor. Press Start. The
cates L.
Y
N
The actuator for the External Heat Roll Retract Sensor
Procedure
display
NOTE: When using component control to energize the External Heat Roll Retract Motor, the
following conditions occur:
Go to Flag 2 on BSD 10.6 and check the harness for an open or short circuit.
When the code[10-027] (contact) is first entered, the motor will drive until the External
Heat Roll Retract Sensor senses that the External Heat Roll is in the contact position.
Then the code switches to off.
If the harness is good, replace the External Heat Roll Retract Sensor (PL 8.4)
Subsequent attempts to enter [10-027] have no effect. In order to test code [10-027]
again, code [10-028] (retract) must be entered first in order to drive the External Heat Roll
to the retracted position.
indi-
Missing and/or broken External Heat Roll Retract Motor gear (PL 8.4)
Binding in the linkage of the contact/retract mechanism for the External Heat Roll (PL 8.4)
Loose connectors and pins for the External Heat Roll Retract Motor and Sensor
Enter dC330 010-027 External Heat Roll Retract Motor (Contact). Press Start. The External Heat Roll Retract Motor energizes.
Y
N
Press Stop. + 24 VDC is measured at P/J413A-1 on the IOT Drive PWB.
Y
N
Y
N
good, replace the External Heat Roll Retract Motor (PL 8.4).
NOTE: In the next step, the drop in voltage may be momentary or may be for a longer
duration, but a drop in voltage should occur.
Press Start. The voltage at P/J413A-1 drops to less than +20.0 VDC.
Y
N
Replace the External Heat Roll Retract Motor (PL 8.4).
The External Heat Roll Retract Motor stops after several seconds.
Reissue
DocuColor 12/DCCS50
1/05
2-155
10-355 External Heat Roll Contact Failure RAP
10-356 External Heat Roll Retract Failure RAP

The External Heat Roll Retract Sensor did not go H within 5 seconds after the External Heat
Roll Retract Motor started rotating.
Initial Actions
Enter dC330 010-221 External Heat Roll Retract Sensor. Press Start. The display indicates H.
Y
N
The actuator (on the Camshaft) for the External Heat Roll Retract Sensor. If the actuator binds, ensure that the Bracket (PL 8.4) on which the sensor is mounted is free
from damage.

1.
Open the Drawer
2.
Remove the Oil Cartridge (PL 8.1)
3.
Remove the Front Cover (PL 8.1)
4.
Remove the Top Cover (PL 8.2)
5.
Close the Drawer.
6.
Switch the power off, then on.
B
Go to Flag 2 and Flag 3 on BSD 10.6 and check the harness for an open circuit. If the harness is good, go to Flag 7 on BSD 10.6 and check the harness for an open circuit. If the
harness is good, replace the External Heat Roll Retract Sensor (PL 8.4). If the problem
continues, replace the IOT Drive PWB.
Go to Flag 3 on BSD 10.6 and check the harness for a short circuit.
If the harness is good, replace the External Heat Roll Retract Sensor (PL 8.4)
Missing and/or broken External Heat Roll Retract Motor gear (PL 8.4)
Procedure
Binding in the linkage of the contact/retract mechanism for the External Heat Roll (PL 8.4)
Loose connectors and pins for the External Heat Roll Retract Motor and Sensor
Enter dC330 010-027 External Heat Roll Retract Motor (Contact). Press Start. The External Heat Roll Retract Motor energizes.
Y
N
Press Stop. + 24 VDC is measured at P/J413A-1 on the IOT Drive PWB.
Y
N
Y
N
good, replace the External Heat Roll Retract Motor (PL 8.4).
NOTE: In the next step, the drop in voltage may be momentary or may be for a longer
duration, but a drop in voltage should occur.
Press Start. The voltage at P/J413A-1 drops to less than +20.0 VDC.
Y
N
Replace the External Heat Roll Retract Motor (PL 8.4).
The External Heat Roll Retract Motor stops after several seconds.
Y
N
Y
N
+5 VDC is measured between P/J413A-14 on the IOT Drive PWB and P/J44-7 on the
Distribution PWB.
Y
N
A
B
10-356 External Heat Roll Retract Failure RAP
1/05
2-156
Reissue
DocuColor 12/DCCS50
10-359 Heat Roll Control Thermistor Failure RAP
10-360 Heat Roll Overheat Thermistor Failure RAP
The Heat Roll Control Thermistor detected an abnormal resistance value continuously for more
than 1500 msec (Heat Roll Control Thermistor disconnected).
The Heat Roll Overheat Thermistor detected an abnormal resistance value continuously for
more than 1500 msec (Heat Roll Overheat Thermistor disconnected).
Initial Actions
Initial Actions
Open the Drawer and extend it to the service position. Perform the following:
Remove the Oil Cartridge (PL 8.1).
Remove the Front Cover (PL 8.1).
Remove the Top Cover (PL 8.2).
Check the Heat Roll Control Thermistor for cleanliness, damage and excessive wear at
the point where the Thermistor contacts the Heat Roll. If the surface of the Thermistor is
worn, replace the Heat Roll Control Thermistor (PL 8.4). Inspect the surface of the Heat
Roll for excessive wear due to the Thermistor. Replace the Heat Roll if necessary (PL
8.3).
Check the Heat Roll Overheat Thermistor for cleanliness, damage and excessive wear at
worn, replace the Heat Roll Overheat Thermistor (PL 8.4). Inspect the surface of the Heat
8.3).
Check the Drawer connector P700B at the rear of the Fuser for damaged pins. Check the
mating connector on the IOT, and ensure that the mounting plate for the IOT connector is
not bent or misaligned.
Procedure
Procedure
NOTE: Prior to replacing a component, disconnect the connectors to the component (Heat Roll
Control Thermistor and IOT Drive PWB). Check the connectors for broken, bent and dirty pins.
Disconnect and reconnect the connectors several times to remove contaminants due to oxidation.
Overheat Thermistor and IOT Drive PWB). Check the connectors for broken, bent and dirty
pins. Disconnect and reconnect the connectors several times to remove contaminants due to
oxidation.
Switch the power off. Disconnect P/J171 on the Heat Roll Control Thermistor. Measure the
resistance between P/J171-1 and P/J171-2 on the Heat Roll Control Thermistor. The resistance of the Thermistor should be in the range of 0.78K Ohms when hot to 150K Ohms when
cool (room temperature). Note the measurement if it is in specification. The resistance of the
Thermistor is in specification.
Y
N
Replace the Heat Roll Control Thermistor (PL 8.4).
Switch the power off. Disconnect P/J172 on the Heat Roll Overheat Thermistor. Measure the
resistance between P/J172-1 and P/J172-2 on the Heat Roll Overheat Thermistor. The resistance of the Thermistor should be in the range of 0.78K Ohms when hot to 150K Ohms when
cool (room temperature). Note the measurement if it is in specification. The resistance of the
Thermistor is in specification.
Y
N
Replace the Heat Roll Overheat Thermistor (PL 8.4).
Reconnect P/J171 to the Heat Roll Control Thermistor. Close the Drawer. Disconnect P/
J413A from the IOT Drive PWB. Measure the resistance from P/J413A-13 to P/J413A-7. The
resistance measurement is the same as the measurement noted above (+/- 5%).
Y
N
Go to Flag 1 and Flag 3 on BSD 10.2. Check the harness for an open circuit.
Reconnect P/J172 to the Heat Roll Overheat Thermistor. Close the Drawer. Disconnect P/
Y
N
Reissue
DocuColor 12/DCCS50
1/05
2-157
10-359 Heat Roll Control Thermistor Failure RAP,
10-361 Power On Heat Roll Not Ready RAP
10-362 Standby Heat Roll Not Ready RAP
The Heat Roll did not reach the Ready temperature within 12 minutes after Power On.
The Heat Roll Lamp was On continuously for 90 seconds during Standby Mode, but the Heat
Roll did not reach operating temperature.
Initial Actions
Initial Actions
Procedure
Cheat the Front Door Interlock. Switch on the power. The Heat Roll Heater Rod illuminates
after self-test completes.
Y
N
Go to the OF10-3 Heat Roll AC Power RAP.
Switch off the power. Cheat the Front Door Interlock Switch. Disconnect P/J413A from the IOT
Drive PWB. Check the resistance between J413 -13 and J413-A7 of the harness. The resistance should be in the range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when
cool (room temperature). The resistance is within specification.
Y
N
Disconnect P/J171 on the Heat Roll Control Thermistor. The resistance from pin 1 to pin
2 should be in the range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when
Y
N
Procedure
Y
N
Drive PWB. Check the resistance between J413-13 and J413-A7 of the harness. The resistance should be in the range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when
Y
N
Disconnect P/J171 on the Heat Roll Control Thermistor. The resistance should be in the
range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when cool (room temperature). The resistance is within specification.
Y
N
Go to Flag 1 and Flag 3 of BSD 10.2. Check for a loose wire or connector, or an intermittent short circuit to ground.
Check the H/R Control Thermistor for cleanliness, damage and excessive wear at the
point where the Thermistor contacts the Heat Roll. Ensure that it is installed correctly.
If the surface of the Thermistor is worn, replace the H/R Control Thermistor (PL 8.4).
Inspect the surface of the Heat Roll for excessive wear due to the Thermistor. Replace the
Heat Roll if necessary (PL 8.3).
If the problem continues, replace the H/R Control Thermistor (PL 8.4). If the fault persists,
10-361 Power On Heat Roll Not Ready RAP, 10-362
1/05
2-158
Reissue
DocuColor 12/DCCS50
10-363 Job Complete Heat Roll Not Ready RAP
10-364 Job Incomplete Heat Roll Not Ready RAP
The Heat Roll Lamp was On continuously for 3 minutes after the current job completed, but the
Heat Roll did not reach operating temperature.
The Heat Roll declared Not Ready during a job and the Heat Roll Lamp was On continuously
for 4 minutes after the machine stopped, but the Heat Roll did not reach operating temperature.
Initial Actions
Initial Actions
Procedure
Procedure
Y
N
Y
N
Drive PWB. Check the resistance between J413 -13 and J413- A7 of the harness. The resistance should be in the range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when
Y
N
Y
N
Drive PWB. Check the resistance between J413- A13 and J413- A7 of the harness. The resistance should be in the range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when
Y
N
Y
N
Reissue
DocuColor 12/DCCS50
1/05
2-159
10-363 Job Complete Heat Roll Not Ready RAP, 10-
10-366 Heat Roll Control Thermistor Overheat Failure RAP
B
Y
The Heat Roll Control Thermistor detected a temperature in excess of 230 C (446 F) on the
Heat Roll.
N
This indicates that the problem is intermittent. Replace the Heat Roll Control
Thermistor (PL 8.4).
Replace the SSR (PL 9.3).

Power On. To reset this code, enter Diagnostics and change the value in NVM location 777160 Fuser Over heating Failure from 1 to 0.
Initial Actions
Go to Flag 3 on BSD 10.2 and check for a short circuit to ground between P/J171-1 and P/
J413A-7 If OK, replace the Heat Roll Control Thermistor (PL 8.4). If the problem continues,
Go to Flag 9 (Flag 19 w/ TAG P31) on BSD 10.2 and check the harness for a short circuit
to ground. If OK, replace the IOT Drive PWB (PL 9.2).
Check the Heat Roll Control Thermistor for cleanliness, damage and excessive wear at
worn, replace the Heat Roll Control Thermistor (PL 8.4). Inspect the surface of the Heat
8.3).
Procedure
disconnect and reconnect the connectors several times to remove contaminants due to oxidation.
Ensure NVM location 777-160 is reset to 0. Switch off the power. Cheat the Front Door Interlock Switch. Disconnect P/J171 on the Heat Roll Control Thermistor. The resistance of the
Thermistor should be in the range of 0.78K Ohms when hot, to 150K Ohms when cool (room
temperature). The resistance is in specification.
Y
N
Reconnect the connector. Close the Drawer. Switch on the power. The
10-366
fault
is
declared immediately after self-test completes.
Y
N
Switch off the power. Check the voltage at P/J105-4 on the SSR and GND. Switch on the
power. There is 0 VDC present when self-test completes.
Y
N
The voltage at P/J105-4 increases to approximately +4.3 VDC within 12 minutes.
Y
N
The Heater Rod remains illuminated while P/J105-4 still reads approximately
+4.3 VDC.
A
B
10-366 Heat Roll Control Thermistor Overheat Failure
1/05
2-160
Reissue
DocuColor 12/DCCS50
10-367 Heat Roll Overheat Thermistor Overheat Failure

RAP
Heat Roll Overheat Thermistor detected a temperature in excess of 230 C (446 F) on the
Heat Roll.
Initial Actions
B
N
This indicates that the problem is intermittent. Replace the Heat Roll Overheat
Thermistor (PL 8.4).

Go to Flag 9 (Flag 19 w/ Tag P31) on BSD 10.2 and check the harness for a short circuit
J413A-8. If OK, replace the Heat Roll Overheat Thermistor (PL 8.4). If the problem continues,
Check the Heat Roll Overheat Thermistor for cleanliness, damage and excessive wear at
worn, replace the Heat Roll Overheat Thermistor (PL 8.4). Inspect the surface of the Heat
8.3).
Procedure
Overheat Thermistor and IOT Drive PWB). Check the connectors for broken, bent and dirty
pins. disconnect and reconnect the connectors several times to remove contaminants due to
oxidation.
Ensure NVM location 777-160 is reset to 0. Switch off the power. Cheat the Front Door Interlock Switch. Disconnect P/J172 on the Heat Roll Overheat Thermistor. The resistance of the
Y
N
Replace the Heat Roll Overheat Thermistor (PL 8.4).
10-367
fault
is
Y
N
Y
N
Y
N
+4.3 VDC.
A
B
Reissue
DocuColor 12/DCCS50
1/05
2-161
10-367 Heat Roll Overheat Thermistor Overheat
10-368 Pressure Roll Control Thermistor Failure RAP
10-369 Pressure Roll Overheat Thermistor Failure RAP
The Pressure Roll Control Thermistor detected an abnormal resistance value continuously for
over 1500 msec (Pressure Roll Control Thermistor disconnected).
The Pressure Roll Overheat Thermistor detected an abnormal resistance value continuously
for over 1500 msec (Pressure Roll Overheat Thermistor disconnected).
Initial Actions
Initial Actions
Check the Pressure Roll Control Thermistor for cleanliness, damage and excessive wear
at the point where the Thermistor contacts the Pressure Roll. If the surface of the Thermistor is worn, replace the Pressure Roll Control Thermistor (PL 8.6). Inspect the surface
of the Pressure Roll for excessive wear due to the Thermistor. Replace the Pressure Roll
if necessary (PL 8.3).
Check the Pressure Roll Overheat Thermistor for cleanliness, damage and excessive
wear at the point where the Thermistor contacts the Pressure Roll. If the surface of the
Thermistor is worn, replace the Pressure Roll Overheat Thermistor (PL 8.6). Inspect the
surface of the Pressure Roll for excessive wear due to the Thermistor. Replace the Pressure Roll if necessary (PL 8.3).
Check the Drawer connector P700B at the rear of the Fuser for damaged pins.
Procedure
Disconnect and reconnect the connectors several times to remove contaminants due to oxidation.
Switch the power off. Disconnect P/J173 on the Pressure Roll Control Thermistor. Measure
the resistance between P/J173-1 and P/J173-2 on the Pressure Roll Control Thermistor. The
resistance of the Thermistor should be in the range of 0.78K Ohms when hot to 150K Ohms
when cool (room temperature). Note the measurement if it is in specification. The resistance
of the Thermistor is in specification.
Y
N
Procedure
NOTE: Prior to replacing a component, disconnect the connectors to the component (Pressure
Roll Overheat Thermistor and IOT Drive PWB). Check the connectors for broken, bent and
dirty pins. Disconnect and reconnect the connectors several times to remove contaminants
due to oxidation.
Switch the power off. Disconnect P/J174 on the Pressure Roll Overheat Thermistor. Measure
the resistance between P/J174-1 and P/J174-2 on the Pressure Roll Overheat Thermistor.
The resistance of the Thermistor should be in the range of 0.78K Ohms when hot to 150K
Ohms when cool (room temperature). Note the measurement if it is in specification. The
resistance of the Thermistor is in specification.
Y
N
NOTE: To remove the harness guard (PL 8.6) around the thermistor wires, press the tab
on the guard that is located below the front cam (PL 8.6).
Replace the Pressure Roll Control Thermistor (PL 8.6).
Reconnect P/J173 to the Pressure Roll Control Thermistor. Close the Drawer. Disconnect P/
Y
N
Go to Flag 5 on BSD 10.2. Check the harness for an open circuit.
Replace the Pressure Roll Overheat Thermistor (PL 8.6).

Reconnect P/J174 to the Pressure Roll Overheat Thermistor. Close the Drawer. Disconnect
P/J413A from the IOT Drive PWB. Measure the resistance from P/J413A-13 to P/J413A-10.
The resistance measurement is the same as the measurement noted above (+/- 5%).
Y
N
10-368 Pressure Roll Control Thermistor Failure RAP,
1/05
2-162
Reissue
DocuColor 12/DCCS50
10-370 Power On Pressure Roll Not Ready RAP
10-371 Stand By Pressure Roll Not Ready RAP
The Pressure Roll did not reach the Ready temperature within 8 minutes after Power On.
The Pressure Roll Heater Rod was On continuously for 90 seconds during the Standby Mode,
but the Pressure Roll did not reach operating temperature.
Initial Actions
Initial Actions
Procedure
Cheat the Front Door Interlock. Switch on the power. Enter dC330 010-031 Pressure Roll
Heater Rod On. Press Start. The Pressure Roll Heater Rod illuminates momentarily.
Y
N
Go to the OF10-4 Pressure Roll AC Power RAP.
Drive PWB. Check the resistance between J413- A13 and J413-A9 of the harness. The resistance should be in the range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when
Y
N
Disconnect P/J173 on the Pressure Roll Control Thermistor. The resistance should be in
the range of 0.78K ohms when the Roll is hot, to 150K ohms when cool (room temperature). The resistance is within specification.
Y
N
Replace the P/R Control Thermistor (PL 8.6).
Procedure
Y
N
Y
N
Y
N
Check the P/R Control Thermistor for cleanliness, damage and excessive wear at the
point where the Thermistor contacts the Pressure Roll. Ensure that it is installed correctly.
If the surface of the Thermistor is worn, replace the P/R Control Thermistor (PL 8.6).
Inspect the surface of the Pressure Roll for excessive wear due to the Thermistor.
Replace the Pressure Roll if necessary (PL 8.3).
If the problem continues, replace the P/R Control Thermistor (PL 8.6). If the fault persists,
Reissue
DocuColor 12/DCCS50
1/05
2-163
10-370 Power On Pressure Roll Not Ready RAP, 10-
10-372 Job Complete Pressure Roll Not Ready RAP

The Pressure Roll Lamp was On continuously for 3 minutes after the current job completed,
but the Pressure Roll did not reach operation temperature.
Initial Actions
10-373 Job Incomplete Pressure Roll Not Ready Failure

RAP
The Pressure Roll declared Not Ready during a job and the Pressure Roll Lamp was On continuously for 3 minutes after the machine stopped, but the Pressure Roll did not reach operation temperature.
Initial Actions
Procedure
Y
N
Drive PWB. Check the resistance between J413-A13 and J413-A9 of the harness. The resistance should be in the range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when
Y
N
Y
N
Procedure
Y
N
Y
N
Y
N
Go to Go to Flag 1 and Flag 4 of BSD 10.2. Check for a loose wire or connector, or an
intermittent short circuit to ground.
10-372 Job Complete Pressure Roll Not Ready RAP,
1/05
2-164
Reissue
DocuColor 12/DCCS50
10-375 Pressure Roll Control Thermistor Overheat Failure

RAP
The Pressure Roll Control Thermistor detected a temperature in excess of 230 C (446 F) on
the Pressure Roll.
J413A-9. If OK, replace the Pressure Roll Control Thermistor (PL 8.6). If the problem continues, replace the IOT Drive PWB (PL 9.2).
C
+4.3 VDC.
Y
N
This indicates that the problem is intermittent. Replace the Pressure Roll Control Thermistor (PL 8.6).
Initial Actions
Check the Pressure Roll Control Thermistor for cleanliness, damage and excessive wear
at the point where the Thermistor contacts the Pressure Roll. If the surface of the Thermistor is worn, replace the Pressure Roll Control Thermistor (PL 8.6). Inspect the surface
of the Pressure Roll for excessive wear due to the Thermistor. Replace the Pressure Roll
if necessary (PL 8.3).
Procedure
Roll Control Thermistor and IOT Drive PWB). Check the connectors for broken, bent and dirty
pins. disconnect and reconnect the connectors several times to remove contaminants due to
oxidation.
Ensure NVM location 777-160 is reset to 0. Switch off the power. Cheat the Front Door Interlock Switch. Disconnect P/J173 on the Pressure Roll Control Thermistor. The resistance of the
Y
N
Replace the Pressure Roll Control Thermistor (PL 8.6).
10-375
fault
is
Y
N
Y
N
Y
N
A
B
C
Reissue
DocuColor 12/DCCS50
1/05
2-165
10-375 Pressure Roll Control Thermistor Overheat
10-376 Pressure Roll Overheat Thermistor Overheat

Failure RAP
The Pressure Roll Overheat Thermistor detected a temperature in excess of 230 C (446 F)
on the Pressure Roll.
J413A-10. If OK, replace the Pressure Roll Overheat Thermistor (PL 8.6). If the problem continues, replace the IOT Drive PWB (PL 9.2).
C
+4.3 VDC.
Y
N
This indicates that the problem is intermittent. Replace the Pressure Roll Overheat Thermistor (PL 8.6).
Initial Actions
Check the Pressure Roll Overheat Thermistor for cleanliness, damage and excessive
wear at the point where the Thermistor contacts the Pressure Roll. If the surface of the
Thermistor is worn, replace the Pressure Roll Overheat Thermistor (PL 8.6). Inspect the
surface of the Pressure Roll for excessive wear due to the Thermistor. Replace the Pressure Roll if necessary (PL 8.3).
Procedure
Roll Overheat Thermistor and IOT Drive PWB). Check the connectors for broken, bent and
dirty pins. disconnect and reconnect the connectors several times to remove contaminants due
to oxidation.
Ensure NVM location 777-160 is reset to 0. Switch off the power. Cheat the Front Door Interlock Switch. Disconnect P/J174 on the Pressure Roll Overheat Thermistor. The resistance of
the Thermistor should be in the range of 0.78K Ohms when hot, to 150K Ohms when cool
(room temperature). The resistance is in specification.
Y
N
Replace the Pressure Roll Overheat Thermistor (PL 8.6).
10-376
fault
is
Y
N
Y
N
Y
N
A
B
C
10-376 Pressure Roll Overheat Thermistor Overheat
1/05
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DocuColor 12/DCCS50
10-377 External Heat Roll Control Thermistor Failure RAP

The External Heat Roll Control Thermistor detected an abnormal resistance value continuously
for 1500 msec (External Heat Roll Control Thermistor disconnected).
Initial Actions
The External Heat Roll Overheat Thermistor detected an abnormal resistance value continuously for 1500 msec (External Heat Roll Overheat Thermistor disconnected).
Initial Actions
10-378 External Heat Roll Overheat Thermistor Failure

RAP
Check the External Heat Roll Control Thermistor for cleanliness, damage and excessive
wear at the point where the Thermistor contacts the External Heat Roll. If the surface of
the Thermistor is worn, replace the External Heat Roll Control Thermistor (PL 8.8).
Inspect the surface of the External Heat Roll for excessive wear due to the Thermistor.
Replace the External Heat Roll if necessary (PL 8.8).
Procedure
NOTE: Prior to replacing a component, disconnect the connectors to the component (External
Heat Roll Control Thermistor and IOT Drive PWB). Check the connectors for broken, bent and
dirty pins. Disconnect and reconnect the connectors several times to remove contaminants
due to oxidation.
Switch the power off. Disconnect P/J175 on the External Heat Roll Control Thermistor. Measure the resistance between P/J175-1 and P/J175-2 on the External Heat Roll Control Thermistor. The resistance of the Thermistor should be in the range of 0.78K Ohms when hot, to
150K Ohms when cool (room temperature). Note the measurement if it is in specification.
The resistance of the Thermistor is in specification.
Y
N
Replace the External Heat Roll Control Thermistor (PL 8.8).
Reconnect P/J175 to the External Heat Roll Control Thermistor. Close the Drawer. Disconnect
P/J413A from the IOT Drive PWB. Measure the resistance from P/J413A-13 to P/J413A-11.
The resistance measurement is the same as the measurement noted above (+/- 5%).
Y
N
Check the External Heat Roll Overheat Thermistor for cleanliness, damage and excessive wear at the point where the Thermistor contacts the External Heat Roll. If the surface
of the Thermistor is worn, replace the External Heat Roll Overheat Thermistor (PL 8.8).
Inspect the surface of the External Heat Roll for excessive wear due to the Thermistor.
Replace the External Heat Roll if necessary (PL 8.8).
Procedure
Heat Roll Overheat Thermistor and IOT Drive PWB). Check the connectors for broken, bent
and dirty pins. Disconnect and reconnect the connectors several times to remove contaminants due to oxidation.
Switch the power off. Disconnect P/J176 on the External Heat Roll Overheat Thermistor. Measure the resistance between P/J176-1 and P/J176-2 on the External Heat Roll Overheat Thermistor. The resistance of the Thermistor should be in the range of 0.78K Ohms when hot to
150K Ohms when cool (room temperature). Note the measurement if it is in specification.
The resistance of the Thermistor is in specification.
Y
N
Replace the External Heat Roll Overheat Thermistor (PL 8.8).
Reconnect P/J176 to the External Heat Roll Overheat Thermistor. Close the Drawer. Disconnect P/J413A from the IOT Drive PWB. Measure the resistance from P/J413A-13 to P/J413A12. The resistance measurement is the same as the measurement noted above (+/- 5%).
Y
N
Reissue
DocuColor 12/DCCS50
1/05
2-167
10-377 External Heat Roll Control Thermistor Fail-
10-379 Power On External Heat Roll Not Ready RAP
N
Replace the External Heat Roll Thermostat (PL 8.8).
The External Heat Roll did not reach the Ready temperature within 5 minutes after Power On.
Initial Actions
If the harness is good, go to Flag 14 on BSD 10.2 and check the harness for an open circuit.
Disconnect the connectors to the components (External Heat Roll Thermostat, AC Driver
PWB, SSR, and the IOT Drive PWB). Check the connectors for broken, bent, or dirty pins.
Disconnect, then reconnect, the connectors several times to remove contaminants due to
oxidation.
Check the External Heat Roll Control Thermistor (PL 8.8). Replace the Thermistor if worn,
or dirty.
Ensure that connectors P/J422B, P/J193, P/J196, P/J105, and P/J100 are seated
correctly on the IOT Drive PWB, AC Driver PWB, SSR, Heat Roll Thermostat, and
the External Heat Roll Heater Rod and there are no obvious crimped or broken
wires.
Ensure that NVM location 777-003 External Heat Roll Temperature Control = 178
(NASG), 193 (ESG) and NVM location 777-012 External Heat Roll Ready Temperature =
165 (NASG), 188 (ESG).
Procedure
Close the Drawer. Cheat the Front Door Interlock. Switch on the power. Enter dC330 010-029
External Heat Roll Lamp. Press Start. ACH is measured momentarily between P/J100-1
on the SSR and P/J15-1 on the AC Driver PWB (ACN into AC Driver PWB).
Y
N
There is +5 VDC between P/J105-1 on the SSR and GND.
Y
N
Y
N
Replace the SSR (PL 9.3) if no problems is found with the connectors.
There is +4.5 VDC between P/J105-2 on the IOT Drive PWB and GND
Y
N
Press Start. The voltage at P/J105-2 decreases momentarily to less than +1.0 VDC.
Y
N
good, replace the SSR (PL 9.3).
Open the drawer. Remove the cheater on the Front Door Interlock. Measure the resistance
across the External Heat Roll Heater Rod ( P/J193-1 to P/J196-1). The resistance is less
than 10 Ohms.
Y
N
Replace the External Heat Roll Heater Rod (PL 8.8).
Measure the resistance across the External Heat Roll Thermostat. The resistance is less
than 10 Ohms.
10-379 Power On External Heat Roll Not Ready RAP
1/05
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Reissue
DocuColor 12/DCCS50
10-382 Stand By External Heat Roll Not Ready RAP
10-383 Job Complete External Heat Roll Not Ready RAP
The External Heat Roll Lamp was On continuously for 1 minute during the Standby Mode, but
the External Heat Roll did not reach operating temperature.
The External Heat Roll Lamp was On continuously for 3 minutes after the current job completed, but the External Heat Roll did not reach operating temperature.
Initial Actions
Initial Actions
Procedure
Procedure
Cheat the Front Door Interlock. Switch on the power. Enter dC330 010-029 External Heat Roll
Lamp. Press Start. ACH is measured momentarily between P/J100-1 on the SSR and P/
J15-1 on the AC Driver PWB (ACN into AC Driver PWB).
Y
N
Go to the OF10-5 External Heat Roll AC Power RAP.
Y
N
than 10 Ohms.
Y
N
than 10 Ohms.
Y
N
than 10 Ohms.
Y
N
than 10 Ohms.
Y
N
Drive PWB. Check the resistance between J413-A13 and J413-A11 of the harness. The resistance should be in the range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when
Y
N
Disconnect P/J175 on the External Heat Roll Control Thermistor. The resistance should
be in the range of 0.78K ohms when the Roll is hot, to 150K ohms when cool (room temperature). The resistance is within specification.
Y
N
Y
N
Y
N
Go to Flag 6 and Flag 4 of BSD 10.3. Check for an intermittent open circuit or short circuit
to ground.
Go to Flag 6 and Flag 4 of BSD 10.3. Check for an intermittent open circuit or short circuit
to ground.
Check the External Heat Control Thermistor for cleanliness, damage and excessive wear
at the point where the Thermistor contacts the Heat Roll. Ensure that it is installed correctly.
If the surface of the Thermistor is worn, replace the External Heat Roll Control Thermistor
(PL 8.8).
(PL 8.8).
Pressure Roll if necessary (PL 8.8).
Pressure Roll if necessary (PL 8.8).
If the problem continues, replace the External Heat Roll Control Thermistor (PL 8.8). If the fault
persists, replace the IOT Drive PWB (PL 9.2).
Reissue
DocuColor 12/DCCS50
If the problem continues, replace the External Heat Roll Control Thermistor (PL 8.8). If the fault
persists, replace the IOT Drive PWB (PL 9.2).
1/05
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10-382 Stand By External Heat Roll Not Ready RAP,
10-384 Job Incomplete External Heat Roll Not Ready RAP
The External Heat Roll declared Not Ready during a job and the External Heat Roll Lamp was
On continuously for 3 minutes after the machine stopped, but the External Heat Roll did not
reach operating temperature.
Inspect the surface of the Heat Roll for excessive wear due to the Thermistor.
Initial Actions
(PL 8.8).
If the problem continues, replace the External Heat Roll Control Thermistor (PL 8.8).
If the fault persists, replace the IOT Drive PWB (PL 9.2).
Procedure
Y
N
than 10 Ohms.
Y
N
than 10 Ohms.
Y
N
Check the resistance of the harness as follows:
Switch off the power.
Cheat the Front Door Interlock Switch.
Disconnect P/J413A from the IOT Drive PWB.
Check the resistance between J413- A13 and J413-A11 of the harness. The resistance
should be in the range of 0.78K ohms when the Heat Roll is hot, to 150K ohms when cool
(room temperature).
The resistance is within specification.

Y
N
Y
N
Go to Flag 6 and Flag 4 of BSD 10.3. Check for an open circuit or short circuit to ground.
10-384 Job Incomplete External Heat Roll Not Ready
1/05
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Reissue
DocuColor 12/DCCS50
10-386 External Heat Roll Control Thermistor Overheat

Failure RAP
The External Heat Roll Control Thermistor detected a temperature in excess of 230 C (446 F)
on the External Heat Roll.
Initial Actions
B
N
This indicates that the problem is intermittent. Replace the External Heat Roll
Control Thermistor (PL 8.8).

Go to Flag 7 on BSD 10.3 and check the harness for a short circuit to ground. If OK,
J413A-11. If OK, replace the External Heat Roll Control Thermistor (PL 8.8). If the problem
continues, replace the IOT Drive PWB (PL 9.2).
Check the External Heat Roll Control Thermistor for cleanliness, damage, or excessive
the Thermistor is worn, replace the External Heat Roll Control Thermistor (PL 8.8).
External Heat Roll if necessary (PL 8.8).
Procedure
Heat Roll Control Thermistor and IOT Drive PWB). Check the connectors for broken, bent and
dirty pins. disconnect and reconnect the connectors several times to remove contaminants due
to oxidation.
Ensure NVM location 777-160 is reset to 0. Switch off the power. Cheat the Front Door Interlock Switch. Disconnect P/J175 on the External Heat Roll Control Thermistor. The resistance
of the Thermistor should be in the range of 0.78K Ohms when hot to 150K Ohms when cool
(room temperature). The resistance is in specification.
Y
N
10-386
fault
is
Y
N
Y
N
Y
N
+4.3 VDC.
A
B
Reissue
DocuColor 12/DCCS50
1/05
2-171
10-386 External Heat Roll Control Thermistor Over-
10-387 External Heat Roll Overheat Thermistor Overheat

Failure RAP
The External Heat Roll Overheat Thermistor detected a temperature in excess of 230 C (446
F) on the External Heat Roll.
Initial Actions
B
N
This indicates that the problem is intermittent. Replace the External Heat Roll
Overheat Thermistor (PL 8.8).

Go to Flag 7 on BSD 10.3 and check the harness for a short circuit to ground. If OK,
J413A-12. If OK, replace the External Heat Roll Control Thermistor (PL 8.8). If the problem
continues, replace the IOT Drive PWB (PL 9.2).
Check the External Heat Roll Overheat Thermistor for cleanliness, damage, or excessive
the Thermistor is worn, replace the External Heat Roll Overheat Thermistor (PL 8.8).
External Heat Roll if necessary (PL 8.8).
Procedure
Heat Roll Overheat Thermistor and IOT Drive PWB). Check the connectors for broken, bent
and dirty pins. disconnect and reconnect the connectors several times to remove contaminants
due to oxidation.
Ensure NVM location 777-160 is reset to 0. Switch off the power. Cheat the Front Door Interlock Switch. Disconnect P/J176 on the External Heat Roll Overheat Thermistor. The resistance of the Thermistor should be in the range of 0.78K Ohms when hot to 150K Ohms when
cool (room temperature). The resistance is in specification.
Y
N
Replace the External Heat Roll Overheat Thermistor (PL 8.8).
10-387
fault
is
Y
N
Y
N
Y
N
+4.3 VDC.
A
B
10-387 External Heat Roll Overheat Thermistor Over-
1/05
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Reissue
DocuColor 12/DCCS50
A
NOTE: In the following step, if the Pressure Roll latches against the Heat Roll but does not
remain latched, answer Yes to the statement.
10-389 Fuser Nip Contact Failure RAP

The Nip Sensor did not go L within 5 seconds after the Fuser Nip Clutch was energized (Pressure Roll started moving against the Heat Roll).
and the Nip Sensor and there are no obvious crimped or broken wires.
Enter dC330 010-023 Fuser Nip Clutch (Nip). Press Start. The Pressure Roll latches
against the Heat Roll.
Y
N
Press Stop. +24 VDC is measured between P/J417A-12 on the IOT Drive PWB and
GND.
Y
N
Y
N
Check Fuse F1 on the AC Driver PWB. If the fuse is blown, replace it (PL 9.3). If the fuse
blows again, go to the +24 VDC Wirenets (Figure 1) and check for a short circuit in the
harness.
good, replace the Fuser Nip Clutch (PL 1.6).
Open the Drawer and extend it to the Service Position. Rotate the Gear on the latching
mechanism in the CCW direction (as viewed from the front of the machine) and ensure it
rotates freely and the Pressure Roll moves up and down as the Gear is rotated (PL 8.6).
Leave the Pressure Roll unlatched.
Initial Actions
Refer to BSD 10.6, BSD 10.9, and 10.12 for the following procedure.
Press Start. The voltage at P/J417A-12 decreases to less than +1.0 VDC.
Y
N
Replace the Fuser Nip Clutch (PL 1.6).
Procedure
Enter dC330 010-033 Oil Pump. Press Start. The Exit Motor energizes.
Y
N
Press Stop. There is +24 VDC from P/J411 pin 6 to P/J411 pin 8.
Y
N
Refer to Wirenets +24VDC-1 (Figure 1) and +24VDC-1 (Figure 5). troubleshoot the
24V input power from the IOT LVPS to the Exit Motor.
Approximately +7 VDC is measured between P/J418B-17 on the IOT Drive PWB and
GND.
Y
N
Y
N
The Pressure Roll remains latched against the Heat Roll.

Y
N
Press Stop (the Exit Motor should still be running). Enter dC330 010-220 Nip Sensor.
Press Start. Enter dC330 010-023 Fuser Nip Clutch (Nip). Press Start. As the Pressure Roll latches and unlatches, the status of the Nip Sensor changes from L to H
to L.
Y
N
The status is a constant H.
Y
N
Go to Flag 5 on BSD 10.6 and check the harness for a short circuit. If the harness is good, replace the Nip Sensor (PL 8.6).
Y
N
+5 VDC is measured between P/J413A-1 on the IOT Drive PWB and P/J44-7 on
the Distribution PWB.
Y
N
Y
N
Y
N
Go to and Flag 5 on BSD 10.6 and check the harness for an open circuit. If the harness is good, replace the Nip Sensor (PL 8.6).
Replace the Nip Clutch (PL 1.6).
Go to Flag 2 and Flag 3 on BSD 10.9 and check the harness for an open circuit. If the harness is good, replace the Exit Motor (PL 1.6). If the problem continues, replace the IOT
Drive PWB (PL 9.2).
A
Reissue
DocuColor 12/DCCS50
Check for obvious damage and/or broken Exit Motor and Fuser Nip Clutch gear assemblies
that would cause the Pressure Roll latching mechanism to be slow to actuate the Nip Sensor. If
the problem continues, replace the Nip Sensor (PL 8.6). If the problem continues, replace the
Fuser Nip Clutch (PL 1.6).
1/05
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10-389 Fuser Nip Contact Failure RAP
10-390 Fuser Nip Retract Failure RAP
The Nip Sensor did not go H within 5 seconds after the Fuser Nip Clutch was energized to
retract the Pressure Roll.
Initial Actions
Refer to BSD 10.6, BSD 10.9, and 10.12 for the following procedure.
good, replace the Fuser Nip Clutch (PL 1.6).
and the Nip Sensor and there are no obvious crimped or broken wires.
Check Fuse F1 on the AC Driver PWB. If the fuse is blown, replace it (PL 9.3). If the fuse
blows again, go to the +24 VDC Wirenet and check for a short circuit in the harness.
Open the Drawer and extend it to the Service Position. Rotate the Gear on the latching
mechanism in the CCW direction (as viewed from the front of the machine) and ensure it
rotates freely and the Pressure Roll moves up and down as the Gear is rotated (PL 8.6).
Leave the Pressure Roll unlatched.
Procedure
Enter dC330 010-033 Oil Pump. Press Start. The Exit Motor energizes.
Y
N
Press Stop. There is +24 VDC from P/J411 pin 6 to P/J411 pin 8.
Y
N
Refer to Wirenets +24VDC-1 (Figure 1) and +24VDC-1 (Figure 5). troubleshoot the
24V input power from the IOT LVPS to the Exit Motor.
GND.
Y
N
N
Press Stop. +24 VDC is measured between P/J417A-12 on the IOT Drive PWB and
GND.
Y
N
Y
N
Press Start. The voltage at P/J417A-12 decreases to less than +1.0 VDC.
Y
N
Replace the Fuser Nip Clutch (PL 1.6).
The Pressure Roll remains latched against the Heat Roll.
Y
N
Press Stop (the Exit Motor should still be running). Enter dC330 010-220 Nip Sensor.
Press Start. Enter dC330 010-023 Fuser Nip Clutch (Nip). Press Start. As the Pressure Roll latches and unlatches, the status of the Nip Sensor changes from L to H
to L.
Y
N
The status is a constant H.
Y
N
Go to Flag 5 on BSD 10.6 and check the harness for a short circuit. If the harness is good, replace the Nip Sensor (PL 8.6).
Y
N
Y
N
+5 VDC is measured between P/J413A-1 on the IOT Drive PWB and P/J44-7 on
the Distribution PWB.
Y
N
Y
N
Go to and Flag 5 on BSD 10.6 and check the harness for an open circuit. If the harness is good, replace the Nip Sensor (PL 8.6).
PWB (PL 9.2).
NOTE: In the following step, if the Pressure Roll latches against the Heat Roll but does not
remain latched, answer Yes to the statement.
Enter dC330 010-023 Fuser Nip Clutch (Nip). Press Start. The
against the Heat Roll.
10-390 Fuser Nip Retract Failure RAP
Pressure
Roll
Replace the Nip Clutch (PL 1.6).

Check for obvious damage and/or broken Exit Motor and Fuser Nip Clutch gear assemblies
that would cause the Pressure Roll latching mechanism to be slow to actuate the Nip Sensor. If
the problem continues, replace the Nip Sensor (PL 8.6). If the problem continues, replace the
Fuser Nip Clutch (PL 1.6).
latches
1/05
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Reissue
DocuColor 12/DCCS50
10-391 Fail Unit Failure RAP
10-398 Fuser Fan Failure RAP
The Failure detection circuit (hardware) indicated an abnormal operation but a failure did not
occur for the Heat Roll, Pressure Roll and External Heat Roll.
The Fuser Fan Failed.

On. To reset this code, enter Diagnostics and change the value in NVM location 772-017 Fuser
Fan from 1 to 0.
Initial Actions
Initial Actions
Procedure
Close the Drawer. Cheat the Front Door Interlock. Switch on the power. The Heat Roll Heater
Rod illuminates after self-test completes.
Y
N
Go to the OF10-3 Heat Roll AC Power RAP
Enter dC330 010-031 Pressure Roll Heater Rod On. Press Start. The Pressure Roll Heater
Rod illuminates momentarily.
Y
N
Go to the OF10-4 Pressure Roll AC Power RAP
Enter dC330 010-029 External Heat Roll Lamp. Press Start. ACH is measured momentarily between P/J100-1 on the SSR and P/J15-1 on the AC Driver PWB (ACN into AC
Driver PWB).
Y
N
Ensure that connector P/J11B is seated correctly on the AC Driver PWB and there are no obvious crimped or broken wires.
Procedure
Switch the power Off then On. Enter dC330 010-004 Fuser Fan-Low Speed. Press Start.
Press Stop. The Fuser Fan switches from High Speed to Low Speed and back to High
Speed.
Y
N
+12 VDC is measured between P/J11B-13 on the AC Driver PWB and GND.
Y
N
good, replace the AC Driver PWB (PL 9.3).
+12 VDC is measured between P/J11B-13 and P/J11B-14 on the AC Driver PWB.
Y
N
than 10 Ohms.
Y
N
Approximately +4 VDC is measured between P/J11B-12 on the AC Driver PWB and

GND.
Y
N
the harness is good, replace the Fuser Fan (PL 10.2).
than 10 Ohms.
Y
N
GND.
Y
N
Go to Flag 11 on BSD 10.1 and check the harness for an open circuit. If the harness
is good, replace the AC Driver PWB (PL 9.3). If the problem continues, replace the
Disconnect the connectors to the components (Heat Roll, Pressure Roll, and External
Heat Roll Thermostats; AC Driver PWB; SSR; and the IOT Drive PWB). Check for broken,
bent, or dirty pins. Disconnect, then reconnect, the connectors several times to remove
contaminants due to oxidation.
Check the Heat Roll Control Thermistor (PL 8.4), Pressure Roll Control Thermistor (PL
8.6), or External Heat Roll Control Thermistor (PL 8.8). Replace the Thermistor if worn, or
dirty.
If no problem is found with the connectors, replace the SSR (PL 9.3).
If the problem persists, replace these components in the following order until the problem
is resolved: IOT CPU PWB (PL 9.2), IOT NVM PWB (PL 9.2).
Reissue
DocuColor 12/DCCS50
Replace the Fuser Fan (PL 10.2).

Less than +1.0 VDC is measured between P/J419B-12 on the IOT Driver and GND.
Y
N
good, replace the Fuser Fan (PL 10.2). If the problem continues, replace the IOT Drive
PWB (PL 9.2).
Replace the Fuser Fan (PL 10.2). If the problem continues, replace the IOT Drive PWB (PL
9.2).
1/05
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10-391 Fail Unit Failure RAP, 10-398 Fuser Fan Fail-
10-399 Fuser Intake Fan Failure RAP
10-421 Fuser Oil Level RAP
The Fuser Intake Fan Failed.
The Oil Empty Sensor detected the Oil Near Empty Condition continuously for 5 seconds.
On. To reset this code, enter Diagnostics and change the value in NVM location 772-018 Fuser
Intake Fan from 1 to 0.
NOTE: The Oil Near Empty Condition occurs when the sensor detects that the oil is low
(approximately 40k prints have been printed). The machine issues a warning when it detects
Fuser Oil Near Empty. When another 2000 - 4000 prints are printed out without servicing the
Fuser Oil, the machine issues a stop message and then stops printing.
Initial Actions
NOTE: Oil usage varies depending on the types of images and paper being used. 30 - 40k
prints per bottle is typical. However, when an oil metering system (Metering Blade, Donor Roll,
etc.) is in need of service, it can use oil at two to three times the normal rate.

and Fuser Intake Fan.
and there are no obvious crimped or broken wires.
Initial Actions
Procedure
1.
Open the Drawer.
Open the Front Door. Cheat the Interlock. Enter dC330 010-061 Fuser Intake Fan-High Speed.
Press Start. Press Stop. The Fuser Intake Fan switches from Low Speed to High Speed
and back to Low Speed.
Y
N
Press Stop. +24 VDC is measured between P/J413B-13 on the IOT Drive PWB and
GND.
Y
N
2.
Remove the Oil Cartridge (PL 8.1). Verify that there is oil in the bottle. If not, install a new
Oil Cartridge.
3.
Close the Drawer.
4.
Switch the power Off and then On.
+24 VDC is measured between P/J413B-13 and P/J413B-14 on the IOT Drive PWB.
Y
N
the Harness is good, replace the IOT Drive PWB (PL 9.2).
GND.
Y
N
Go to Flag 5 on BSD 10.1 and check the harness for an open circuit. If the Harness
is good, replace the Fuser Intake Fan (PL 10.1).
Procedure
NOTE: This RAP assumes that there is fuser oil in the bottle and therefore is not a cause of the
10-421 Fault Code.
Enter dC330 010-222 Oil Empty Sensor. Press Start. The Oil Empty Sensor status is H.
Y
N
Press Stop. There is +5 VDC between P/J413A-3 on the IOT Drive PWB and GND.
Y
N
There is +5 VDC between P/J413A-14 on the IOT Drive PWB and P/J44-7 on the
Distribution PWB.
Y
N
Replace the Fuser Intake Fan (PL 10.1).

Less than +1.0 VDC is measured between P/J413B-11 on the IOT Driver and GND.
Y
N
replace the Fuser Intake Fan (PL 10.1). If the problem continues, replace the IOT Drive
PWB (PL 9.2).
Replace the IOT Driver PWB (PL 9.2).
good, replace the Oil Empty Sensor (PL 8.7). If the problem continues, replace the IOT
Drive PWB (PL 9.2).
Replace the Fuser Intake Fan (PL 10.1). If the problem continues, replace the IOT Drive PWB
(PL 9.2).
10-399 Fuser Intake Fan Failure RAP, 10-421 Fuser Oil
1/05
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DocuColor 12/DCCS50
10-422 Web CRU RAP
10-500 Fuser Web CRU Not Present RAP
A faulty connection has occurred between the Web CRU and the IOT Drive PWB.
The Web CRU detection circuit detected that the CRU was not present or was not fully seated.
NOTE: A legitimate Fuser Web Near Empty Condition occurs when 1458 minutes of Web On
Time has been reached. The machine issues a warning when it detects Fuser Web Near
Empty. With a legitimate Web Near Empty condition, only a message is displayed, not a fault
code.
NOTE: This condition occurs when the Web CRU is not installed, or is not seated fully. It will
also occur if the small 3-pin connector (under the oil bottle) is not connected when the Fuser
Assembly is installed.
On. To reset this code, enter Diagnostics and change the value in NVM location 777-077 Web
Status from 1 to 0.
Initial Actions
1.
Open the Drawer.
2.
Remove and inspect the Web CRU. If the web supply roll is near empty, then replace it
and proceed to the next step.
3.
4.

Close the Drawer.
6.
Switch the power Off, then On.

NOTE: Before proceeding into this procedure, clean the contacts on the CRU connector. Oxidation on the connector has been known to cause this problem. Also try reseating the CRU
several times to see if the problem remains.
Ensure that connectors P/J419A and P/J722 are seated correctly on the IOT Drive PWB, Web
CRU Sensor and there are no obvious crimped or broken wires.
5.
Initial Actions
Procedure
Y
N
+24 VDC is measured between P/J440-1 on the Web Drive PWB and GND.
Y
N
Procedure
Enter dC330 010-223 Web CRU Home. Press Start. The Web CRU status signal is H.
Y
N
Go to Flag 3 on BSD 10.5 and check the harness and connectors for a short circuit to
GND. If the harnesses and connectors are OK, replace the Web CRU.
Press Stop. Power Off. Remove the Fuser Web CRU. Enter dC330 010-223 Web CRU Home.
Press Start. The Web CRU Sensor status is L.
Y
N
Install the Fuser Web CRU. +5 VDC is measured between P/J419A-17 and GND.
Y
N
Check for obstructions or damage that would cause the Web CRU Sensor status to be
blocked (H). There are no obstructions and/or damage.
Y
N
Remove the obstructions and/or damage.
Y
N
Check the Web Motor (PL 8.4) for an open circuit. If it is OK, replace the Web Drive
PWB (PL 8.4).
+2.2 VDC is measured between P/J419A-16 and GND.

Y
N
Enter DC330 010-032 Web Motor. Press Start. The voltage at P/J413A-2 decreases from
+24 VDC to less than +1.0 VDC.
Y
N
Replace the IOT Drive PWB (PL 9.2). Install the Web CRU, Front Cover and Oil Cartridge.
Check for obvious damage, missing and/or broken Fuser Web Drive gear assemblies. Install
the Fuser Web CRU.
Replace the Web Drive PWB (PL 8.4). If that does not correct the problem, replace the Web
Motor (PL 8.4).
Reissue
DocuColor 12/DCCS50
1/05
2-177
10-422 Web CRU RAP, 10-500 Fuser Web CRU Not
10-900 Fuser Cycle Down RAP
OF10-1 OCT Detection Failure RAP
The Fuser temperature fell below the normal value during the job. The machine cycled down
and temporarily stopped the copying job; and when it reached the operating temperature, canceled the above condition and started again automatically (the job resumes).
The system does not detect an OCT when one is installed.
NOTE: This condition should be expected to happen occasionally, especially when running a
long job. (No recovery steps are necessary.) If this condition occurs frequently, continue with
this RAP.
Ensure that the External Heat Roll Retract Sensor (PL 8.4) is fully seated.
Procedure
Enter dC330 010-296 OCT Detect. The display indicates L.
Y
N
Go to Flag 7 and Flag 8 on BSD 10.11. Check the harness for an open circuit. If the harness is good, replace the IOT Drive PWB (PL 9.2).
Initial Actions
Initial Actions
Procedure
Close the Drawer. Cheat the Front Door Interlock. Switch on the power. The Heat Roll Heater
Rod illuminates after self-test completes.
Y
N
Enter dC330 010-031 Pressure Roll Heater Rod On. Press Start. The Pressure Roll Heater
Rod illuminates momentarily.
Y
N
Enter dC330 010-029 External Heat Roll Lamp. Press Start. ACH is measured momentarily between P/J100-1 on the SSR and P/J15-1 on the AC Driver PWB (ACN into AC
Driver PWB).
Y
N
than 10 Ohms.
Y
N
than 10 Ohms.
Y
N
Disconnect the connectors to the Heat Roll, Pressure Roll, and External Heat Roll Thermostats; AC Driver PWB; SSR; and the IOT Drive PWB. Check for broken, bent, or dirty
pins. Disconnect/reconnect the connectors several times to remove oxidation.
Check the Heat Roll Control Thermistor (PL 8.4), Pressure Roll Control Thermistor (PL
8.6), or External Heat Roll Control Thermistor (PL 8.8). Replace if worn, or dirty.
10-900 Fuser Cycle Down RAP, OF10-1 OCT Detec-
1/05
2-178
Reissue
DocuColor 12/DCCS50
OF10-2 Fuser Oil Pump RAP
OF10-3 Heat Roll AC Power RAP
The Fuser Oil Pump is not dispensing Fuser Oil.
Initial Actions
Initial Actions
Procedure
Enter dC330 010-033 Oil Pump. Press Start and Stop several times. Approximately
100
VAC is measured between P/J199-1 and P/J199-2 on the Fuser Oil Pump.
Y
N
Approximately 100 VAC is measured between P/J18-3 and P/J18-1 on the AC
Driver PWB.
Y
N
Press Stop. +5.8 VDC is measured between P/J11A-14 on the AC Driver PWB
and GND.
Y
N
+5 VDC is measured between P/J19-1 and P/J19-7 on the AC Driver PWB.
Y
N
Go to Flag 5 on BSD 10.5 and check the harness for an open circuit. If the
harness is OK, replace the Distribution PWB (PL 9.3).
Go to Flag 4 on BSD 10.5 and check the harness for an open circuit. If the harness is OK, replace the AC Driver PWB (PL 9.3).
Press Start. The voltage at P/J11A-14 goes to less than +1.0 VDC.
Y
N
replace the Fuser Oil Pump (PL 8.7).
Ensure that connectors P/J422B, P/J419B, P/J194, P/J191, P/J105, P/J100, P/J11A,
and P/J18 are seated correctly on the IOT Drive PWB, AC Driver PWB, SSR, Heat Roll
Thermostat, and the Heat Roll Heater Rod and there are no obvious crimped or broken
wires.
Procedure
Close the Drawer. Cheat the Front Door Interlock. Switch on the power. ACH is measured
between P/J100-4 on the SSR and P/J18-2 on the AC Driver PWB.
Y
N
ACH is measured between P/J100-4 on the SSR and P/J15-1 on the AC Driver PWB
(ACN into the AC Driver PWB).
Y
N
ACH is measured between P/J100-3 on the SSR and P/J15-1 on the AC Driver
PWB.
Y
N
ACH is measured between P/J18-4 on the AC Driver PWB and P/J15-1 on
the AC Driver PWB.
Y
N
Open the drawer. There is +24 VDC between P/J11A-4 on the AC
Driver PWB and GND.
Y
N
There is +24 VDC between P/J419B-17 on the IOT Drive and GND.
Y
N
Go to Flag 6 (Flag 16 w/ Tag P31) on BSD 10.2 and check for an
open circuit.
Replace the Fuser Oil Pump (PL 8.7).
Close the drawer. The voltage at P/J419B-17 decreases to less than

+1.0 VDC.
Y
N
Go to Flag 15 (Flag 26 w/ TAG P31) on BSD 10.2 and check for an open circuit.
If TAG P31 is present, replace the Varistor PWB if the problem persists.
A
Reissue
DocuColor 12/DCCS50
1/05
2-179
B
OF10-2 Fuser Oil Pump RAP, OF10-3 Heat Roll AC
B
Y
N
If the wires are OK, replace the IOT Drive PWB (PL 9.2).
C
Go to Flag 20, Flag 23, and Flag 27 on BSD 10.2 and check for an open circuit. If the wires are
OK, replace AC Driver PWB (PL 9.3). Replace the Varistor PWB (PL 9.6) if the problem persists.
If the problem continues, replace the SSR (PL 9.3), then the IOT Drive PWB (PL 9.2).
There is approximately +4.3 VDC between P/J105-4 on the SSR and GND when
the lamp is off.
Y
N
Check for an open wire at pin 4 of P/J105. If OK, replace the SSR (PL 9.3).
Enter dC330 010-030 Heat Roll Heater Rod On. Press Start. The voltage at
J105-4 decreases to less than +1.0 VDC.
Y
N
P/
Go to Flag 9 (Flag 19 w/ TAG P31) on BSD 10.2 and check for an open circuit. If the
wires are OK, replace the SSR (PL 9.3).
across the Heat Roll Heater Rod. The resistance is less than 10 Ohms.
Y
N
Replace the Heat Roll Heater Rod (PL 8.3).
Check the resistance across the Heat Roll Thermostat. The value is less than 10 Ohms.
Y
N
Replace the Heat Roll Thermostat (PL 8.4).
Switch off the power. Disconnect the connectors to the Heat Roll Thermostat, AC Driver PWB,
SSR, and the IOT Drive PWB. Check the connectors for broken, bent, or dirty pins. Disconnect, then reconnect, the connectors several times to remove oxidation. TAG P31 is present.
Y
N
Go to Flag 10 and Flag 13 on BSD 10.2 and check for an open circuit. If the wires are OK,
replace the AC Driver PWB (PL 9.3). If the problem continues, replace the SSR (PL 9.3).
If the problem persists, replace the IOT Drive PWB (PL 9.2).
Switch on the power. There is +5 VDC from J73 to J74 on the Surge SSR.
Y
N
There is +5 VDC from J73 on the Surge SSR to frame ground
Y
N
Go to Flag 28. Check for an open circuit. If the wire is OK, replace the AC Driver
PWB (PL 9.3). If the problem continues, replace the Surge SSR (PL 9.6).
Go to Flag 30. Check for an open circuit. If the wires and the AC Driver PWB (PL 9.3) are
Switch off the power. Disconnect P/J70. The resistance from J70-1 to J70-2 is 55 ohms +/20%.
Y
N
Replace Surge Resistor (PL 9.6).
C
OF10-3 Heat Roll AC Power RAP
1/05
2-180
Reissue
DocuColor 12/DCCS50
OF10-4 Pressure Roll AC Power RAP

The Pressure Roll did not reach the Ready temperature within 8 minutes after Power On.

Ensure that NVM location 777-002 Pressure Roll Temperature Control = 130
(NASG/ESG) and NVM location 777-011 Pressure Roll Ready Temperature = 123
(NASG), 125 (ESG).
D

Y
N
Go to Flag 8 (Flag 18 w/ TAG P31) on BSD 10.2 and check the harness for an
open circuit. If the harness is good, replace the IOT Drive PWB (PL 9.2).
Initial Actions
There is approximately +4.3 VDC between P/J105-3 on the SSR and GND when
the lamp is off.
Y
N
Check for an open connection at pin 3 of P/J105. If OK, replace the SSR (PL
9.3).
Enter dC330 010-031 Pressure Roll Heater Rod On. Press Start. The voltage at P/
J105-3 decreases to less than +1.0 VDC.
Y
N
Ensure that connectors P/J422B, P/J419B, P/J195, P/J192, P/J105, P/J100, P/

J11A, and P/J18 are seated correctly on the IOT Drive PWB, AC Driver PWB, SSR,
Pressure Roll Thermostat, and the Pressure Roll Heater Rod and there are no obvious crimped or broken wires.
Go to Flag 7 (Flag 17 w/ TAG P31) on BSD 10.2 and check the harness for an open
circuit. If the harness is good, replace the SSR (PL 9.3).
Procedure
Pressure Roll Heater Rod On. Press Start. Press Start. ACH is measured momentarily
between P/J100-2 on the SSR and P/J18-1 on the AC Driver PWB.
Y
N
Press Start. ACH is measured momentarily between P/J100-2 on the SSR and P/
J15-1 on the AC Driver PWB (ACN into the AC Driver PWB).
Y
N
ACH is measured between P/J100-3 on the SSR and P/J15-1 on the AC Driver
PWB.
Y
N
ACH is measured between P/J18-4 on the AC Driver PWB and P/J15-1 on
the AC Driver PWB.
Y
N
Open the drawer. There is +24 VDC between P/J11A-4 on the AC
Driver PWB and GND.
Y
N
There is +24 VDC between P/J419B-17 on the IOT Drive and GND.
Y
N
Go to Flag 6 (Flag 16 w/ TAG P31) on BSD 10.2 and check for an
open circuit.
Close the drawer. The voltage at P/J419B-17 decreases to less than
+1.0 VDC.
Y
N

across the Pressure Roll Heater Rod. The resistance is less than 10 Ohms.
Y
N
Replace the Pressure Roll Heater Rod (PL 8.3).
Measure the resistance across the Pressure Roll Thermostat. The resistance is less than
10 Ohms.
Y
N
Replace the Pressure Roll Thermostat (PL 8.6).
Go to Flag 11 and Flag 12 (Flag 21 and Flag 22 w/ TAG P31) on BSD 10.2 and check for an
open circuit. If the wires are OK, replace the AC Driver PWB (PL 9.3). If Tag P31 is present,
replace the Varistor PWB (PL 9.6) if the problem persists
Disconnect the connectors to the components (Pressure Roll Thermostat, AC Driver

oxidation.
Check the Pressure Roll Control Thermistor (PL 8.6). Replace the Thermistor if worn or
dirty.

A
B
C
Reissue
DocuColor 12/DCCS50
1/05
2-181
OF10-4 Pressure Roll AC Power RAP
OF10-5 External Heat Roll AC Power RAP
The External Heat Roll Lamp was On continuously for 1 minute during the Standby Mode, but
the External Heat Roll did not reach operating temperature.
Disconnect the connectors to the components (External Heat Roll Thermostat, AC Driver
oxidation.
Check the External Heat Roll Control Thermistor (PL 8.8). Replace the Thermistor if worn,
or dirty.
NVM location 777-012 External Heat Roll Ready Temperature = 165 (NASG), 188 (ESG).
NVM location 777-008 External Heat Roll Power Save Temperature = 165 (NASG) and
120 (ESG).
If the problem continues, replace the SSR (PL 9.3). If the problem persists, replace the Varistor
PWB (PL 9.6). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Initial Actions
NVM location 777-003 External Heat Roll Temperature Control = 178 (NASG), 193 (ESG)
Flag 14 (Flag 24 w/ TAG P31) on BSD 10.2.
If the wires s are OK, check the following:
Ensure that connectors P/J422B, P/J193, P/J196, and P/J100 are seated correctly on
the IOT Drive PWB, AC Driver PWB, SSR, Heat Roll Thermostat, and the External Heat
Roll Heater Rod; and there are no obvious crimped or broken wires.
Procedure
External Heat Roll Lamp. Press Start. ACH is measured momentarily between P/J100-1
on the SSR and P/J15-1 on the AC Driver PWB (ACN into AC Driver PWB).
Y
N
Y
N
Y
N
There is +4.5 VDC between P/J105-2 on the SSR and GND.
Y
N
Press Start. The voltage at P/J105-2 decreases momentarily to less than +1.0 VDC.
Y
N
good, replace the SSR (PL 9.3).
Check the following areas of the harness for an open circuit:
Flag 2 on BSD 10.3.
Flag 3 on BSD 10.3.
OF10-5 External Heat Roll AC Power RAP
1/05
2-182
Reissue
DocuColor 12/DCCS50
OF 10-6 Fuser Out of Oil Rap

The purpose of this RAP is to resolve problems where the machine runs out of Fuser Oil without declaring a Low Oil or Out of Oil fault.
NOTE: to decrease the interval between detection of low oil level and fault declaration change
NVM location 777-056 to 500, and location 777-058 to 3.
Procedure
Enter dC330 010-222 Oil Empty Sensor. Press Start. The Oil Empty Sensor status is L.
Y
N
Perform the following steps
1.
Open the Front Door and pull out the Drawer Assembly.
2.
Remove the Fuser Top Cover (PL 8.2) and Front Cover (PL 8.1).
3.
Slide the Fuser back in position. Latch the Drawer Assembly
4.
Remove the Oil Empty Sensor from the Oil Tank (PL 8.7). Thoroughly clean the sensor, but do not disconnect it or reinstall it.
5.
Install a cheater in the Front Door Interlock, and allow the machine to come to
Ready.
The UI displays Replace the Fuser Oil Cartridge soon.

Y
N
There is +5 VDC between P/J167 pins 1 and 3.
Y
N
Go to Flag 2 on BSD 10.5 (2 of 2) and troubleshoot the +5V circuit.
Go to Flag 1 on BSD 10.5 (2 of 2) and check the wire between P/J167-2 on the Oil
Empty Sensor and P/J413A-3 on the IOT Drive PWB for an open circuit or a short
circuit to a voltage source. If the wire is OK, replace the Oil Empty Sensor (PL 8.7). If
the problem continues, replace the IOT Drive PWB (PL 9.2).
Reinstall the Sensor. Make Sure that the green circuit pwb faces AWAY from the Heat
Lamps. Close the Front Door. If the Replace the Fuser Oil Cartridge soon message
remains, check for a loose connection at P/J167or P/J413A. If the harness is good,
replace the Oil Empty Sensor (PL 8.7).
Reissue
DocuColor 12/DCCS50
1/05
2-183
1/05
2-184
Reissue
DocuColor 12/DCCS50
11-107 OCT Exit Sensor On Jam Long RAP

The OCT Exit Sensor did not detect the lead edge of the paper within the specified time after
the Decurler Exit Sensor detected the lead edge of the same paper.
Ensure that the Mail Box Drive Motor Pulley is fastened to the motor shaft.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D,11-107 SCT Exit
Sensor On Jam Long RAP to troubleshoot this Fault Code.
NOTE: Long indicates that the trail edge of the paper has not passed through the Decurler
Exit Sensor.
Refer to BSD11.2 and BSD 11.4 and BSD 11.8 for the following procedure.
Obstructions in the Mail Box paper path
Bent or out of position paper chutes/guides in the Mail Box paper path
Ensure that there is sufficient nip force at the Mail Box Transport Roll and the Oct Exit
Roll.
Ensure that connectors P/J562 on the Mail Box Control PWB and P/J566 on the OCT
Exit Sensor are seated correctly and there are no obvious crimped or broken wires.
The lead edge of the paper is at or past the Oct Exit Sensor.
Y
N
The paper entered the Vertical Transport.
Y
N
Enter dC330 011-005 Mailbox Drive Motor. Press Start. The Mail Box Transport
Roll is rotating.
Y
N
The Mail Box Drive Belt is moving.
Y
N
The Mail Box Drive Motor is rotating
Y
N
+24 VDC is measured between P/J572-1 and P/J572-2 of the
Mail Box Drive Motor
Y
N
Go to Flag 1 on BSD11.2. Check the wires for an open circuit. If
the wires are good, replace the Mail Box Control PWB (PL
13.10).
Entrance Roll
Pinch Rollers
Exit Roll
Drive Belt
Less than +1 VDC is measured between P/J562-1 and GND

Y
N
Replace the Mail Box Control PWB (PL 13.10)
Go to Flag 5 on BSD 11.4. Check the wires for an open circuit. If the wires
are good, replace the OCT Gate Solenoid (PL 13.9).
good, ensure that the OCT gate is connected to the OCT Gate Solenoid and
that it moves freely. If the problem continues replace the OCT Gate (PL 13.9)
and the OCT Gate Solenoid (PL 13.9).
Press Start. Less than +1 VDC is measured between P/J572-3

and GND.
Y
N
DocuColor 12/DCCS50
Press Stop. +5 VDC is measured between P/J572-3 and GND.

Y
N
Go to Flag 3 on BSD 11.2. Check the wire for an open circuit. If
the wire is good, replace the Mail Box Control PWB (PL 13.10).
Check that the gear pulleys are properly fastened to the drive rolls
The OCT Gate is in the Up or OCT position

Y
N
Enter dC330 011-081 OCT Gate Solenoid OCT On. Press Start. The OCT Gate
Solenoid energized.
Y
N
+24 VDC is measured between P/J562-2 and P/J562-1 on the Mail Box
Control PWB.
Y
N
+24 VDC is Measured between P/J562-2 Mail Box Control PWB and
GND
Y
N
+24 VDC is measured between P/J563-1 on the Mail Box Control
PWB and GND.
Y
N
Go to the +24 VDC Wirenet and troubleshoot the wire between
P/J563-1 on the Mail Box Control PWB and P/J45-6 on the Distribution PWB
Procedure
Check the Drive Belt for Damage
Check the Drive Belt Tension Roll for proper tension.
Check the following parts for wear, glazing, or slipping.
Initial Actions
A
B
C
Reissue
F
Replace the Mail Box Drive Motor (PL 13.10).
Ensure that the OCT gate is connected to the OCT Gate Solenoid and that it moves
freely. If the problem continues replace the OCT Gate (PL 13.9) and the OCT Gate
Solenoid (PL 13.9).
A
1/05
2-185
G
11-107 OCT Exit Sensor On Jam Long RAP
Check the paper path for any obstructions that could cause the paper to enter the
Vertical Transport.
11-108 OCT Exit Sensor Off Jam RAP
Ensure that the OCT gate moves freely. If the problem continues replace the OCT
Gate (PL 13.9) and the OCT Gate Solenoid (PL 13.9).
The OCT Exit Sensor did not deactuate within the specified time after the OCT Exit Sensor
actuated.
Enter dC330 011-107 OCT Exit Sensor. Manually actuate the OCT Exit Sensor actuator. The
display changes from L to H to L as the actuator moves in and out of the sensor.
Y
N
The display is always H
Y
N
Go to Flag 1on BSD 11.4. Check the harness for a short circuit to ground. If the harness is good, replace the Oct Exit Sensor (PL 13.9).
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-108 SCT Exit
Sensor Off Jam RAP to troubleshoot this Fault Code.
+5 VDC is measured between P/J562-4 and P/J562-6

Y
N
CR1 on the Mail Box Control PWB is on.
Y
N
Go to the +5 VDC wirenet and troubleshoot the wires between P/J569-1 and P/
J44-6 on the Distribution PWB.
Initial Actions
Roll.
Ensure that the OCT Full Stack Sensor is operating correctly. Refer to the 11-921 Offset
Catch Tray Full Stack RAP.
Replace the Mail Box Control PWB (PL 13.10).

Go to Flag 2 and Flag 4 on BSD11.4. Check the harness for an open circuit. If the harness
is good, replace the Oct Exit Sensor (PL 13.9).
With paper at the sensor, less than +1 VDC is measured between P/J562-5 and GND.
Y
N
Replace the OCT Exit Sensor (PL 13.9).
Entrance Roll (PL 13.9)
Pinch Rollers (PL 13.9)
Exit Roll (PL 13.9)
Drive Belt (PL 13.10)
Procedure
The trail edge of the paper is past the Oct Exit Sensor
Y
N
Enter dC330 011-005 Mailbox Drive Motor. Press Start. The Mail Box Transport Roll
is rotating.
Y
N
The Mailbox drive Belt is moving.
Y
N
Y
N
+24 VDC is measured between P/J572-1 and P/J572-2 of the Mail
Box Drive Motor
Y
N
Go to Flag 1 on BSD11.2. Check the wires for an open circuit. If the
wires are good, replace the Mail Box Control PWB (PL 13.10).
Y
N
Go to Flag 3 on BSD 11.2. Check the wire for an open circuit. If the
wire is good, replace the Mail Box Control PWB (PL 13.10).
Press Start. Less than +1 VDC is measured between P/J572-3 and
GND.
Y
N
A
11-107 OCT Exit Sensor On Jam Long RAP, 11-108
1/05
2-186
C
Reissue
DocuColor 12/DCCS50
11-109 OCT Exit Sensor On Jam Short RAP

The OCT Exit Sensor did not detect the lead edge of the paper within the specified time after
the Decurler Exit Sensor detected the trail edge of the same paper.
Exit Roll (PL 13.9)
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-109 SCT Exit
Sensor On Jam Short RAP to troubleshoot this Fault Code.
NOTE: Short indicates that the trail edge of the paper has passed through the Decurler Exit
Sensor.
Initial Actions

Check the OCT Exit Sensor Actuator for binding as it moves in and out of the sensor. The
actuator is binding.
Y
N
belts that would cause the copy to be slow to actuate the OCT Exit Sensor.
Refer to BSD11.2 and BSD 11.4 and BSD 11.8 for the following procedure.
Roll.
Procedure
The lead edge of the paper is at or past the Oct Exit Sensor
Y
N
Y
N
Enter dC330 011-005 Mailbox Drive Motor. Press Start. The Mail Box Transport
Roll is rotating.
Y
N
Y
N
Y
N
Y
N
Go to Flag 1on BSD11.2. Check the wires for an open circuit. If
13.10).
Y
N
the wire is good, replace the Mail Box Control PWB (PL 13.10).
and GND.
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
2-187
F
11-108 OCT Exit Sensor Off Jam RAP, 11-109 OCT
F
H
Ensure that the OCT gate is connected to the OCT Gate Solenoid and that it moves
freely. If the problem continues replace the OCT Gate (PL 13.9) and the OCT Gate
Solenoid (PL 13.9).
Vertical Transport.
Ensure that the OCT gate moves freely. If the problem continues replace the OCT
Exit Roll (PL 13.9)
Enter dC330 011-107 OCT Exit Sensor. Manually actuate the OCT Exit Sensor actuator. The
display changes from L to H to L as the actuator moves in and out of the sensor.
Y
N
Y
N
Go to Flag 1on BSD 11.4. Check the harness for a short circuit to ground. If the harness is good, replace the Oct Exit Sensor (PL 13.9).

The OCT Gate is in the Up or OCT position
Y
N
Enter dC330 011-081 OCT Gate Solenoid OCT On. Press Start. The OCT Gate
Solenoid energized.
Y
N
+24 VDC is measured between P/J562-2 and P/J562-1 on the Mail Box
Control PWB.
Y
N
+24 VDC is Measured between P/J562-2 Mail Box Control PWB and
GND
Y
N
+24 VDC is measured between P/J563-1 on the Mail Box Control
PWB and GND.
Y
N
P/J563-1 on the Mail Box Control PWB and P/J45-6 on the Distribution PWB
Y
N

Y
N
Y
N
Y
N
Exit Roll (PL 13.9)
are good, replace the OCT Gate Solenoid (PL 13.9).
good, ensure that the OCT gate is connected to the OCT Gate Solenoid and
that it moves freely. If the problem continues replace the OCT Gate (PL 13.9)
and the OCT Gate Solenoid (PL 13.9).
A
G H
11-109 OCT Exit Sensor On Jam Short RAP
1/05
2-188
Reissue
DocuColor 12/DCCS50
11-110 Paper Remains at Decurler Exit Sensor Long RAP
11-111 Paper Remains at Decurler Exit Sensor Short RAP
The Control Logic detected that paper remained on the Decurler Exit Sensor at power on.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-110 Paper
Remains at Decurler Exit Sensor Long RAP to troubleshoot this Fault Code.
Remains at Decurler Exit Sensor Short RAP to troubleshoot this Fault Code.
NOTE: Ensure that Sorter S-1 Tag is installed.
Initial Actions
Initial Actions
Refer to BSD11.3 for the following procedure.
Ensure that no paper is blocking the Decurler Exit sensor
Ensure that P/J570 on the Mail Box Control PWB, Double Plug J571, P/J651 and P/
J654 on the Decurler Control PWB, and P/J658 on the Decurler Exit Sensor are connected before beginning this RAP.
J654on the Decurler Control PWB, and P/J658 on the Decurler Exit Sensor are connected before beginning this RAP.
Procedure
Procedure
Enter dC330 011-145 Decurler Exit Sensor. Press Start. The display is H.
Y
N
replace the Decurler Exit Sensor (PL 13.12). If the problem continues, replace the Mail
Box Control PWB (PL 13.10).
Y
N
More than +4.3 VDC is measured between P/J654-2 and GND on the Decurler Control
PWB.
Y
N
Replace the Decurler Exit Sensor (PL 13.12).
PWB.
Y
N
Check the Decurler Exit Sensor for intermittent operation. If the sensor is good, Replace the
Mail Box Control PWB (PL 13.10).
Reissue
DocuColor 12/DCCS50
1/05
2-189
11-110 Paper Remains at Decurler Exit Sensor
11-115 Mail Box Vertical Sensor / Bin 1 Sensor On Jam

RAP
Initial Actions
Refer to BSD11.2, BSD11.5 and BSD11.8 for the following procedure.
Ensure that the Mail Box front Door is closed properly, in order to provide proper nip pressure to the Vertical Transport Rolls.
Ensure that connectors P/J551 on the Mail Box Control PWB, and P/J818, and P/J819
on the Mail Box Vertical Sensor are seated correctly and there are no obvious crimped or
broken wires.
Exit Roll (PL 13.9)
Enter dC330 011-115 Mailbox Vertical Sensor. Manually block the Mail Box Vertical Sensor
with a sheet of paper. The display changes from L to H to L as the paper moves in and out
of the sensor.
Y
N
Y
N
Go to Flag 1 on BSD 11.5. Check the harness for a short circuit to ground. If the harness is good, replace the Mail Box Vertical Sensor (PL 13.9).
Procedure
The Vertical LED is on.

Y
N
Y
N
Y
N
Go to the +5 VDC wirenet and troubleshoot the wires between P/J569-1
and P/J44-6 on the Distribution PWB.
The lead edge of the paper is at or past the Mail Box Vertical Sensor
Y
N
is rotating.
Y
N
Y
N
Y
N
Box Drive Motor
Y
N
Y
N
GND.
Y
N
The Mail Box Vertical Sensor did not detect the lead edge of the paper within the specified time
after the Decurler Exit Sensor detected the lead edge of the same paper.

Go to Flag 2 and Flag 3 on BSD11.5. Check the harness for an open circuit. If the
harness is good, replace the Vertical LED (PL 13.5).
Go to Flag 1 on BSD 11.5. Check the wire for an open circuit. If the wire is good, replace
the Mail Box Vertical Sensor (PL 13.9).
With paper at the sensor, more than +4.3 VDC is measured between P/ P/J551-4 and
GND.
Y
N
Replace the Mail Box Vertical Sensor (PL 13.9).
Exit Roll (PL 13.9)
A
B
11-115 Mail Box Vertical Sensor / Bin 1 Sensor On
1/05
2-190
Reissue
DocuColor 12/DCCS50
11-116 Mail Box Vertical Sensor / Bin 1 Sensor Off Jam

RAP
The Mail Box Vertical Sensor did not detect the Trail edge of the paper within the specified time
after the Mail Box Vertical Sensor detected the lead edge of the same paper.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-116 Mailbox Vertical Sensor / Bin 1 Sensor Off Jam RAP to troubleshoot this Fault Code.
Check the bin entrance area for obstructions.
Ensure that the Mail Box front Door is closed properly, in order to provide proper nip
pressure to the Vertical Transport Rolls.
Initial Actions
Refer to BSD11.2 and BSD11.5 for the following procedure.
Pinch Rolls (PL 13.9)
Ensure that connectors P/J551 on the Mail Box Control PWB and P/J818, and P/J819
on the Mail Box Vertical Sensor are seated correctly and there are no obvious crimped or
broken wires.
Check the Mail Box Vertical Sensor for intermittent operation. Replace the Mail Box Vertical Sensor (PL 13.9) if the problem is not resolved.
Procedure
The trail edge of the paper is past the Mail Box Vertical Sensor
Y
N
Enter dC330 011-005 Mailbox Drive Motor. Press Start. The Vertical Transport Rolls
are rotating.
Y
N
Y
N
Y
N
Box Drive Motor
Y
N
Y
N
GND.
Y
N
A
B
C
Reissue
DocuColor 12/DCCS50
1/05
2-191
11-116 Mail Box Vertical Sensor / Bin 1 Sensor Off
11-142 V-Tra In Sensor On Jam Long RAP

The V-Tra In Sensor did not detect the lead edge of the paper within the specified time after the
Decurler Exit Sensor detected the lead edge of the same paper.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-142 Mailbox
Entrance Sensor On Jam Long RAP to troubleshoot this Fault Code.
E
are good, ensure that the OCT gate is connected to the OCT Gate Solenoid and that it moves freely. If the problem continues replace the OCT
Ensure that the OCT gate is connected to the OCT Gate Solenoid and that it
moves freely. If the problem continues replace the OCT Gate (PL 13.9) and the
OCT Gate Solenoid (PL 13.9).
Initial Actions
Check the paper path for any obstructions that could cause the paper not to
enter the Vertical Transport.
Ensure that the OCT gate moves freely. If the problem continues replace the
OCT Gate (PL 13.9) and the OCT Gate Solenoid (PL 13.9).
Ensure that connectors P/J562 on the Mail Box Control PWB and P/J567 on the V-Tra In
Sensor are seated correctly and there are no obvious crimped or broken wires.
is rotating.
Y
N
Y
N
Y
N
Box Drive Motor
Y
N
Procedure
The lead edge of the paper is at or past the V-Tra In Sensor
Y
N
Y
N
The OCT Gate is in the down or Bin Tray position
Y
N
Enter dC330 011-082 OCT Gate Solenoid Bin Tray On. Press Start. The
OCT Gate Solenoid energized.
Y
N
+24 VDC is measured between P/J562-2 and P/J562-3 on the Mail
Box Control PWB.
Y
N
+24 VDC is Measured between P/J562-2 Mail Box Control PWB
and GND
Y
N
+24 VDC is measured between P/J563-1 on the Mail Box
Control PWB and GND.
Y
N
Go to the +24 VDC Wirenet and troubleshoot the wire
between P/J563-1 on the Mail Box Control PWB and P/
J45-6 on the Distribution PWB

Y
N
GND.
Y
N

Y
N
Go to Flag 6 on BSD 11.4. Check the wires for an open circuit. If the
wires are good, replace the OCT Gate Solenoid (PL 13.9).
A
B
C
D
E
11-142 V-Tra In Sensor On Jam Long RAP
Exit Roll (PL 13.9)
A
1/05
2-192
Reissue
DocuColor 12/DCCS50
11-143 V-Tra In Sensor Off Jam RAP

Enter dC330 011-142 Vertical Transport In Sensor. Manually actuate the V-Tra In Sensor
actuator. The display changes from L to H to L as the actuator moves in and out of the
sensor.
Y
N
Y
N
Go to Flag 1 on BSD 11.4. Check the harness for a short circuit to ground. If the harness is good, replace the V-Tra Sensor (PL 13.9).
Y
N
Y
N
Go to the +5 VDC wirenet and troubleshoot the wires between P/J569-1 and
P/J44-6 on the Distribution PWB.
The V-Tra In Sensor did not deactuate within the specified time after the V-Tra In Sensor actuated.
Entrance Sensor Off Jam RAP to troubleshoot this Fault Code.
Initial Actions

With paper at the sensor, less than +0.5 VDC is measured between P/ P/J562-8 and
GND.
Y
N
Replace the V-Tra In Sensor (PL 13.9).
Exit Roll (PL 13.9)
Procedure
The trail edge of the paper is past the Oct Exit Sensor
Y
N
is rotating.
Y
N
Y
N
Y
N
Box Drive Motor
Y
N
Switch Off the Power. Disconnect P/J572 from the Mail Box Drive
Motor. Switch On the Power. +24 VDC is measured between P/
J572-1 and P/J572-2.
Y
N
13.10).
Replace the Mail Box Drive Motor (PL 13.10)
Y
N
GND.
A
Reissue
DocuColor 12/DCCS50
1/05
2-193
D
11-142 V-Tra In Sensor On Jam Long RAP, 11-143
D
Y
11-144 V-Tra In Sensor On Jam Short RAP
N
The V-Tra In Sensor did not detect the lead edge of the paper within the specified time after the
Decurler Exit Sensor detects the lead edge of the same paper.

Entrance Sensor On Jam Short RAP to troubleshoot this Fault Code.
Initial Actions
Entrance Roll
Pinch Rollers
Exit Roll
Drive Belt

Check the V-Tra In Sensor Actuator for binding as it moves in and out of the sensor. The actuator is binding.
Y
N
belts that would cause the fed paper to be slow to deactuate the V-Tra In Sensor.
Procedure
The lead edge of the paper is at or past the V-Tra In Sensor
Y
N
Y
N
The OCT Gate is in the down or Bin Tray position
Y
N
Enter dC330 011-082 OCT Gate Solenoid Bin Tray On. Press Start. The
OCT Gate Solenoid energized.
Y
N
+24 VDC is measured between P/J562-2 and P/J562-3 on the Mail
Box Control PWB.
Y
N
+24 VDC is Measured between P/J562-2 Mail Box Control PWB
and GND
Y
N
+24 VDC is measured between P/J563-1 on the Mail Box
Y
N
between P/J563-1 on the Mail Box Control PWB and P/
J45-6 on the Distribution PWB
Y
N
Go to Flag 6on BSD 11.4. Check the wires for an open circuit. If the
wires are good, replace the OCT Gate Solenoid (PL 13.9).
A
11-143 V-Tra In Sensor Off Jam RAP, 11-144 V-Tra In
1/05
2-194
E
Reissue
DocuColor 12/DCCS50
E
are good, ensure that the OCT gate is connected to the OCT Gate Solenoid and that it moves freely. If the problem continues replace the OCT
Ensure that the OCT gate is connected to the OCT Gate Solenoid and that it
moves freely. If the problem continues replace the OCT Gate (PL 13.9) and the
OCT Gate Solenoid (PL 13.9).
Ensure that the OCT gate moves freely. If the problem continues replace the
OCT Gate (PL 13.9) and the OCT Gate Solenoid (PL 13.9).
Enter dC330, 011-005 Mailbox Drive Motor. Press Start. The Mail Box Transport Roll
is rotating.
Y
N
Y
N
Y
N
Box Drive Motor
Y
N
Y
N
GND.
Y
N
A
Enter dC330 011-142 Vertical Transport In Sensor. Manually actuate the V-Tra In Sensor
actuator. The display changes from L to H to L as the actuator moves in and out of the
sensor.
Y
N
Y
N
Go to Flag 1 on BSD 11.4. Check the harness for a short circuit to ground. If the harness is good, replace the V-Tra In Sensor (PL 13.9).
Y
N
Y
N
is good, replace the V-Tra In Sensor (PL 13.9).
With paper at the sensor, less than +0.5 VDC is measured between P/J562-8 and GND.
Y
N
Exit Roll (PL 13.9)

Exit Roll (PL 13.9)
A
Reissue
DocuColor 12/DCCS50
1/05
2-195
11-144 V-Tra In Sensor On Jam Short RAP
11-145 Decurler Exit Sensor On Jam Long RAP
The Decurler Exit Sensor did not detect the lead edge of the paper within the specified time
after the M/C Exit Sensor detected the lead edge of the same paper.
Press Start. +2.5 VDC is measured between P/J651-A5 and GND.

Y
N
Replace the Mail Box control PWB (PL 13.10).
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-145 Decurler Exit
Sensor On Jam Long RAP to troubleshoot this Fault Code.
Initial Actions
Press Stop. +5 VDC is measured between P/J570-A6 and GND

Y
N
Go to Flag 5 on BSD11.2. Check the wire for an open circuit. If
the wire is good, replace the Mail Box control PWB (PL 13.10).
Refer toBSD11.1, BSD11.2, BSD 11.3 and BSD11.4 for the following procedure.
Obstructions in the Decurler paper path
Bent or out of position paper chutes/guides in the Decurler paper path
N
Ensure that there is sufficient nip force at the MC Exit Roll and the Decurler Entrance Roll.
Ensure that connectors P/J654, P/J653, and P/J651 on the Decurler Control PWB, Double Plug J571, P/J570 on the Mail Box Control PWB and P/J658 on the Decurler Exit
+less than 0.5 VDC is measured between P/J651-A6 and GND.

Y
N
Replace the Decurler Control PWB (PL 13.12).
Replace the Decurler Stepping Motor (PL 13.14).
Procedure
The Entrance Rolls are rotating.

Y
N
Check the following parts for wear, damage, or slipping.
The lead edge of the paper is at or past the Decurler Exit Sensor.
Y
N
The paper entered the Decurler.
Y
N
The Entrance Rolls are rotating when the Jam occurs
Y
N
Enter dC330 011-010 Decurler Stepping Motor Speed 60. The
Decurler
Stepping Motor rotates.
Y
N
+24 VDC is measured between P/J653-1 and GND on the Decurler
Control PWB.
Y
N
+24 VDC is Measured between P/J570-A1 and GND on the Mail
Box Control PWB.
Y
N
Decurler Drive Roll Torque Limiter Gear (PL 13.14)
Decurler Stepping Motor Drive Gear (PL 13.14)

Decurler
Y
N
Approximately +16 VDC is measured between P/J653-3, 4, 5, 6 and
GND.
Y
N
Press Stop. +24 VDC is measured between P/J653-3, 4, 5, 6 and GND

on the Decurler Control PWB.
Y
N
Replace the Decurler Stepping Motor (PL 13.14). If the problem continues, replace the Decurler Control PWB (PL 13.12).
Press Start. approximately +1.5 VDC is measured between P/J653-3,

4, 5, 6 and GND on the Decurler Control PWB.
Y
N
Entrance Roll Drive Gear (PL 13.14)
Enter dC330 011-011-011 Decurler Stepping Motor Speed 130. The

Decurler Stepping Motor rotates.
Y
N
Approximately +1.5VDC is measured between P/J653-3, 4, 5, 6 and
GND.
Y
N
Go to Flag 4 on BSD11.1. Check the wire for an open circuit. If the

wire is good, replace the Decurler Control PWB (PL 13.12).
A
B
C
D
E

A
1/05
2-196
Decurler
C
Reissue
DocuColor 12/DCCS50
C
Y
N
GND.
Y
N
Exit Roll (PL 13.14)
Drive gears (PL 13.13) (PL 13.14)
F
More than +4.5 VDC is measured between P/J658-2 and GND.
Y
N
Go to the 10-111 Machine Exit Sensor Off Jam RAP

Ensure that the Decurler paper path is free of any paper. Enter dC330 011-145 Decurler Exit
Sensor. The display is L.
Y
N
Y
N
good, replace the Decurler Exit Sensor (PL 13.12).
Less than +0.5 VDC is measured between P/J570-B5 and GND.
Y
N
replace the Decurler Control PWB (PL 13.12).
Use a sheet of paper to actuate the Decurler Exit Sensor. The display changes to H.
Y
N
+5 VDC is measured between P/J654-1 and P/J654-3 on the Decurler Control PWB.
Y
N
Y
N
Go to Flag 3 on BSD 11.3. Check the wire for an open circuit. If the wires are good,
replace the Decurler Exit Sensor (PL 13.12).
F
Reissue
DocuColor 12/DCCS50
1/05
2-197
11-146 Decurler Exit Sensor On Jam Short RAP
after the MC Exit Sensor detected the lead edge of the same paper.

Y
N
Sensor On Jam Short RAP to troubleshoot this Fault Code.
Initial Actions

Y
N
Refer toBSD11.1, BSD11.2 BSD11.3 and BSD11.4 for the following procedure.
N
Ensure that connectors P/J654, P/J653, and P/J651 on the Decurler Control PWB, Double Plug J571, P/J570 on the Mail Box Control PWB and P/J658 on the Decurler Exit
+less than 0.5 VDC is measured between P/J651-A6 and GND.

Y
N
Procedure

Y
N
The lead edge of the paper is at or past the Decurler Exit Sensor
Y
N
Y
N
Y
N
Decurler
Y
N
+24 VDC is measured between P/J653-1 and GND on the Decurler
Control PWB.
Y
N
+24 VDC is Measured between P/J570 -A1 and GND on the Mail
Box Control PWB.
Y
N
Decurler Stepping Motor Drive Gear

Decurler
Y
N
GND.
Y
N
Press Stop. +24 VDC is measured between P/J653-3, 4, 5, 6 and GND

on the Decurler Control PWB.
Y
N
Replace the Decurler Stepping Motor (PL 13.14). If the problem continues, replace the Decurler Control PWB (PL 13.12).
Press Start. approximately +1.5 VDC is measured between P/J653-3,

4, 5, 6 and GND on the Decurler Control PWB.
Y
N
Decurler Drive Roll Torque Limiter Gear
Enter dC330 011-011-011 Decurler Stepping Motor Speed 130. The

Decurler Stepping Motor rotates.
Y
N
GND.
Y
N
Go to Flag 4 on BSD11.1. Check the wire for an open circuit. If the

wire is good, replace the Decurler Control PWB (PL 13.12).
A
B
C
D
E
Entrance Roll Drive Gear

A
1/05
2-198
Decurler
C
Reissue
DocuColor 12/DCCS50
C
Y
N
GND.
Y
N
Entrance Roll
Pinch Rollers
Exit Roll
Drive gears
F
More than +4.5 VDC is measured between P/J658-2 and GND.
Y
N
Entrance Roll
Pinch Rollers
Exit Roll
Drive gears
Go to the 10-111 Machine Exit Sensor Off Jam RAP

Entrance Roll
Pinch Rollers
Exit Roll
Drive gears
Y
N
Y
N
Y
N
Y
N
+5 VDC is measured between P/J656-1 and P/J661-3 on the Decurler Control PWB.
Y
N
Y
N
Go to Flag 3 on BSD 11.3. Check the wire for an open circuit. If the wires are good,
F
Reissue
DocuColor 12/DCCS50
1/05
2-199
11-190 Paper Remains on V-Tra In Sensor RAP
11-191 Paper Remains at Mail Box Vertical Sensor / 1 Bin

Sensor RAP
The Control Logic detected that paper remained on the V-Tra In Sensor at power on.
Remains on V-Tra In Sensor RAP to troubleshoot this Fault Code.
The Control Logic detected that paper remained on the Mail Box Vertical Sensor at power on.
Remains at Mailbox Vertical Sensor / 1 Bin Sensor RAP to troubleshoot this Fault Code.
Initial Actions
Refer to BSD11.4 and BSD 11.8 for the following procedure.
Initial Actions
Ensure that no paper is blocking the V-Tra In sensor and the sensor actuator moves freely.
Ensure that no paper or foreign object is blocking the Mail Box Vertical sensor.
Ensure that P/J562 on the Mail Box Control PWB, and P/J567 on the V-Tra In Sensor
Ensure that the Mail Box Vertical sensor and the Vertical LED are clean.
Ensure that P/J551 on the Mail Box Control PWB, and P/J818 and P/J819 on the Mail
Box Vertical Sensor are connected before beginning this RAP.
Procedure
Enter dC330 011-142 Vertical Transport In Sensor. Press Start. The display is L.
Y
N
replace the V-Tra In Sensor (PL 13.9).If the problem continues, replace the Mail Box Control PWB (PL 13.10).
More than +4.3 VDC is measured between P/J562-8 and GND on the Mail Box Control
PWB.
Y
N
Procedure
Enter dC330 011-115 Mailbox Vertical Sensor. Press Start. The display is L.
Y
N
+5 VDC is measured between P/J551-3 and P/J551-5 on the Mail Box Control PWB
Y
N
Y
N
Check the V-Tra In Sensor for intermittent operation. If the sensor is good, Replace the Mail
Go to Flag 1, Flag 2, and Flag 3 on BSD 11.5 and check the harness for an open circuit. If
the harness is good, replace the Mail Box Vertical Sensor (PL 13.9). If the problem continues, replace the Mail Box Control PWB (PL 13.10).
Less than +0.5 VDC is measured between P/J551-4 and GND on the Mail Box Control
PWB.
Y
N
Replace the Mail Box Vertical Sensor (PL 13.9).
Check the Mail Box Vertical Sensor for intermittent operation. If the sensor is good, Replace
the Mail Box Control PWB (PL 13.10).
11-190 Paper Remains on V-Tra In Sensor RAP, 11-
1/05
2-200
Reissue
DocuColor 12/DCCS50
11-192 Paper Remains at OCT Exit Sensor RAP
11-193 Decurler Exit Sensor Static Jam RAP
The Control Logic detected that paper remained on the Oct Exit Sensor at power on.
Remains at SCT Exit Sensor RAP to troubleshoot this Fault Code.
Sensor Static Jam RAP to troubleshoot this Fault Code.
Initial Actions
Initial Actions
Ensure that no paper is blocking the OCT Exit sensor and the sensor actuator moves
freely.
Check for excessive static on copies.
J654 on the Decurler Control PWB, and P/J658 on the Decurler Exit Sensor are connected before beginning this RAP.
Ensure that P/J562 on the Mail Box Control PWB, and P/J567 on the V-Tra In Sensor
Procedure
Enter dC330 011-107 OCT Exit Sensor. Press Start. The display is L.
Y
N
replace the OCT Exit Sensor (PL 13.9).If the problem continues, replace the Mail Box
More than +4.3 VDC is measured between P/J562-5 and GND on the Mail Box Control
PWB.
Y
N
Procedure
Y
N
PWB.
Y
N
Check the OCT Exit Sensor for intermittent operation. If the sensor is good, Replace the Mail
Reissue
DocuColor 12/DCCS50
1/05
2-201
11-192 Paper Remains at OCT Exit Sensor RAP, 11-
11-273 Mail Box OCT Offset Fail RAP
Enter dC330 011-274 Offset Position Sensor. Press Start. Block the Offset Home sensor with a sheet of paper. The display indicates H.
Y
N
+5 VDC is measured between P/J564-6 on the Mail Box Control PWB and GND
Y
N
Go to Flag 4 on BSD 11.7. Check the wire for a short circuit to ground. If the
wire is good, replace the Offset Position Sensor (PL 14.1).
The Control Logic determined that either the Offset Home Sensor or the Offset Position Sensor
did not detect the OCT position within 600msec. for three consecutive attempts.
Initial Actions
Ensure that connectors P/J564 on the Mail Box Control PWB, Shorting Plug P/J801A,
Double Plug J880, P/J803 on the Offset Motor, P/J806 on the Offset Position Sensor,
and P/J806 on the Offset Home Sensor are seated correctly and there are no obvious
crimped or broken wires.
Procedure
Manually move the Offset Catch Tray to the front/home position. Enter dC330 011-273 Offset
Home Sensor. The display indicates H.
Y
N
Remove the Offset Catch Tray from the machine. leave the Offset Catch Tray electrically
connected. Open the Offset Catch Tray to expose the motor and sensors.
Enter dC330 011-273 Offset Home Sensor. Press Start. Block the Offset Home sensor
with a sheet of paper. The display indicates H.
Y
N
+5 VDC is measured between P/J564-7 on the Mail Box Control PWB and GND
Y
N
wire is good, replace the Offset Home Sensor (PL 14.1).
Ensure that the sensor actuator is properly installed, and not bent or distorted. If the problem continues, replace the Offset Home Sensor (PL 14.1).
Manually move the Offset Catch Tray to the rear/offset position. The display changes to L.
Y
N
Y
N

Ensure that the sensor actuator is properly installed, and not bent or distorted. If the problem continues, replace the Offset Position Sensor (PL 14.1).
Manually move the Offset Catch Tray to the front/home position. The display changes to L.
Y
N
Y
N
Disconnect P/J564 from the Mail Box Control PWB. +5 VDC is measured between P/
J564-4 and GND.
Y
N
Go to Flag 2, Flag 4 on BSD 11.7, and Flag 5 on BSD 11.7. Check the wires for an open
circuit. If the wires are good, replace the Offset Position Sensor (PL 14.1).
Enter dC330 011-095 OCT Offset Motor Rear On. Press Start. The Offset Catch
moves to the rear/offset position.
Y
N
Press Stop. Less than +1 VDC is measured between P/J564-1 and P/J564-2
Y
N
Enter dC330 011-095 OCT Offset Motor Rear On. Press Start. +24 VDC is measured
between P/J564-1 and P/J564-2
Y
N
Disconnect P/J564 from the Mail Box Control PWB. Press Stop. Press Start. +24
VDC is measured between P/J564-1 and P/J564-2
Y
N
Disconnect P/J564 form the Mail Box Control PWB. +5 VDC is measured between P/
J564-4 and GND.
Y
N
Go to Flag 2 on BSD 11.7. Check the wires for a short circuit to ground. If the wires
are good, replace the Offset Motor (PL 14.1).
Go to Flag 2, Flag 3, and Flag 5 on BSD 11.7. Check the wires for an open circuit. If the
wires are good, replace the Offset Home Sensor (PL 14.1).
Enter dC330 011-274 Offset Position Sensor. The display indicates H.
Y
N
Remove the Offset Catch Tray from the machine. leave the Offset Catch Tray electrically
connected. Open the Offset Catch Tray to expose the motor and sensors.
A
11-273 Mail Box OCT Offset Fail RAP
Tray
replace the Offset Motor (PL 14.1).
Enter dC330 011-093 OCT Offset Motor Front On. Press Start. The
moves to the front/home position.
Y
N
B
1/05
2-202
Offset
Catch
Tray
Reissue
DocuColor 12/DCCS50
B
The Offset Catch Tray Offset function appears to be functioning correctly. Check the sensors
for intermittent operation. Ensure that the Offset Motor gear and rack are not damaged or binding.
If the problem continues, replace the following parts in the order listed.
Offset Sensors (PL 14.1)
Offset Motor (PL 14.1)
Mail Box Control PWB (PL 13.10)
11-301 Front Cover A Interlock Open RAP

Front Cover A Interlock Open Failure. This status code is declared when the Mailbox Front
Door Interlock is open.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-301 Mailbox Door
Interlock Open RAP to troubleshoot this Fault Code.
Initial Actions
Ensure that P/J551 on the Mail Box Control PWB, and P/J564 on the Mail Box Front
Cover Interlock Switch are connected before beginning this RAP.
Check the Front Cover for proper alignment.
Verify that the Front Cover closes properly.
Procedure
Enter dC330 011-301 Mailbox Front Cover Intlk Sw. The state of the Mail Box Front Cover
Interlock Switch is Low and switches to High when the Mail Box Front Cover is opened.
Y
N
With the Front Cover closed, there is +0 VDC between P/J551-2 on the Mail Box
Y
N
Go to the Flag 1 on BSD 11.1. Check the wires for an open circuit. If the wires are
good, replace the Mail Box Front Cover Interlock Switch (PL 13.4). If the problem
continues, replace the Mail Box Control PWB (PL 13.10)
Check the Mail Box Front Cover Interlock Switch for intermittent operation. Ensure that the
switch and the cover are properly aligned and adjusted. If the problem continues, replace
switch and the cover are properly aligned and adjusted. If the problem continues, replace the
Reissue
DocuColor 12/DCCS50
1/05
2-203
11-273 Mail Box OCT Offset Fail RAP, 11-301 Front
11-302 Front Cover B Interlock Open RAP
11-303 Docking Interlock Open RAP
Front Cover B Interlock Open Failure. This status code is declared when the Mail Box Front
Cover is open.
Docking Interlock Open failure. This status code is declared when the Mail Box is not properly
docked.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-302 Decurler
Door Interlock Open RAP to troubleshoot this Fault Code.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-303 Docking
Interlock Open RAP to troubleshoot this Fault Code.
Initial Actions
Initial Actions
Ensure that P/J551 on the Mail Box Control PWB, and P/J564 on the Mail Box Front
Cover Interlock Switch are connected before beginning this RAP.
Ensure that P/J570 on the Mail Box Control PWB, P/J665 and P/J664 on the Mail Box
Docking Interlock Switches, and P/J652 on the Decurler Control PWB are connected
Check the Mail Box for proper alignment.
Procedure
Procedure
Enter dC330 011-301 Mailbox Front Cover Intlk Sw. The state of the Mail Box Front Cover
Interlock Switch is Low and switches to High when the Mail Box Front Cover is opened.
Y
N
With the Front Cover closed, there is +0 VDC between P/J551-2 on the Mail Box
Y
N
Go to the Flag 1 on BSD 11.1. Check the wires for an open circuit. If the wires are
good, replace the Mail Box Front Cover Interlock Switch (PL 13.4). If the problem
continues, replace the Mail Box Control PWB (PL 13.10)
Enter dC330 011-303 Mailbox Docking INTLK Switches. The status of the Mail Box
Docking Interlock Switches is High and changes to Low when the Mail Box is undocked.
Y
N
With the Mail Box docked, there is +5 VDC between P/J570-B7 on the Mail Box
Y
N
Disconnect P/J665 from the Mail Box Docking Interlock Switch 2. With the Mail
Box docked, there is +5 VDC between P/J570-B7 on the Mail Box Control PWB
and GND.
Y
N
Disconnect P/J664 from the Mail Box Docking Interlock Switch 1. With
the
Mail Box docked, there is +5 VDC between P/J570-B7 on the Mail Box
Y
N
Go to the Flag 2 on BSD 11.1. Check the wires for an short circuit to
ground. If the wires are good, replace the Mail Box Control PWB (PL
13.10).
switch and the cover are properly aligned and adjusted. If the problem continues, replace the
Replace the Mailbox Docking Interlock Switch 1 (PL 13.12).

Replace the Mailbox Docking Interlock Switch 2 (PL 13.12).
Check the Mail Box Docking Interlock Switches for intermittent operation. Ensure that the
switches are properly aligned and adjusted. If the problem continues, replace the Mail Box
switch and the cover are properly aligned and adjusted. Check that the Mail Box is standing on
an even floor. Adjust Castors if necessary. If the problem continues, replace the Mail Box Control PWB (PL 13.10).
11-302 Front Cover B Interlock Open RAP, 11-303
1/05
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11-350 Decurler 1 Fail RAP
This status code is declared when the Decurler Cam Position Sensor did not energize within
the specified time (1400msec) after the Decurler Clutch is energized.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-350 Decurler 1
Fail RAP to troubleshoot this Fault Code.
Go to Flag 4 on BSD11.1. Check the wire for an open circuit. If the wire is good,
Initial Actions
Ensure that connectors P/J652, and P/J651 on the Decurler Control PWB, Double Plug
J571, P/J570 on the Mail Box Control PWB and P/J656 on the Decurler Cam Sensor are
seated correctly and there are no obvious crimped or broken wires.
Press Stop. +24 VDC is measured between P/J653-3, 4, 5, 6 and GND on the
Decurler Control PWB.
Y
N
Replace the Decurler Stepping Motor (PL 13.14). If the problem continues, replace
the Decurler Control PWB (PL 13.12).
Procedure
Press Start. approximately +1.5 VDC is measured between P/J653-3, 4, 5, 6 and

GND on the Decurler Control PWB.
Y
N
Y
N
replace the Mail Box control PWB (PL 13.10).
At Power On, the Mail Box Drive Belt is moving

Y
N
Enter dC330 011-005 Mailbox Drive Motor. Press Start. The Mail Box Drive Motor is
rotating
Y
N
+24 VDC is measured between P/J572-1 and P/J572-2 of the Mail Box Drive
Motor
Y
N
Switch Off the Power. Disconnect P/ P/J572 from the Mail Box Drive Motor.
Switch On the Power. +24 VDC is measured between P/J572-1 and P/J5722.
Y
N
Go to Flag 1 on BSD11.2. Check the wires for an open circuit. If the wires
are good, replace the Mail Box Control PWB (PL 13.10).

Y
N
Y
N
Go to Flag 5 on BSD 11.2. Check the wire for an open circuit. If the wire is
good, replace the Mail Box control PWB (PL 13.10).
Replace the Mail Box Drive Motor (PL 13.10)
less than 0.5 VDC is measured between P/J651-A6 and GND.

Y
N

Y
N
good, replace the Mail Box Control PWB (PL 13.10).
Press Start. Less than +1 VDC is measured between P/J572-3 and GND.
Y
N

Y
N

Ensure that the Mail Box Drive Motor Pulley is fastened to the motor shaft and the drive
belt is properly tensioned.
Enter dC330 011-010 Decurler Stepping Motor Speed 60. The Decurler Stepping Motor
rotates.
Y
N
+24 VDC is measured between P/J653-1 and GND on the Decurler Control PWB.
A
Reissue
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N
+24 VDC is Measured between P/J570 -A1 and GND on the Mail Box Control
PWB.
Y
N
Enter dC330 011-011-011 Decurler Stepping Motor Speed 130. The Decurler Stepping
Motor rotates.
Y
N
Approximately +1.5VDC is measured between P/J653-3, 4, 5, 6 and GND.
B
1/05
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B
Y
C
Clean the Decurler Cam Sensor and the Decurler Cam Sensor Reflector. Ensure that there are
no obstructions between the Decurler Cam Sensor and the Decurler Cam sensor Reflector. If
the problem continues, replace the Decurler Cam Sensor (PL 13.13).
N

rotates.
Y
N
Approximately +16 VDC is measured between P/J653-3, 4, 5, 6 and GND.
Y
N
rotates.
Y
N
Y
N
Enter dC330 011-276 Decurler Cam Position Sensor A. Press Start. Manually move the
Reflector in and out of the sensor The Decurler Cam Sensor Roll A Position alternates
between H and L as the reflector is moved in and out of the sensor.
Y
N
The Display is always L
Y
N
Y
N
wire is good, replace the Decurler Cam Sensor (PL 13.13). If the problem continues, replace the Decurler Control PWB (PL 13.12).
Less than +0.5 VDC is measured between P/J651-9 and GND.
Y
N
good, replace the Decurler Control PWB (PL 13.12). If the problem continues,
replace the Mail Box Control PWB (PL 13.10).
+5 VDC is Measured between P/J652-1 and P/J652-3 on the Decurler Control PWB.
Y
N
replace the Decurler Cam Sensor (PL 13.13). If the problem continues, replace the
Decurler Control PWB (PL 13.12).
C
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11-512 Offset Catch Tray / Simple Catch Tray Full Stack

RAP
11-911 Bin 1 Full Stack RAP

The Control Logic detected that Bin 1 is full.
The Control Logic detected that the Offset Catch Tray/Simple Catch Tray is full.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-512 Simple Catch
Tray (SCT) Full Stack RAP to troubleshoot this Fault Code.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-911 Bin 1 Full
Stack RAP to troubleshoot this Fault Code.
Initial Actions
Initial Actions
Ensure that Bin 1 is empty
Ensure that the Offset Catch Tray/Simple Catch Tray is empty
Double Plug J880, and P/J807 on the Full Stack Sensor are seated correctly and there
are no obvious crimped or broken wires.
Procedure
Enter 011-275 Full Stack Sensor. Press Start. The display is H.
Y
N
+5 VDC is measured between P/J564-5 and DC-COM on the Mail Box PWB.
Y
N
Go to Flag 1 on BSD11.7. Check the wire for a short circuit to ground. If the wire is
good, replace the Full Stack Sensor (PL 14.1).
Procedure
Enter dC330 011-281 Bin 1 Full Sensor. Press Start. Manually move the actuator in and out
of the sensor The display Changes from H to L to H as the actuator is moved in and out
of the sensor.
Y
N
Check the Bin 1 Full Sensor for intermittent operation. If the problem continues, replace the

Block the Full Stack Sensor with a sheet of paper. The display changes to L.
Y
N
+5 VDC is measured between P/J564-4 and P/J564-3 on the Mail Box PWB.
Y
N
Y
N
Go to Flag 1 and Flag 2 on BSD 11.7. Check the harness for an open circuit. If the harness is good, replace the Full Stack Sensor (PL 14.1).
Check the Full Stack Sensor for intermittent operation, If the problem continues, replace the
Full Stack Sensor (PL 14.1).
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11-512 Offset Catch Tray / Simple Catch Tray Full
Initial Actions
Initial Actions
Procedure
Procedure
of the sensor.
Y
N
of the sensor.
Y
N
Mail Box Control PWB (PL 13.10.
11-912 Bin 2 Full Stack RAP, 11-913 Bin 3 Full Stack
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Initial Actions
Initial Actions
Procedure
Procedure
of the sensor.
Y
N
of the sensor.
Y
N
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Initial Actions
Initial Actions
Procedure
Procedure
of the sensor.
Y
N
of the sensor.
Y
N
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Initial Actions
Initial Actions
Procedure
Procedure
of the sensor.
Y
N
of the sensor.
Y
N
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1/05
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11-921 Offset Catch Tray Full Stack RAP
The Control Logic detected that the Offset Catch Tray is full.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-921 SCT Tray
Full Stack RAP to troubleshoot this Fault Code.
Initial Actions
Initial Actions
Ensure that the Offset Catch Tray is empty
Double Plug J880, and P/J807 on the Full Stack Sensor are seated correctly and there
are no obvious crimped or broken wires.
Procedure
of the sensor.
Y
N
Procedure
Enter dC330 011-275 Full Stack Sensor. Press Start. The display is H.
Y
N
+5 VDC is measured between P/J564-5 and DC-COM on the Mail Box PWB.
Y
N
good, replace the Full Stack Sensor (PL 14.1).
Block the Full Stack Sensor with a sheet of paper. The display changes to L.
Y
N
+5 VDC is measured between P/J564 -4 and P/J564-3 on the Mail Box PWB.
Y
N
Y
N
Go to Flag 1 and Flag 2 on BSD 11.7. Check the harness for an open circuit. If the harness is good, replace the Full Stack Sensor (PL 14.1).
the Full Stack Sensor for intermittent operation, If the problem continues, replace the Full Stack
Sensor (PL 14.1).
11-920 Bin 10 Full Stack RAP, 11-921 Offset Catch
1/05
2-212
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11-922 Sorter Stacker Full RAP

The Control Logic has determined that bin 10 is full while operating in the Stack Mode.
NOTE: If this machine has a Finisher/Sorter Accessory, go to Section 8D, 11-921 Offset Catch
Tray Full Stack RAP to troubleshoot this Fault Code.
Initial Actions
Ensure that there are no obstructions in the Stacker area
Procedure
Go to 11-921 Offset Catch Tray Full Stack RAP to check out the Stacker Full Sensor for any
malfunctions.
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1/05
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1/05
2-214
Reissue
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14-372 ROS Motor Fail RAP
14-376 Half Tone PWB Fail RAP
The SOS Sensor did not go Low within a specified time after the Polygon Motor energized.
The System wrote data in the Asic Register on the Half Tone PWB, but could not read the data.
Initial Actions
Initial Actions
Refer to BSD 6.5, BSD 6.6, and BSD 6.7 in the following procedure.
PO/PO the machine. If the Fault continues, perform the following.
Verify that the Drum Unit is firmly seated and that the screws that hold the unit in place
are installed.
Refer to BSD 6.5, BSD 6.6, and BSD 6.7 in the following procedure:
Ensure that P/J398 on the Half Tone PWB is seated properly.
Verify that P/J420A on the lOT Drive PWB, and P/J399 AND P/J395 on the Half Tone
PWB are firmly connected.
Ensure that P/J345 and P/J341 on the LDD PWB are seated properly.
Go to Flag 2 and Flag 3 on BSD 6.5 and check the wires for damage or an open or short
circuit.
Check for other Chain 14 faults. Troubleshoot those faults first.
Procedure
Open the Front Door and cheat the Interlock. Enter dC330 014-050 Polygon Motor Low Speed.
Press Start. When the Polygon Motor rotates you can feel vibrations by placing your hand on
the Drum Module Cover. The Polygon Motor is rotating.
Y
N
Press Stop. There is approximately 3.5 - 5.0 VDC between P/J420A-B16 on the IOT
Drive PWB and GND.
Y
N
Switch off the power. Go to Flag 1 on BSD 6.6 and check for an open circuit or a
short to GND. If the wires are OK, replace the ROS Assembly (PL 4.1).
Enter dC330 014-050 Polygon Motor Low Speed. Press Start. +0.0 - +1.5 VDC is measured between P/J420A-B16 on the IOT Drive PWB and GND.
Y
N
Go to Flag 1 on BSD 6.6 and check for an open circuit or a short to GND. If the wires
are OK, replace the IOT Drive PWB (PL 9.2).
There is +24 VDC from P/J420A-B14 to P/J420-B15 on the IOT Drive PWB.
Y
N
Go to the +24 VDC Wirenets (Figure 5) and troubleshoot the 24 VDC circuits.
Go to Flag 5 on BSD 6.6. Check for an open circuit or a short to GND. If the wires are OK,
replace the ROS (PL 4.1). If the problem continues, replace the IOT Drive PWB (PL 9.2).
Procedure
Open the Front Door and cheat the Interlock. Enter dC330 014-050 Polygon Motor Low Speed.
Press Start. When the Polygon Motor rotates you can feel vibrations by placing your hand on
the Drum Module Cover. The Polygon Motor is rotating.
Y
N
Go to the 14-372 ROS Motor Fail RAP.
+5VDC is measured between P/J342-1 and P/J342-3 on the ROS Assembly.
Y
N
Go to Flag 3 and Flag 4 on BSD 6.6. Check the wires for an open or short circuit. If the
wires are OK, replace the Half Tone PWB (PL 9.2).
+5VDC is measured between P/J399-2 and gnd.
Y
N
Go to Flag 2 on BSD 6.6. Check the wires for an open or short circuit. If the wires are OK,
replace the Half Tone PWB (PL 9.2).
Go to Flag 2 and Flag 3 on BSD 6.6. Check the wires for an open or short circuit. If the wires
are OK, replace the ROS Assembly (PL 4.1). If the problem persists, replace the IOT CPU
PWB (PL 9.2).
Switch on the power. +5 VDC is measured between P/J399-1 and P/J399-3 on the HalfTone PWB.
Y
N
+5 VDC is measured between P/J395-1 and P/J395-3 on the Half-Tone PWB.
Y
N
Go to the +5 VDC Wirenets (Figure 1) and troubleshoot the 5 VDC circuits.
Replace the Half Tone PWB (PL 9.2)
Switch off the power. Go to Flag 1 and Flag 2 on BSD 6.5 and check for an open circuit. Go to
Flag 2 on BSD 6.6 and check for a short to ground. If the wires are OK, replace the following:
lOT Drive PWB (PL 9.2).
ROS Assembly (PL 4.1).
Reissue
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14-372 ROS Motor Fail RAP, 14-376 Half Tone PWB
14-380 SOS Fail 1 RAP
14-384 SOS Fail 2 RAP
The SOS Interval became longer than normal while the Polygon Motor was energized.
The SOS Interval became shorter than normal while the Polygon Motor was energized.
Initial Actions
Initial Actions
Verify that P/J420A on the IOT Drive PWB is firmly seated.
Verify that P/J420A on the IOT Drive PWB is firmly seated.
Verify that P/J345 and P/J341 on the LDD PWB is firmly seated.
Verify that P/J345 and P/J341 on the LDD PWB is firmly seated.
Verify that P/J347 and P/J342 on the ROS are firmly seated.
Verify that P/J347 on the ROS is firmly seated.
Verify that P/J399 on the Halftone PWB is firmly seated.
Verify that P/J342 on the ROS is firmly seated.
Procedure
Procedure
ROS (PL 4.1)
ROS (PL 4.1)
IOT Drive PWB (PL 9.2)
IOT Drive PWB (PL 9.2)
14-380 SOS Fail 1 RAP, 14-384 SOS Fail 2 RAP
1/05
2-216
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14-388 XPC ASIC Fail RAP

The Control Logic detected a ROS Pickup ASIC Failure
Initial Actions
Refer to BSD 1.1, BSD 6.6 and BSD 6.7 in the following procedure:
Ensure that P/J398 on the Halftone PWB and the P/J345 and P/J341 on the LDD PWB
are fully seated.
Go to Flag 2 and Flag 3 on BSD 6.5 and check the wires for an open or shorted circuit.
Procedure
PO/PO the machine. If the fault continues, go to 14-376 Half Tone PWB Fail RAP.
Reissue
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1/05
2-217
1/05
2-218
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15-270 Coordinate Bus Fail RAP
15-281 Pre-IPS X Recognize Fail RAP
Communication failure between IPS and UI at power-on when an Edit Pad is installed.
The BR PWB Detected paper money during the first scan.
NOTE: This fault code is not displayed on the UI; it is logged into the PWS only.
Initial Actions
Refer to Edit Pad BSD2.5 (Figure 1) and BSD 2.6 (Figure 2), and IOT BSD 3.1 (Figure 1)
Check the following Connectors:
P800 on the Edit Pad cable
P491 on the UI PWB
P/J821 and P/J824 on the Edit Pad
P571 on the IPS PWB
Procedure
NOTE: The fault code is not displayed on the UI, but is recorded in the DC120 Counter (Fail/
Jam) Fail Counter and DC122 History (Fail/Jam) Fail History. The UI will display the customer
message Check copy output - see that your original is not a prohibited item for copying.
Initial Actions
Verify that the original is not a prohibited item for copying.
Ensure that P/J560 in the BR PWB and the Pre IPS PWB are firmly connected.
Procedure
Reseat the BR PWB. If the problem continues, replace the BR PWB (PL 3.5)
There is +3.4 VDC from P/J490 pin 14 on the UI PWB to DC COM.

Y
N
Replace the UI PWB (PL 9.5). Perform ADJ 9.1.18.
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15-270 Coordinate Bus Fail RAP, 15-281 Pre-IPS X
15-284 POST IPS X Recognize Fail RAP
15-342 IPS NVM Fail RAP
The BR PWB detected currency on the Platen during the 2nd scan.
The control logic detected a POST IPS NVM Test Failure at power on.
NOTE: The Fault Code is not displayed on the UI, but is recorded in the DC120 Fail Counter
and the DC122 Fail History. The UI will display the message Check Copy Output - See that
your original is not a prohibited item for copying.
Initial Actions
Initial Actions
Procedure
PO/PO the machine. If the fault continues, replace the POST IPS PWB (PL 3.5)
Verify that the original is not a prohibited item for copying.
Procedure
Reset the BR PWB. If the problem continues, replace the BR PWB (PL 3.5).
15-284 POST IPS X Recognize Fail RAP, 15-342 IPS
1/05
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15-361 POST IPS PWB Fail (Self Test) RAP
15-362 X Hard Fail RAP
The POST IPS PWB I/O Port reported an error at power on.
Communication Failure between the Pre IPS PWB and the BR PWB.
Initial Actions
Initial Actions
Ensure that P/J560 in the BR PWB and the Pre IPS PWB are firmly connected.
Ensure that the connection at the BR PWB has not been tampered with.
Ensure that the BR PWB mounting screws are tight.
Procedure
PO/PO the copier/printer. If the error code persists, replace the Post IPS PWB (PL 3.5)
Procedure
Reseat the BR PWB. If the problem continues, replace the following:
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BR PWB (PL 3.5)
1/05
2-221
15-361 POST IPS PWB Fail (Self Test) RAP, 15-362
15-363 IIT Memory Fail RAP
15-365 X Comm Fail RAP
The control logic detected a memory clearance error.
The control logic detected that the POST IPS PWB could not detect a change in the signal
from the Pre IPS PWB.
Initial Actions
Initial Actions
Ensure that P/J514 on the Pre IPS PWB and the MEM SYS PWB are fully seated.
Ensure that P/J514 on the Pre IPS PWB, P/J560, P/J561 between the MEM SYS PWB
and the POST IPS PWB are fully seated.
Procedure
PO/PO the machine. If the fault continues, replace the following:
15-363 IIT Memory Fail RAP, 15-365 X Comm Fail RAP
Procedure
POST IPS PWB (PL 3.5)
1/05
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15-367 X - Fail 4 RAP
15-370 X - Fail 5 RAP
The control logic on the Pre IPS PWB detected a hardware failure.
Initial Actions
Initial Actions
Ensure that P/J560 on the Pre IPS PWB and the BR PWB is fully seated.
Procedure
Procedure
BR PWB (PL 3.5)
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15-367 X - Fail 4 RAP, 15-370 X - Fail 5 RAP
15-371 X - Fail 6RAP

Initial Actions
Ensure that P/J560 on the Pre IPS PWB and the BR PWB is fully seated.
Procedure
BR PWB (PL 3.5)
15-380/15-381 / 15-382 / 15-383 / 15-384 / 15-385 CCD AGC

Fail RAP
The Automatic Gain Control (AGC) for a specific channel from the CCD PWB failed.
15-380: CCD Channel 1 RED (odd) AGC Fail
15-381: CCD Channel 2 RED (even) AGC Fail.
15-382: CCD Channel 3 GREEN (odd) AGC Fail.
15-383: CCD Channel 4 GREEN (even) AGC Fail.
15-384: CCD Channel 5 BLUE (odd) AGC Fail.
15-385: CCD Channel 6 BLUE (even) AGC Fail.
Initial Actions
Verify that the Platen Glass is installed correctly.
Verify that the following NVM values match the Machine Configuration on the Platen or
the DADF: NVM715-125: 0=Platen, 1=DADF.
Procedure
Enter dC330 006-002 ITT Exposure Lamp. Press Start. The Exposure Lamp lights.
Y
N
Go to the 6-371 Exposure Lamp Fail RAP.
The Exposure Lamp lights at the correct intensity without flickering.
Y
N
Go to Flag 1 on BSD 6.1 and check the wires for an open or short circuit. Verify that P/
J535 on the Lamp Ballast PWB and P/J521 on the IIT Driver PWB are seated. If the wires
are connectors are OK, replace the following:
Exposure Lamp (PL 3.4)
Lamp Ballast PWB (PL 3.4)
The White Reference Strip on the bottom of the Platen Glass (Platen top machines PL
3.1) or underneath the Plate (PL 12.11) for DADF machines is clean and undamaged.
Y
N
Clean the White reference Strip or replace the Platen Glass (PL 3.1) or the Plate (PL
12.11) on DADF equipped machines.
Go to Flag 1 on BSD 6.2 and check the Flat Cable P/J510 on the Pre IPS PWB and P/J500 on
the CCD PWB for damage. Reseat the Flat Cable. If the problem continues, replace the following:
CCD PWB (PL 3.2)
15-371 X - Fail 6RAP, 15-380/15-381 / 15-382 / 15-383 /
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Pre-IPS PWB (PL 3.5)
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PO/PO the machine. If the Fault continues, ensure that the P/J514 on the Pre IPS PWB and
MEM SYS PWB, P/J560 on the MEM SYS PWB and POST IPS PWB are fully seated. If the
Fault continues, replace the following:
POST IPS PWB (PL 3.5)
PRE IPS PWB (PL 3.5)
15-386 / 15-387 / 15-388 / 15-389 / 15-390 / 15-391 CCD AOC

Fail RAP
The Automatic Offset Control (AOC) for a specific signal from the CCD PWB could not set the
value within range.
15-386: CCD Channel 1 RED (odd) AOC Fail
15-387: CCD Channel 2 RED (even) AOC Fail
15-388: CCD Channel 3 GREEN (odd) AOC Fail
15-389: CCD Channel 4 GREEN (even) AOC Fail
15-390: CCD Channel 5 BLUE (odd) AOC Fail
15-391: CCD Channel 6 BLUE (even) AOC Fail
Initial Actions
Procedure
Switch off the power. Go to Flag 1 on BSD 6.2 and check the Flat Cable for damage. Reseat
the Flat Cable connector P/J500 and P/J510.
If the problem continues, replace the following
Reissue
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CCD PWB (PL 3.2)
Pre-IPS PWB (PL 3.5)
1/05
2-225
15-380/15-381 / 15-382 / 15-383 / 15-384 / 15-385
15-560 Expected Time Margin Fault RAP

The control logic determined that the Image Output was requested during the transaction of the
POST IPS PWB.
Initial Actions
Ensure that P/J404 on the IOT CPU PWB, J571 on the POST IPS PWB and P/J514 on
the Pre IPS PWB are fully seated.
Procedure
PO/PO the machine. If the fault continues, go to OF4-002 Drum Motor RAP. If the fault persists, replace the following:
POST IPS PWB (PL 3.5
IOT CPU PWB (PL 9.2)
15-560 Expected Time Margin Fault RAP
1/05
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OF19-1 IDFE Fault Entry RAP

NOTE: There are two configurations of the IDFE for this machine. They are identifiable by the
Product Code on the ID tag and by the number of Diagnostic LEDs. Early versions have 5
LEDs and are labeled Product Code GL2. Later versions have 6 LEDs and are labeled Product
Code MFY. This RAP applies generically to both. Where differences between the units exist,
the applicable information is followed by the product code for the specific IDFE.
NOTE: Centerware Network Services is the official name for web client and web UI.
NOTE: The IOT does not log or display Integrated Digital Front End (IDFE) fault codes.
Verify that the DC wire harness connector, P/J 889 is correctly seated into the IDFE.
From your machine log, obtain the Configuration Report and verify that the version of firmware and software for the IDFE and the IOT are compatible.
Procedure (Product Code GL2)

NOTE: Before evaluating the fault indicated by the Diagnostic LEDs, allow 70-180 seconds to
pass for the Diagnostic LEDs to come to a steady state condition after the IDFE has been
switched-on.
NOTE: If more than one fault is detected the first error encountered is the one displayed.
This RAP is intended to help analyze the fault code(s), indicated by the LED display on the
IDFE, or by the Configuration Report and to direct the field service representative to the applicable RAP.
NOTE: If a hard fault is detected during power up, the software boot sequence test stops. If a
soft fault is detected, the Software boot process will continue.
Switch on the power. Observe the IDFE Diagnostic LEDs (Figure 1) as the system performs
self -test. Compare the observations with the Fault Indication descriptions in Table 1 and
Table 2. Refer to Table 3 for a description of the function of each LED.
Initial Actions
Refer to BSD 16.1.

Table 1 Power-on Self Tests (GL2)
Fault Indication
Fault
Within 10 seconds of Power-On if any of the LEDs on the DC Power Fault

IDFE are de-energized or if the Green Power LED is deenergized.
Go to RAP:
Type of Fault Comments
19-001 DC Power Fault RAP
Hard
IDFE does not log or display fault.
NOTE: After a PO/PO is performed all LEDs should

energize for approximately 10 seconds. If this does not
occur, perform RAP 19-001.
Red Failure LED is energized continuously.
Booting or Hardware Failure
19-002 BIOS/Self-Test Fault RAP
Hard
Amber Heartbeat LED is energized continuously or deenergized continuously
Software Load Halted
19-003 Hard Disk Fault RAP
Hard
Amber Heartbeat LED is energizes for 0.5 seconds and

de-energizes for 0.5 seconds.
Software Running
Red Failure LED energizes for 0.25 seconds and deenergizes for 2.0 seconds in a continuously repeated
pattern.
DDI IOT Failed Internal

Loop back Test
19-004 Printer DDI Communication Fault 1 RAP
Hard
IDFE does not log or display fault, web UI

remains active
Red Failure LED energizes twice in 0.25 second intervals, then de-energizes for 2 seconds. This pattern is
continuously repeated.
DDI IOT Failure, End to

End (Cable, IOT or IDFE
Failure)
Soft
IDFE does not log or display fault, web UI

remains active
Red Failure LED energizes three times in 0.25 second

intervals, then de-energizes for 2 seconds. This pattern
is continuously repeated.

Loop back Test
19-006 Scanner DDI Communication Fault 1 RAP
Hard
Printer and web UI remain active
Red Failure LED energizes four times in 0.25 second


Failure)
Soft
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Normal operation when software is running.
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Table 2 Network/Connectivity Hardware Tests (GL2)

Fault Indication
Fault
Green Link LED is de-energized.
Network Connection Fault 19-012 Network Connection Fault RAP
Go to RAP:

Soft
Amber Activity LED energized continuously with a

solid non-blinking light.
Network Connection Fault 19-013 Network Connection Fault RAP
Soft

NOTE: On busy networks, the Amber Activity LED may appear to be continuously
energized. Ensure that the customer can
connect to the network by using CentreWare Internet Services.
N/A, fault declared through web client, XCMI settings Ethernet Speed Detection 19-014 Ethernet Speed Detection Fault RAP
and the configuration report
Fault
Soft
Declared through web client, XCMI settings;

reported on the configuration report.
N/A, fault declared through web client, XCMI settings Token Ring Speed Detec- 19-015 Token Ring Speed Detection Fault RAP
tion Fault
and the configuration report
Soft
Declared through web client, XCMI settings,

reported on the configuration report.
Table 3 (GL2) IDFE Diagnostic LEDs - Normal Operation

Green Power LED
Energizes when DC Power is supplied to the IDFE (Refer to Table 3)
Red Failure LED
Energizes when the power up sequence fails (Refer to Table 3)
Amber Heartbeat LED
Energizes when IDFE software is running (Refer to Table 3)
Green Link LED
Energizes when the IDFE is connected to a 10/100BaseT Ethernet

network
IDFE
Green Power LED
Amber Activity LED
NOTE: The Green Link and Amber Diagnostic LEDs only energize
when the IDFE is connected by a 10 or 100 BaseT Ethernet Network connection.
Amber Activity LED
Energizes when network activity is occurring over a 10/100 BaseT

Ethernet Network (Refer to Table 2)
NOTE: The Green Link and Amber Diagnostic LEDs only energize
when the IDFE is connected by a 10 or 100 BaseT Ethernet Network connection.
Green Link LED
Red Failure LED
Amber Heartbeat LED
Figure 1 IDFE (GL2) Diagnostic LEDs
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Procedure (product code MFY)
The normal "Boot-Sequence" LED indications (MFY only) are:
NOTE: Before evaluating the fault indicated by the Diagnostic LEDs, allow 70-180 seconds to
pass for the Diagnostic LEDs to come to a steady state condition after the IDFE has been
switched-on.
From power on, to approximately 1 to 1.5 minutes, the ERR, HB, and PWR LEDs are on
steady and the ACT LED is flashing.
After approximately 1.5 minutes, the ACT LED goes out.
NOTE: If more than one fault is detected the first error encountered is the one displayed.
Approximately 1 minute and 45 seconds after power on the LINK LED will light.
After approximately 2 minutes, the HB LED will flash.
Finally, (if enabled) after approximately 4 minutes, a configuration sheet is printed.
NOTE: If a hard fault is detected during power up, the software boot sequence test stops. If a
soft fault is detected, the Software boot process will continue.
Switch on the power. Observe the IDFE Diagnostic LEDs (Figure 2) as the system performs
self -test. Compare the observations with the Fault Indication descriptions in Table 4 and
Table 5. Refer to Table 6 for a description of the function of each LED.
Table 4 Power-on Self Tests (MFY)

Fault Indication
Fault
Within 10 seconds of Power-On if any of the LEDs on the DC Power Fault

IDFE are de-energized or if the Green Power LED is deenergized.
Go to RAP:
Hard
Red Failure LED is energized continuously.
Booting or Hardware Fail- 19-002 BIOS/Self-Test Fault RAP

ure
Hard
Amber Heartbeat LED is energized continuously or deenergized continuously
Software Load Halted
Hard
Amber Heartbeat LED is energizes for 0.5 seconds and

de-energizes for 0.5 seconds.
Software Running
Red Failure LED energizes for 0.25 seconds and deenergizes for 2.0 seconds in a continuously repeated
pattern.

Loop back Test
19-004 Printer DDI Communication

Fault 1 RAP
Hard
IDFE does not log or display fault, web UI remains

active
Red Failure LED energizes twice in 0.25 second intervals, then de-energizes for 2 seconds. This pattern is
continuously repeated.

Failure)
19-005 Printer DDI Communication

Fault 2 RAP
Soft
IDFE does not log or display fault, web UI remains

active
Red Failure LED energizes three times in 0.25 second


Loop back Test
19-006 Scanner DDI Communication

Fault 1 RAP
Hard
Red Failure LED energizes four times in 0.25 second


Failure)
19-007 Scanner DDI Communication

Fault 2 RAP
Soft
Normal operation when software is running.
Table 5 Network/Connectivity Hardware Tests (MFY)

Fault Indication
Fault
Amber 10-100 LED is de-energized.
Network Connection Fault 19-012 Network Connection Fault RAP Soft
Green Activity LED energized continuously with a

solid non-blinking light.
Network Connection Fault 19-013 Network Connection Fault RAP Soft
N/A, fault declared through web client, XCMI settings and the configuration report
Ethernet Speed Detection 19-014 Ethernet Speed Detection Fault Soft

Fault
RAP
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Go to RAP:
Type of Fault
Comments
NOTE: On busy networks, the Green Activity LED may

appear to be continuously energized. Ensure that the
customer can connect to the network by using CentreWare Internet Services.
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Declared through web client, XCMI settings; reported

on the configuration report.
Table 6 IDFE (MFY) Diagnostic LEDs - Normal Operation

Green Power LED (PWR)
Energizes when DC Power is supplied to the

IDFE
Red Failure LED (ERR)
Energizes when the power up sequence fails
Amber Heartbeat LED (HB)
Energizes when IDFE software is running
Amber 10/100 LED (100)
Energizes when the IDFE is connected to a

10/100BaseT Ethernet network Solid-ON
indicates 100mbps, LED-OFF indicates
10mbps connection
Green Activity LED (ACT)
Energizes when network activity is occurring

over a 10/100 BaseT Ethernet Network
(Refer to Table 5)
NOTE: The Green Link and Amber Diagnostic LEDs only energize when the IDFE is
connected by a 10 or 100 BaseT Ethernet
Network connection.
Red LED
Not Used

A 19-001 fault is a DC Power failure to the IDFE. The green Power LED on the IDFE, when deenergized, indicates a 19-001 fault.
Initial Actions
Refer to BSD 16.1.

NOTE: Before replacing any of the parts shown in BSD 16.1, ensure that the connectors
for the parts are correctly seated.
Inspect and re-seat DC wiring harness connector P/J899 (Flag 1). This connector supplies DC power to the IDFE.
Refer to OF19-1 IDFE Fault Entry Rap, Figure 1 (GL2) or Figure 2 (MFY), Diagnostic
LEDs and their locations.
Procedure
Red Failure LED
(ERR)
Red LED (not used)
Amber Heartbeat
LED (HB)
PO/PO the machine (GP 8 IDFE Power OFF/Power ON (PO/PO) ). The green Power LED
switches off within 10 sec. of Power-On.
Y
N
If an intermittent fault is suspected, perform the following:
Go to Flag 1 and Flag 2 of BSD 16.1. Check for loose connections.
Green Power LED

(PWR)
Green Activity LED

(ACT)
Amber 100/10
Network LED
(100)
IDFE (MFY)
Open the IDFE (GL2 only) and ensure that the Connector for the LED PWBA is correctly seated.
Replace the Printer SSR (PL 9.3).
Replace the Printer LVPS (PL 9.3).
Replace the IDFE (PL 19.1).
Check for +5 VDC at, (Flag 1, Flag 2) 1 through 8.
Check for +12 VDC at (Flag 1, Flag 2) 9,11.
Go to Flag 1 of BSD 16.1, and check for an open/short circuit.
Go to BSD16.1, Flag 2, and check for an open/short circuit.
Figure 2 IDFE (MFY) Diagnostic LEDs
OF19-1 IDFE Fault Entry RAP, 19-001 DC Power Fault
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19-002 BIOS/Self-Test Fault RAP
A 19-002 fault is a BIOS-level hard fault, that was detected at power up. A continuously energized red Failure LED indicates that a 19-002 fault has occurred.
Initial Actions
Refer to BSD 16.1.

Inspect and re-seat DC wiring harness connector P/J899 (Flag 1). This connector supplies DC power to the IDFE.
A 19-003 fault indicates that the applications software could not be successfully loaded and
executed. The amber Heartbeat LED on the IDFE, when continuously energized or de-energized, indicates a 19-003 fault.
Initial Actions
Refer to BSD 16.1.

Inspect and re-seat the IDFE DC wiring harness connector P/J899 (Flag 1).
Procedure
PO/PO the machine (GP 8 IDFE Power OFF/Power ON (PO/PO)).
Procedure
NOTE: Check the red Failure LED 70-180 seconds (GL2) or 60 - 80 seconds (MFY) after PO/
PO.
The red Failure LED is continuously energized after 70-180 seconds (GL2) or 60 - 80 seconds (MFY) s after power up.
Y
N
Go to Flag 1 and Flag 2 of BSD 16.1, and check for loose connections.
Check that the Memory DIMMs are correctly installed and are not damaged (REP
19.3).
Check that the Memory DIMMs for the IDFE are correctly installed (REP 19.3).
NOTE: Check the amber Heartbeat LED 70-180 seconds (GL2) or 90 - 120 seconds (MFY)
after PO/PO.
The amber Heartbeat LED is energized or de-energized continuously without blinking.
Y
N
Reload software using the IDFE CD-ROM Drive (GP 9 IDFE Software Installation
(CD-ROM)).
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Reload software using the IDFE CD-ROM Drive (GP 9 IDFE Software Installation (CDROM)).
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If the Heartbeat LED does not return to its heartbeat blinking pattern, replace the IDFE
(PL 19.1).
19-002 BIOS/Self-Test Fault RAP, 19-003 Hard Disk
A 19-004 fault indicates that the internal loop-back test failed for the printer interface. The red
Failure LED on the IDFE, when energized for 0.25 seconds and de-energized for 2.0 seconds
in a continuously repeated pattern, indicates a 19-004 fault.
A 19-005 fault indicates that a problem occurred in the DDI Power-On Sequence Test. The red
Failure LED on the IDFE, energizing twice at 0.25 second intervals and then de-energizing for
2.0 seconds in a continuously repeated pattern, indicates a 19-005 fault.
Initial Actions
Initial Actions
Refer to BSD 16.1.

Refer to BSD 16.1.

Inspect and re-seat IDFE DC wiring harness connector P/J899 (Flag 1).
Inspect and re-seat the DDI Cables.
Inspect and re-seat the IDFE DC wiring harness connector P/J899 (Flag 1).
Procedure
Procedure

PO for the continually repeated pattern.
The red Failure LED is energized for 0.25 seconds and de-energized for 2.0 seconds in a
continuously repeated pattern.
Y
N
(CD-ROM)).

The Failure LED on the IDFE energizes twice at 0.25 second intervals and then de-energizes for 2.0 seconds in a continuously repeated pattern.
Y
N
Go to Flag 1 and Flag 2 of BSD 16.1 and check for loose connections.
(CD-ROM)).
Replace the Flat Cable (PL 9.2).
Replace the V-Sel PWB (PL 9.2).
If the Failure LED energizes for 0.25 seconds and de-energizes for 2.0 seconds in a continuously repeated pattern, replace the IDFE (PL 19.1).
19-004 Printer DDI Communication Fault 1 RAP, 19-
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A 19-006 fault indicates that the UART communication channel for the print path failed the
internal loop-back test.
A 19-007 fault indicates a failure in the DDI Power-on Sequence Test by the DDI Client and the
Link Layer protocols. The red Failure LED on the IDFE, energizes four times at 0.25 second
intervals and then de-energizes for 2 seconds in a continuously repeated pattern. This indicates a 19-007 fault.
The red Failure LED, when energized three times at 0.25 second intervals and then de-energized for 2 seconds in a continuously repeated pattern, indicates a 19-006 fault.
Initial Actions
Initial Actions
Refer to BSD 16.1.

Refer to BSD 16.1.

Inspect and re-seat the DDI Cables.
Inspect and reseat the IDFE DC wiring harness connector P/J899 (Flag 1).
Inspect and re-seat IDFE DC wiring harness connector P/J899 (Flag 1).
Procedure
Procedure
The red Failure LED on the IDFE energizes three times at 0.25 second intervals and then
de-energizes for 2 seconds in a continuously repeated pattern.
Y
N
The red Failure LED energizes four times at 0.25 second intervals and then de-energizes
for 2 seconds in a continuously repeated pattern.
Y
N
(CD-ROM)).
(CD-ROM)).
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Replace the Flat Cables (PL 9.2).
Replace the V-Sel PWB (PL 9.2).
Replace the V-Sel E PWB (PL 9.2)
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19-006 Scanner DDI Communication Fault 1 RAP,
19-012 Network Connection Fault RAP
Call the System Administrator.
NOTE: The Netware Internet Services is the official name for web client and web UI.
NOTE: The green (GL2) or amber (MFY) Link and amber Diagnostic LEDs only energize when
the IDFE is connected by a 10 or 100 BaseT Ethernet Network connection.
NOTE: If a Token Ring PWBA is installed only the Power and Heartbeat LED swill energize.
NOTE: The Live Connection Test continuously monitors the network connections on the IDFE
(or optional hardware). If there is a proper hardware link to the network, the test is successful,
and the Link will be ON constantly. If there is not a proper hardware link to the network, the Link
LED will be OFF, thus indicating a 19-012 Fault.
NOTE: This note applies to the GL2 IDFE only. Xerox may elect to use a Print Server box,
and/or a BNC Transceiver that does not have a Link LED. In that case, the result of the Live
Connection Test cannot be indicated by the Link LED. Continue with this RAP, if a Network
Connection Fault is suspected in the absence of a Link LED.
A 19-012 fault indicates that the hardware link to the network has failed. When the Link LED is
de-energized a 19-012 fault is indicated.
NOTE: Hardware link failures to the Network can include IOT failure or IOT software failures.
Initial Actions
Inspect and reseat the network connector.
Run a Configuration Report. With the assistance of the Systems Administrator verify that
the connectivity settings for the IDFE and Network are correct.
Remove and re-install software for the IOT. Refer to GP 11 Software Upgrade Procedure.
Locate another working network drop or another printer to test the network connection or
cabling.
Procedure
PO/PO the machine (GP 8 IDFE Power OFF/Power ON (PO/PO)). Wait 70 - 180 seconds
(GL2) 105 - 120 seconds (MFY). The Link LED remains de-energized.
Y
N
Check for an intermittent open circuit in the connectors and cabling to the network drop.
Thoroughly check the network connector and cable electrical continuity and mechanical integrity.
If the connector and network cable checks OK, set up a known good printer using the connectors and cabling to the network drop. The Link LED is de-energized.
Y
N
Repair/replace the connector and cabling to the network drop.

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A
Repair/replace the connector and cabling to the network drop.

Call the System Administrator.
NOTE: The green (GL2) or amber (MFY) Link and amber Diagnostic LEDs only energize when
the IDFE is connected by a 10 or 100 BaseT Ethernet Network connection.
NOTE: If a Token Ring PWBA is installed, only the Power and Heartbeat Diagnostic LEDs will
energize.
NOTE: (GL2 only) The IDFE (or optional hardware) continuously monitors the network connections and the network traffic activity. As long as the network traffic flow is visible to the IDFE
or optional hardware, the Activity LED will switch on and off in a pattern that mimics the network traffic flow. If there is not proper hardware activity to the network, the Activity LED will
remain energized, thus declaring a 19-013 Fault.
NOTE: A Print Server box, a BNC Transceiver or a Token Ring PWB that does not have an
Activity LED may be used. If this occurs, the result of Network Traffic sensing cannot be indicated by an Activity LED. Continue with this RAP, if a Network Connection Failure is suspected
in the absence of an Activity LED.
A 19-013 fault indicates that the IDFE fails to detect network traffic flow. When the Activity LED
is in the energized state, this is an indication of the 19-013 fault.
Initial Actions
Ensure that the customer can connect to the network using CentreWare Internet Services.
Inspect and reseat the network connector.
Verify that the green (GL2) or amber (MFY) Link LED is energized.
Run a Configuration Report. With the assistance of the Systems Administrator verify the
the connectivity settings for the IDFE and the Network are correct.
Locate another working network drop or printer to test the network connection/cabling.
Procedure
NOTE: Check the Activity LED 70-180 seconds (GL2) or 90 - 120 seconds (MFY) after PO/PO.
The Activity LED is continuously energized.
Y
N
Check for an intermittent open circuit in the connectors and cabling to the network drop.
Thoroughly check the network connector and cable electrical continuity and mechanical integrity.
If the connector and network cable checks OK, set up a known good printer using the connectors and cabling to the network drop. The Activity LED is still energized.
Y
N
A
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19-014 Ethernet Speed Detection Fault RAP

NOTE: Follow the procedure closely. Ensure that you disconnect the Network Interface
Cables to the IDFE. After software reload, it is necessary to reboot, while connected to the
network, or the link will not occur.
6.
If necessary, replace the IDFE (PL 19.1).
NOTE: The Centerware Internet Services is the official name for web Client or web UI.
NOTE: This fault is displayed via the web client, XCMI settings, and the configuration report.
NOTE: XCMI (Xerox Common Management Interface) settings is a Xerox Common Network
Interface for the (printer) systems management of Xerox products.
NOTE: Through its resident Ethernet circuitry the Integrated Digital Front End (IDFE) may be
connected to either a 10 Mbps line or to a 100 Mbps line. This Ethernet circuitry automatically
detects the Ethernet line speed and reports it through the web client, XCMI settings, and the
Configuration Report. If the speed of the Ethernet line and that reported by the Configuration
Report, Web Browser client, and the XCMI settings do not agree, a 19-014 fault is declared.
A 19-014 fault indicates that the IDFE failed to detect the proper speed of the Ethernet network
to which it is connected.
Initial Actions
Go to GP 12 Printing Configuration Reports and print a Configuration Report. Check the

Configuration Report for the speed of the connection.
NOTE: For the GL2 configuration, an Ethernet connection is required in order for the
RJ45 Ethernet Port to be enabled, otherwise the controller will default to AUI - 10 mbps.
If the speed of the Ethernet line is manually set by the System Administrator, ask for what
speed the Ethernet line was set.
NOTE: If Ethernet connection speed is adjusted through Printer Administrative Services
or through CentreWare Internet Services, the IDFE software can fail to load. For example,
if the speed is forced to 100 Mbps but the customer has a 10 Mbps network the IDFE will
not successfully load software from the installation CD-ROM. The IDFE Software installation will freeze or lockup. Re-loading software is the only way to reset the Ethernet speed
to Auto.
Procedure
1.
Review the information collected in Initial Actions.
2.
(GL2 only) Verify that the green Link Diagnostic LED is energized.
NOTE: This ensures that a Ethernet Network connection is occurring.
3.
Verify that the Ethernet line speed agrees with that reported by the Configuration Report
(GP 12 Printing Configuration Reports) the Web browser client, and the XCMI settings
4.
(MFY only) Ensure that the status of the amber 10-100 LED matches the data checked
in step 3.
5.
19-014 Ethernet Speed Detection Fault RAP
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19-015 Token Ring Speed Detection Fault RAP
19-016 Token Ring Troubleshooting RAP
NOTE: There are two configurations of the IDFE for this machine. However, this RAP applies
only to the IDFE with the GL2 product code.
NOTE: There are two configurations of the IDFE for this machine. However, this RAP applies
only to the IDFE with the GL2 product code.
NOTE: This fault is declared through The Centerware Internet Services (web client or web UI),
XCMI settings, and the Configuration Report.
This RAP is used to isolate problems related to the IDFE Token Ring PWB. The following procedure is a checklist of potential items that could be the source of problems with the Token
Ring PWB.
NOTE: The Integrated Digital Front End (IDFE) may be connected to either a 4 Mbps line or to
a 16 Mbps line. If the Token Ring PWB is enabled and the drivers properly loaded, the IDFE
automatically detects the Token Ring line speed and reports it through web client, XCMI settings, and the Configuration Report. When the known speed of the Token Ring line and that
reported by the Configuration Report, Web Browser client, and the XCMI settings do not agree,
a 19-015 fault is declared.
Procedure
1.
Token Ring troubleshooting tips:
A 19-015 fault indicates that the IDFE failed to detect the proper speed of the Token Ring to
which it is connected.
Ensure that the Token Ring PWB is correctly plugged into Connectors J3 and J4 of
the SCAN IIT PWBA.
NOTE: This is the slot nearest the IDFE Diagnostic LEDs.
NOTE: Only the Power and Heartbeat LEDs will energize when a Token Ring PWBA
is installed.
Initial Actions
Ensure that the Token Ring PWB is correctly seated.
Ensure that the hardware connections are good between the IOT and IDFE.
Ensure that the 8 PIN Interface Connector is correctly seated in the Token Ring PWB
and is not damaged.
Procedure
Ensure that the twisted pair cable is good (RJ45)
Ensure that the port on the MAU or wall drop is good.
Go to GP 12 Printing Configuration Reports, and print a Configuration Report. Check the

Configuration Report for the speed of the Token Ring connection and verify that the Token
Ring Interface is enabled.
1.
Review the information collected in Initial Actions.
2.
Ensure that the Token Ring PWB is plugged into Connectors J3 and J4 of the SCAN IIT
PWBA (PL 19.1).
NOTE: To be enabled, the Token Ring PWBA must be installed and connected to an
active Token Ring by use of a MAU. This can be confirmed by reading the Configuration Report to determine if the Token Ring is enabled.
NOTE: This is the slot nearest the IDFE Diagnostic LEDs.
NOTE: Source routed packets with route lengths greater than two bytes could be
dropped when packets are transmitted using IP or IPX protocols across a customers combination bridge/router. Installation of maintenance release v1.1 software
solves this problem.
NOTE: Only the Power and Heartbeat LEDs will energize when a Token Ring PWBA is
installed.
3.
Verify that the Token Ring drivers were loaded correctly.

NOTE: If the Token Ring PWB is enabled and operating correctly on the network, printed
on Configuration Report will be the MAC address for the PWB:
2.
Example: MAC Address=80:99:09:E4:A7:55
NOTE: If the Token Ring PWB is enabled, but cannot operate on the network, printed on
the configuration report will be a MAC Address:
Ensure that maintenance release v1.1 or later software is installed.
Token Ring hardware not found or installed is a generic message and can be a result of:
a bad connection to the network
a defective Token Ring PWB
an address conflict with the Token Ring PWB

NOTE: For TCP/IP, ensure that there is not a duplicate IP address on the customers
network.
Example: MAC Address=00:00:00:00:00:00
4.
Verify that the Token Ring PWB is operating correctly on the network.
the Token Ring PWB cannot sense the speed of the Token Ring Network
5.
Verify that the Token Ring line speed agrees with that reported by the Configuration
Report, the Web browser client, and the XCMI settings.
the Novell File Servers are not referenced to on the network
6.
7.
If the Token Ring line speed does not agree with the Configuration Report, the Web
Browser and the XCMI settings, replace the Token Ring PWB (REP 19.2).
8.
If the Token Ring PWB still does not operate correctly, replace the IDFE (PL 19.1).
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19-015 Token Ring Speed Detection Fault RAP, 19-
19-015 Token Ring Speed Detection Fault RAP, 19-
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3 Image Quality
Image Quality RAPs
Introduction .....................................................................................................................
IQ 1 Image Quality Troubleshooting Entry RAP..............................................................
IQ Isolation RAP..............................................................................................................
IQ 2 Defect Listing...........................................................................................................
Defect Description...........................................................................................................
IQ 3 Geometric RAP .......................................................................................................
IQ 4 Developer Checkout Procedure ..............................................................................
IQ 5 Xerographic Subsystem Checkout Procedure ........................................................
IQ6 IIT Checkout Procedure ...........................................................................................
IQ 7 IDFE / Network Checkout Procedure ......................................................................
IQ 8 Residual Image RAP ...............................................................................................
IQ 9 Uneven Density RAP...............................................................................................
IQ 10 Low Image Density RAP .......................................................................................
IQ 11 High Image Density RAP.......................................................................................
IQ 12 Bands, Lines, Smears, or Streaks RAP ................................................................
IQ 13 White, Black or Colored Spots RAP ......................................................................
IQ 14 IOT Solid Black (or Color) Copy RAP....................................................................
IQ 15 Background RAP...................................................................................................
IQ 16 Blank (or Nearly Blank) Copy RAP........................................................................
IQ 17 Deletions RAP .......................................................................................................
IQ 18 IOT Missing Colors RAP .......................................................................................
IQ 19 Bead Carryout RAP...............................................................................................
IQ 20 IOT Graininess RAP ..............................................................................................
IQ 21 Blurred or Fuzzy Image RAP.................................................................................
IQ 22 Mottle RAP ............................................................................................................
IQ 23 Poor Color Balance RAP .......................................................................................
IQ 24 Back Side or Side Two Copy Contamination RAP ................................................
IQ 25 Hollow Character RAP ..........................................................................................
IQ 26 Low Contrast Reproduction RAP ..........................................................................
IQ 27 Color-to-Color Misregistration RAP .......................................................................
IQ 28 Moire RAP .............................................................................................................
IQ 29 Newton Rings RAP................................................................................................
IQ 30 Fuser Offsetting RAP ............................................................................................
IQ 31 Fuser Oil Streak RAP ............................................................................................
IQ 32 ROS Borders RAP.................................................................................................
IQ 33 Solid Area Reproduction RAP ...............................................................................
IQ 34 Text / Image Separation RAP................................................................................
IQ 35 Toner Starvation RAP ...........................................................................................
IQ 36 Unfused Copy RAP ...............................................................................................
IQ 37 Developer Bias HVPS RAP ...................................................................................
IQ 38 Charge Corotron HVPS RAP ................................................................................
IQ 39 Preclean Corotron HVPS RAP ..............................................................................
IQ 40 2nd BTR HVPS RAP .............................................................................................
IQ 41 1st BTR HVPS RAP ..............................................................................................
IQ 42 DTS HVPS RAP ....................................................................................................
IQ 43 Paper Feed Checkout Procedure..........................................................................
Reissue
DocuColor 12/DCCS50
IQ 44 Registration Checkout Procedure..........................................................................

IQ 45 Wrinkle RAP ..........................................................................................................
IQ 46 Black Bead Carryout RAP .....................................................................................
IQ 47 ATC Sensor RAP...................................................................................................
3-3
3-3
3-4
3-5
3-7
3-9
3-10
3-11
3-12
3-13
3-13
3-14
3-15
3-16
3-16
3-18
3-19
3-19
3-20
3-21
3-23
3-23
3-25
3-26
3-26
3-27
3-28
3-28
3-29
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3-30
3-30
3-31
3-32
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3-37
3-38
3-39
3-40
3-40
3-41
3-41
3-42
3-43
Image Quality Specifications

Image Quality Specifications ...........................................................................................
3-47
Image Quality Defects

Image Quality Defects .....................................................................................................
1/05
3-1
3-49
Image Quality
Image Quality
1/05
3-2
Reissue
DocuColor 12/DCCS50
Introduction
IQ 1 Image Quality Troubleshooting Entry RAP
The Image Quality Raps Section contains all the Raps used in troubleshooting image quality
problems.
Image Quality Troubleshooting Entry RAP. This RAP is used to determine the proper course of
action for troubleshooting an image quality defect.
NOTE: When this procedure refers you to an Image Quality Defect Sample, or the Image Quality Specification, go to the appropriate Hard Copy Image Quality Supplement.
Initial Actions
Clean the Document Glass.
Clean the Lens and Mirrors.
Clean/Vacuum all Paper path areas.
Check the output copy to ensure that it is on the correct substrate size and orientation as
the original. If it is not, go to the Paper Size Sensing RAP in Section 2. If it is OK, continue
with this RAP.
Procedure
1.
If the problem is Misregistration, Skew or Magnification related, go to the IQ 3 Geometric

RAP.
2.
Compare the defect on the copy to the defects listed below. These defects are normal
for this product and require additional countermeasures. Go to the procedure indicated for
remedial activities that minimize the effects of these defects.
Table 1 DEFECTS THAT REQUIRE ADDITIONAL COUNTERMEASURES
Reissue
DocuColor 12/DCCS50
1/05
3-3
Bead Carryout (BCO)
Description - Developer beads that are electrostatically

attracted to the copy or print during the transfer process on
this product look like Mottle or low density. BCO is most
noticeable in high density areas and usually does not affect all
four colors at the same time.
IQ 19 Bead Carryout RAP
IQ 47 ATC Sensor RAP
Fuser Oil Streaks
Description - Process direction streaks that show up first on

transparencies or coated paper as low gloss streaks in solid
areas. In severe cases, oil streaks can show up on paper as
low density streaks in large half tone areas.
IQ 31 Fuser Oil Streak RAP
Moire
Description - Patterns on the image areas of the output copy

or print that have the appearance of a screen or grid overlaying the image. It may be uniform or nonuniform in area or
shape.
IQ 28 Moire RAP
Image Quality
Introduction, IQ 1 Image Quality Troubleshooting
IQ Isolation RAP
Table 1 DEFECTS THAT REQUIRE ADDITIONAL COUNTERMEASURES

Text Image Separation/Mosaic Description - (Mosaic): An image defect that can affect fine
line ladders or low screen halftones. It causes closely spaced
lines, low frequency halftones, and certain texts to have a
blotchy appearance.
Description - Vacant Characters: An image defect that
results when the center of a character is filled-in with a (200R)
halftone screen while its outer border is made up of a (600L)
text screen. (Note: This level of detail is best observed with an
eye loop.)
Description - Small Dark Dots on Text: An image defect that
causes a localized area of a character in a text to look like it
contains small dark dots. (Note: This level of detail is best
observed with an eye loop.)
IQ 34 Text / Image Separation RAP
Three Color Toner Explosion
Description - Cyan toner particles surrounding black text and

lines run in three color mode.
IQ 21 Blurred or Fuzzy Image RAP
Toner Starvation
Description - This defect occurs at the transition point

between a high density area and a low density area of the
same color. A localized area of the mag brush becomes
starved for toner due to development fringe field effects.
Starvation tends to worsen at low triboelectric levels (high
toner concentration).
IQ 35 Toner Starvation RAP
3.
If you can identify the defect by name, go to the IQ 2 Defect Listing.
4.
If you are not sure what the defect is, or if you prefer, use the IQ Isolation RAP to isolate
your image quality problem.
Procedure
The defect occurs only in the Print Mode.
Y
N
The defect occurs only in the Copy Mode.
Y
N
The defect is present in both modes. Print test patterns 99, 101, and 103 from the
PWS. The defect is present
Y
N
Replace the VSEL Base TTL PWB (PL 9.2).
Go to the IQ 5 Xerographic Subsystem Checkout Procedure.
Print test patterns 22, 23, and 30 from the PWS. The defect is present.
Y
N
Print test patterns 20 and 21 from the PWS. The defect is present.
Y
N
Print test patterns 1 through 10, 13, 17, and 53 from the PWS. The defect is
present.
Y
N
Clean the optics (refer to Cleaning Procedures in Service Call Procedures).
Reprint test patterns 1 through 10, 13, 17, and 53 from the PWS. The
defect is present.
Y
N
Go to Final Actions in Service Call Procedures.
Replace the CCD PWB (PL 3.2).
Replace the Pre-IPS PWB (PL 3.5).
Replace the Post-IPS PWB (PL 3.5).
Place the Color Test Pattern on the glass Select Photo Mode. Make a copy. The
present.
Y
N
Replace the following as required:
defect
VSEL Base TTL PWB (PL 9.2).
VSEL Extension PWB (PL 9.2).
If the machine is a DCCS50, go to the IQ 7 IDFE / Network Checkout Procedure.
If the machine is a DC12 with DFE, check the DFE and DFE cables.
is
Print test patterns 99, 101, and 103 from the PWS. The defect is present.
Y
N
Replace the VSEL Base TTL PWB (PL 9.2).
Image Quality
IQ 1 Image Quality Troubleshooting Entry RAP, IQ
1/05
3-4
Reissue
DocuColor 12/DCCS50
IQ 2 Defect Listing
Contamination, Back Side of Copy or Side 2 of Copy
Background
Contamination (Back Side or Side 2 of Copy) (Description/Specification)
Background (Description/Specification)
IQ 24 Back Side or Side Two Copy Contamination RAP
Cyan (or Other Colors) - Defect Samples 26
High Monochrome - Defect Sample 11
Deletions
High 4-Color - Defect Sample 10
Deletions (Description/Specification)
IQ 15 Background RAP
Bands, Lines, Smears, or Streaks
Debris-Centered - Defect Sample 19
Nonuniform Streak (Process Direction) - Defect Sample 8
IQ 17 Deletions RAP
Bands, Lines, Smears or Streaks (Description/Specification)
ADC Patch Printout or Band - Defect Sample 27
Density
High Frequency (Black or Colored) - Defect Sample 6
Density (Description/Specification)
Periodic - Defect Sample 9
Rainbow - Defect Sample 23
Line ,Single White (Process Direction) - Defect Sample 22
Color Streaks (Process Direction) - Defect Sample 21
IQ 19 Bead Carryout RAP.

IQ 47 ATC Sensor RAP.
Highlight (Low or High) - Defect Sample 4
Uneven (Process Direction) - Defect Sample 20
Uneven (Perpendicular to Process Direction) - Defect Sample 7
Image (Low) - Defect Sample 3
Image (High)
IQ 12 Bands, Lines, Smears, or Streaks RAP
IQ 26 Low Contrast Reproduction RAP
Bead Carryout
IQ 9 Uneven Density RAP
Bead Carryout (BCO) (Description/Specification)
Bead Carryout - Defect Sample 10
Mottle-like Bead Carryout - Defect Sample 28
Mottle-like, Low Density Only in High Density Areas - Defect Sample 28
IQ 19 Bead Carryout RAP.
IQ 10 Low Image Density RAP
Blank (or Nearly Blank) Copy
IQ 11 High Image Density RAP
Blank Copy (Description/Specification)
Fuser Oil Streaks
IQ 16 Blank (or Nearly Blank) Copy RAP
Fuser Oil Streaks (Description/Specification)
Solid Black (or Color) Copy
Black (or Color), Solid (Description/Specification)
Graininess
IQ 14 IOT Solid Black (or Color) Copy RAP
Graininess (Description/Specification)
Blurred or Fuzzy Image
IQ 20 IOT Graininess RAP
Blurred or Fuzzy Image (Description/Specification)
Hollow Characters
Blur / Toner Explosion - Defect Sample 18
Hollow Characters (Description/Specification)
Color Balance
IQ 25 Hollow Character RAP
Poor Color Balance (Description/Specification)
Low Contrast Reproduction

Low Contrast Reproduction (Description/Specification)
IQ 23 Poor Color Balance RAP
Reissue
DocuColor 12/DCCS50
1/05
3-5
Image Quality
IQ 2 Defect Listing
Misregistration (Color-to-Color)
IQ 32 ROS Borders RAP
Misregistration (Color-to-Color) (Description/Specification)
Process Direction - Defect Sample 1
Perpendicular to Process Direction - Defect Sample 2
Spots
Spots (Description/Specification)
IQ 27 Color-to-Color Misregistration RAP
Barcode Marks (or Spots) - Defect Sample 25
Periodic
Misregistration (System)
Random White, Black or Colored
Misregistration (System) (Description/Specification)
IQ 13 White, Black or Colored Spots RAP
Side Edge
Top Edge
Skew
Solid Area Reproduction

Solid Area Reproduction (Description/Specification)
IQ 3 Geometric RAP
IQ 33 Solid Area Reproduction RAP
Missing Colors
Text / Image Separation Errors
Missing Color(s) (Description/Specification)
Text / Image Separation Errors (Description/Specification)
IQ 18 IOT Missing Colors RAP
Mosaic - Defect Sample 14
Vacant Characters - Defect Sample 15
Moire
Small Dark Dots on Text - Defect Sample 16
Moire (Description/Specification) - Defect Sample 12
IQ 28 Moire RAP
Toner Starvation
Toner Starvation (Description/Specification) - Defect Sample 13
Mottle
Mottle (Description/Specification) - Defect Sample 5
IQ 22 Mottle RAP
Unfused Copy
Unfused Copy (Description/Specification)
Newton Rings
Newton Rings (Description/Specification) - Defect Sample 17
IQ 36 Unfused Copy RAP
IQ 29 Newton Rings RAP
Wrinkled Copy
Wrinkled Copy (Description/Specification)
Offsetting, Fuser
IQ 45 Wrinkle RAP
Offsetting, Fuser (Description/Specification)

IQ 30 Fuser Offsetting RAP
Residual Image
Residual Image (Description/Specification) - Defect Sample 24
ADC Patch Printout - Defect Sample 27
IQ 8 Residual Image RAP
ROS Borders
ROS Borders (Description/Specification)
Image Quality
IQ 2 Defect Listing
1/05
3-6
Reissue
DocuColor 12/DCCS50
Defect Description
NOTE: None of the image from the original is visible in the copy or print.
Background
Bead Carryout (BCO)
Description - Cyan (or Other Colors): Low or medium density background usually of one color,
but possible in more than one color.
Description - Developer beads that are electrostatically attracted to the copy or print during
the transfer process on this product look like Mottle or low density. Bead Carryout is most
noticeable in high density areas and usually does not affect all four color at the same time.
Description - High Monochrome: High density background of a single color covering the entire
copy.
NOTE: Only the effect the carrier beads have on the image of the output copy/print are visible.
The beads are physically trapped by the fuser web and therefore will not be observed on the
copy/print.
Description - High 4-Color: High density background of all four colors covering the entire copy
and possibly accompanied by bead carry out.
Blank Copy
Description - General: Undesirable toner deposits on the copy or print. The toner deposits can
be localized or may cover the entire copy or print. Depending on the density of the background,
it is referred to as low, medium, high, or very high background. It may occur in all colors, single
colors, or any combination of single colors.
Description - Absolutely no toner developed onto the copy or print. This defect should not be
confused with extremely low image density, where some development actually occurs.
Blurred or Fuzzy Image

Description - Images that are not clear, or appear out of focus.
Specification - No background is allowed.
Color Balance, Poor
Bands, Lines, Smears or Streaks
Description - Colored areas of the copy that exhibit a change in hue, as opposed to a change
in density. This is most often judged in the gray areas of the copy or print. Theoretically, a true
gray can be produced with equal amounts of magenta, yellow and cyan toner. Therefore, a
common example of poor color balance is a gray image that is reproduced with slightly more of
one of those color toners. The result is a gray that appears to have a magenta, yellow or cyan
hue, rather than true gray.
Description - ADC Patch Printout or Band: A residual image of one or more of the ADC
patches that runs in the process direction.
Description - High Frequency Bands: A 1.2 mm interval band that is most noticeable in low
density (e.g., 20 -30%) halftone areas of the copy and runs perpendicular to process direction.
Description - Periodic Bands: An interval band that ranges between 14 to 264 mm; is most
noticeable in low density (e.g., 20 -30%) halftone areas of the copy; and runs perpendicular to
process direction.
Contamination (Back Side or Side 2 of Copy)

Description - Toner deposit on the back side of a copy or on the second side of a two-sided
copy.
Description - Rainbow Bands: Narrow bands of color most noticeable in low density (e.g., 20 30%) halftone areas of the copy that run in the process direction.
Deletions
Description - Debris-Centered: Deletions in the areas surrounding Toner agglomerates.
Description - Color Smears: The image appears to have been disturbed (spread out, wiped, or
rubbed), usually in the process direction before the image was fused.
Description - Nonuniform Streak: A deletion in the form of a single streak that runs from the
lead edge to the trail edge of the copy.
Description - Color Streaks: Usually medium-width streaks of (or shifts in) color most noticeable in low density (e.g., 20 -30%) halftone areas of the copy that run in the process direction.
Description - General: The undesirable absence of toner from the copy or print. This defect
can show as white, light, or untrue colored areas on the copy or print. The most common
example is a deletion caused by the tentingof paper from mishandling or moisture, or by
dents or defects in the IBT.
Description - General: The absence or low density of toner in desired image areas, or the
presence of toner in undesired areas in the shape of a line, streak or band. Bands are widths
greater than 0.5 mm. Lines and bands are generally uniform in shape from one end to the
other, and can run in any direction on the copy or print. Lines are defined as measuring less
than 0.5 mm in width: Streaks are generally shorter than lines and are of nonuniform width
along their length. They may have a more ragged or fuzzy appearance than lines, and can run
in any direction on the copy or print.
Specification - The Pattern 82 ROS Half Tone should not show the defect
Density
Description - Mottle-like, Low Density Only in High Density Areas: Developer beads that are
electrostatically attracted to the copy or print during the transfer process on this product look
like Mottle or low density. This defect is most noticeable in high density areas and usually does
not affect all four color at the same time.
Black (or Color), Solid

Description - An image that is reproduced as solid black (or color) from lead edge to trail edge
and from front to rear. The ROS Border may or may not be visible.
Description - Highlight (Low or High): Development of a single color is out-of-specification.

Reissue
DocuColor 12/DCCS50
1/05
3-7
Image Quality
Specification - Highlight: Color Test Pattern; the 10% patches should be visible and the 5%
patches should be barely visible or not visible on the test pattern copy (except for the bottom
row).
Misregistration (System)
Description - Line: The inability to adequately reproduce a text that has low line density.
Specification
Description - The alignment of the image to the edges of the copy paper. It is defined by lead
and side edge registration, and lead and side edge skew.
Specification - Line: Using Test Pattern 82E8220, the copier should reproduce all of the text in
the block.
Description - Low Density: A condition that results when too little toner of a single color or
combination of colors is developed on the copy or print. This results in lighter copies or prints
for the single-color toner or the color that results from the combination of color toners.
Lead Edge Registration: +1.6 mm (Trays 1 - 4), +2.2 mm (Tray 5)
Side Edge Registration: +2.1 mm (Trays 1 - 4), +3.0 mm (Tray 5)
Lead Edge Skew: +1.6 mm (Trays 1 - 4), +2.0 mm (Tray 5)
Side Edge Skew: +2.4 mm (Trays 1 - 4), +3.0 mm (Tray 5)
Missing Color(s)
Description - The loss of one or more of the color toners from the output copy or print.
Depending on the original, this can result in missing areas of the image, or changes in the color
balance of the copy or print.
Description - High Density: A condition that results when too much toner of a single color or
combination of colors is developed on the copy or print. This results in darker copies or prints
for the single color toner or the color that results from the combination of colors.
Moire
Description - Uneven Density: The uneven development of toner on the copy or print from one
area to another. Typically, this results in change in density from front to rear and sometimes
from lead edge to trail edge.
Description - Patterns on the image areas of the output copy or print that have the appearance of a screen or grid overlaying the image. It may be uniform or nonuniform in area or
shape.
Specification - Uneven Density: The density of both the low density and high density bands
(located near the lead edge of the Color Test Pattern) should be uniform from front to rear.
Mottle
Description - Solid area, high density image areas that are reproduced with a surface that
resembles marble.
Fuser Oil Streaks

Description - Process direction streaks that show up first on transparencies or coated paper
as low gloss streaks in solid areas. In severe cases, Oil Streaks can show up on paper as low
density streaks in large half tone areas.
Newton Rings
Description - Repetitive, irregular-shaped marks that occur when making copies of glossy
photographs. These marks are most noticeable in large low-density or highlight areas.
Graininess
Offsetting, Fuser
Description - An image defect that causes solid areas to have a sandy appearance. Graininess is most noticeable in middle density solid areas.
Description - The removal of toner from the copy by the fuser and the subsequent redeposition of that toner on another area of the same or other another copy. Removing toner from the
image leaves the image rough and without gloss. The redeposited toner may appear as a
duplicate image, partially shifted image, or lines and streaks.
Hollow Characters
Description - Small circular-shaped deletions within a character that can occur when the
image density is low or a transparency is used.
Residual Image
Description - A toner image that remains on the photoreceptor or IBT after cleaning. The next
image is place on top of the residual image and both images are transferred to the next copy.
Line, Single White (Process Direction)

Description - A narrow white line that runs from lead edge to trail edge across the entire copy.
ROS Borders
Low Contrast Reproduction

Description - The inability to adequately reproduce a low contrast image.
Description - Intentional lead edge, side edges, and trail edge deletions that make a border on
the copy paper.
Specification - Using Test Pattern 82E8220, the copier should reproduce all of the text in the
0.2 G paragraphs.
Specification
Misregistration (Color-to-Color)
Side Edges: 3 mm +1.0 mm (All Trays)
Trail Edge: 3 mm +1.0 mm (All Trays)
Description - Multi-colored images that are not superimposed and should be. This can occur
in the process direction or perpendicular to process direction.
Image Quality
1/05
3-8
Lead Edge: 5 mm +1.0 mm (All Trays)
Reissue
DocuColor 12/DCCS50
Spots
IQ 3 Geometric RAP
Description - Barcode Marks (or Spots): An image defect that has the appearance of a small
barcode symbol that is read by a barcode scanner. The marks usually appear in a group of
four, and each mark is a different primary color arranged in the sequence -- yellow, magenta,
cyan, and black.
This RAP is used when Skew, Registration, or Magnification are out of spec.
Initial Actions
NOTE: (W/Tag P39): Misuse of the Expanded Imageable Area feature will cause registration
problems when printing on oversize paper (12 x 18 inch / SR-A3). This feature is available for
DC12 machines only, and requires specific IOT and DFE software and hardware levels. Refer
to GP 2 Increased Imageable Area Setup for details.
Description - All Other Spots: Generally circular in shape, these defects can be caused by an
absence of toner in a desired area, or a deposit of toner in an undesired area.
Solid Area Reproduction
Activating this feature on a machine not listed in GP2 will result in an image shift of 0.5 inch (12
mm) or more toward the lead edge of the print when printing on oversize paper. On 12 x 18
inch paper, part of the interimage patch may be visible in the lower left corner of the print.
Description - The inability to adequately reproduce a high-density solid area.

Specification - Using Test Pattern 82E8220, the copier should reproduce the 1.0K blocks with
minimal mottle or graininess.
If this defect is observed, check that NVM locations 720-360 and 720-361 = 0.
This feature can be activated by the customer, using the TOOLS mode. If this has occurred,
inform the customer of the limitations and requirements of this feature.
Text / Image Separation Errors
NOTE: For DCCS50: Check that NVM locations 720-360 and 720-361 = 0.
Description - (Mosaic): An image defect that can affect fine line ladders or low screen halftones. It causes closely spaced lines, low frequency halftones, and certain texts to have a
blotchy appearance.
Load some new, dry 24 lb 11X17/A3 Xerox COLOR Xpressions (NASG), or 90 GSM Colortech
+ (ESG) into each paper tray (use 8.5X11/A4 in Tray 1). Make 3 full color copies from each
paper tray. Mark the appropriate paper tray on these copies.
Description - Vacant Characters: An image defect that results when the center of a character
is filled-in with a (200R) halftone screen while its outer border is made up of a (600L) text
screen. (Note: This level of detail is best observed with an eye loop.)
Procedure
The problem is still present when using the proper paper.
Y
N
Explain to the customer that new, dry, 24 lb. Xerox COLOR Xpressions (NASG), or 90
GSM Colortech + (ESG) paper is the specified paper for use in the DocuColor 12 copier.
Description - Small Dark Dots on Text: An image defect that causes a localized area of a character in a text to look like it contains small dark dots. (Note: This level of detail is best observed
with an eye loop.)
The Problem occurs only in the Printer Mode

Y
N
The defect occurs when the document is manually registered on the platen glass.
Y
N
Ensure that the Document Transport Belt is clean. Go to the Document Handler
Adjustment Procedures ADJ 12.1.1 through ADJ 12.4.1. If the problem continues,
check the DADF drive rolls and pinch rolls for wear or glossing.
Toner Starvation
Description - This defect occurs at the transition point between a high density area and a low
density area of the same color. A localized area of the mag brush becomes starved for toner
due to development fringe field effects. Starvation tends to worsen at low triboelectric levels
(high toner concentration).
Unfused Copy
The Problem is Skew

Y
N
The Problem is MIsregistration
Y
N
Perform ADJ 9.1.16 IIT Horizontal Magnification/Vertical Magnification (IIT
Machine) Adjustment and ADJ 9.1.10 Side/Lead Edge Registration (dC129:
System Registration).
Description - The toner on the copy wipes off easily when moderate pressure is applied.
Wrinkled Copy
Description - Creasing or folds on the copy/print in the lead to trail edge direction or closely
spaced waves in the front to rear direction.
Select Pattern IOT #2 Black on the UI or Pattern # 84 Black on the PWS. Misregistration is present on the copy
Y
N
Perform ADJ 9.1.10 Side/Lead Edge Registration (dC129: System Registration) and ADJ 9.1.15 Side Registration.
The defect occurred on copies from all five paper trays.
A
Reissue
DocuColor 12/DCCS50
1/05
3-9
B
Image Quality
IQ 3 Geometric RAP
B
Y
IQ 4 Developer Checkout Procedure
N
Go to the Paper Feeder Checkout Procedure
The problem is with Lead Edge Registration

Y
N
The problem is with color to color misregistration.
Y
N
Go to ADJ 9.1.10, Lead/Side Edge Adjustment
Initial Actions
Ensure that the toner supply system is functioning properly and there is sufficient toner of each
color.
Procedure
Go to the Color to Color Misregistration Checkout Procedure.
Go to the IQ 37 Developer Bias HVPS RAP. If the Developer Bias HVPS is good, replace the
developer material for the faulty color. If the problem continues, replace the Developer Housing
for the faulty color.
Registration varies from copy to copy.

Y
N
Go to ADJ 9.1.10, Lead/Side Edge Adjustment.
NOTE: After replacing developer material, go to IQ47 ATC Sensor RAP, Appendix 1. ATC setup procedure
Go to the Registration Checkout Procedure.

The defect occurred on copies from all five paper trays.
Y
N
Go to the IQ 43 Paper Feed Checkout Procedure.
Go to the IQ 44 Registration Checkout Procedure.
Go to the IQ 7 IDFE / Network Checkout Procedure.
Image Quality
IQ 3 Geometric RAP, IQ 4 Developer Checkout Proce-
1/05
3-10
Reissue
DocuColor 12/DCCS50
This procedure is used to isolate Image Quality faults in the Xerographic Subsystem.
Initial Actions
If the problem is density or background related, Perform ADJ 9.1.1 Max Setup. If Max Setup
does not complete successfully, use the Fault Codes that are declared to troubleshoot the
problem.
N
The problem is in the IBT, the 2nd BTR, or the Fuser. Repeat the Xerographic Hard Stop
procedure. This time, wait until the paper is on the Vacuum Transport before removing the
interlock cheater. The defect is present on the copy that is on the Vacuum Transport.
Y
N
The problem is in the Fuser. Disassemble the fuser and carefully inspect the following parts for damage or toner buildup.
Pressure Roll (PL 8.3)
Heat Roll Stripper Fingers (PL 8.3)
Procedure
Heat Rolls (PL 8.3)
Perform the following Xerographic Hard Stop Procedure:

1. Remove the Paper Handling Module Cover
Cleaning Roll (PL 8.5)
Web CRU (Machine Consumables)
2.
Make sure that the IBT Handle is up.
3.
Cheat the Front Door Interlock.
4.
Use the Test Pattern that displays the fault.
5.
Press Start.
6.
Watch the Registration Drive Gear (Figure 1).
Go to the IQ 40 2nd BTR HVPS RAP. If the 2nd BTR Power Supply is good, replace the
2nd BTR (PL 9.2). If the problem continues, replace the IBT Belt (PL 7.5).
Repeat the Hard Stop procedure. The defect is present on the Photoreceptor Drum.
Y
N
The problem is in the 2nd BTR or the IBT. Complete the steps below until the problem is
resolved
If the image defect looks like an ADC Patch Printout (see Defect Sample 27), check
for the cause(s) of an IBT cleaning problem.
Go to the IQ 40 2nd BTR HVPS RAP.
If the 2nd BTR Power Supply is OK, replace the 2nd BTR (PL 9.2).
If the problem continues replace the IBT Belt (PL 7.6).
WARNING
Electrocution Hazard! Do not disconnect the red lead labeled C (Charge Supply Wire).
This wire carries over 8000VDC.
Check the voltage from P/J82-1 on the CC/PCC HVPS to frame ground during a copy cycle.
The voltage is between +650 VDC and +750 VDC.
Y
N
Check the photoreceptor, the corotron wire, and the corotron grid for defects or damage.
Replace if required (Machine Consumables). If the problem continues, go to the IQ 38
Charge Corotron HVPS RAP.
Registration
Drive Gear
Check the voltage from P/J422A-7 to frame ground during a copy cycle. The
voltage
between +3.25 VDC and +3.75 VDC.
Y
N
There is 24 VDC from P/J141-1 to P/J141-4 on the ESV Sensor.
Y
N
There is 24 VDC from P/J422B-5 to P/J422B-13 on the IOT Drive PWB.
Y
N
There is 24 VDC from P/J411-6 to P/J411-7 on the IOT Drive PWB.
Y
N
Figure 1 Registration Drive Gear

7.
When the gear starts to rotate, remove the interlock cheater.
8.
Extend the Paper Handling Drawer.
9.
Remove the two screws that secure the IBT Front Frame and turn IBT handle down.
10. Extend the IBT Drawer to the service position.

Observe the Image on the IBT. The defect is present on the IBT.

A
Reissue
DocuColor 12/DCCS50
is
1/05
3-11
C
Image Quality
C
Go to Flag 7 on BSD 9.1 and check for an open circuit or a short circuit to ground.
IQ6 IIT Checkout Procedure

This procedure is used when directed here by the IQ1 IQ Isolation Procedure
Go to Flag 6 on BSD 9.1 and check for an open circuit or a short circuit to ground. If the
wire is OK, replace the ESV Sensor (PL 5.1).
Initial Actions
Check the output of the Developer Bias HVPS, as follows:
Clean the following parts before proceeding
Document Glass
Connect the DMM (+) lead to the developer bias terminal the attaches to the front side of
the developer housing.
Document Transport Belt
Mirrors
Cheat the Front Door Interlock
Exposure Lamp
Connect the DMM (-) lead to the machine frame.
White Reference Strip
Set the DMM to the 1000 VDC range.
Switch on the power.
Procedure
Enter dC 330 [009-076].Press Start.
Run IIT Test Print #1 The Defect is present.

Y
N
Enter DC330 [9-002],Exposure Lamp. Press Start. The Exposure Lamp comes on.
Y
N
Go to 6-371 Exposure Lamp Fail RAP.
There is a steady voltage of approximately -550 VDC present.

Y
N
Go to the IQ 37 Developer Bias HVPS RAP.
Set the DMM to measure 1000 VAC. Enter dC 330 [009-077]. Press Start. There is a steady
voltage of approximately 415 VAC present.
Y
N
Go to the IQ 37 Developer Bias HVPS RAP.
The light from the Lamp is even from end to end, and there are no dark spots.
Y
N
Replace the Exposure Lamp (PL 3.4).
Replace the Half Tone PWB (PL 9.2). If the problem remains, replace the ROS Assembly (PL
4.1).
Replace the CCD PWB (PL 3.2).

Run IIT Test Print #28 The Defect is present.
Y
N
Image Quality
IQ 5 Xerographic Subsystem Checkout Procedure,
1/05
3-12
Reissue
DocuColor 12/DCCS50
IQ 7 IDFE / Network Checkout Procedure
IQ 8 Residual Image RAP
IDFE / Network Checkout. This RAP is used when the image quality problem only occurs in the
Printer Mode and can help isolate the source of the problem to either the IDFE or the Network.
Residual Image RAP. This RAP is used when the copier exhibits ghost images on the output
copy.
Procedure
Procedure
With the aid of the customer or administrator, access the Document Centre Color Series 50
home page. Select the Maintenance tab on the Home page. Next, select the QuickCal radio
button at the top of the Maintenance page. To check the printers current color printing state,
select Color Chart from the Chart pull-down menu and print it. The image quality problem is
present on the Color Chart.
Y
N
This indicates that the problem is Network-related.
Remove the Drum CRU Assembly. Cheat the Front Door Interlock. Enter dC330 [9-050] and
press the Start button.
NOTE: After removing the Drum CRU, cover the CRU with the black bag that is stored in Tray
1.
The Erase Lamp lights.
Y
N
Press the Stop button. There is +5 VDC between P/J418A-2 and on the IOT PWB
and GND.
Y
N
There is +5 VDC between P/J418A-1 and GND.
Y
N
Reload the IDFE System Software. If the problem continues, replace the IDFE.
Go to Flag 1 on BSD and check the harness for an open circuit. If the circuit is OK,
replace the Erase Lamp (PL 5.1).
Enter dC330 [9-050] and press the Start button. Less than +1 VDC is measured
between P/J418B-2 and DC Com on the IOT Drive PWB
Y
N
Replace the Erase Lamp (PL 5.1).
Go to the IQ 39 Preclean Corotron HVPS RAP. The Power Supply is good
Y
N
Replace the CC/PCC HVPS (PL 9.1).
1.
Remove the Paper Handling Module Cover
2.
3.
4.
5.
Press Start.
6.
7.
8.
9.

Y
N
The problem is in the 2nd BTR, or the Fuser. Perform the Xerographic Hard Stop again.
This time, wait until the paper is on the Vacuum Transport before removing the interlock
cheater. The defect is present on the copy that is on the Vacuum Transport.
A
Reissue
DocuColor 12/DCCS50
1/05
3-13
Image Quality
IQ 7 IDFE / Network Checkout Procedure, IQ 8 Re-
A
Y
N
The problem is in the Fuser. Disassembly the fuser and carefully inspect the following parts for damage or toner buildup.
Heat Rolls (PL 8.3)
Web CRU (Machine Consumables)
Initial Actions
Uneven Density RAP. This RAP is used when the IOT output image shows uneven density in
the inboard to outboard direction.
Go to the IQ 40 2nd BTR HVPS RAP. If the 2nd BTR Power Supply is good, inspect/
replace the 2nd BTR (PL 9.2).
The problem is in the Xerographic Module, the 1st BTR, or the IBT Belt. Complete the steps
below until the problem is resolved
Check the IQ 41 1st BTR HVPS RAP
Replace the IBT Belt (PL 7.5)
Clean/replace the IBT Cleaning Blade (PL 7.8)
Replace the Drum CRU (Machine Consumables)
Ensure that all HFSI items that are near or over threshold have been replaced.
Ensure that IBT is positioned correctly in relation to the Copy/Print Cartridge (Xero Drum).
Check the Plate (PL 7.6) that supports the outboard end of the IBT Backup Roll for damage.
Procedure
Place the Color Test Pattern on the platen and make a print in Black, Yellow, Magenta and
Cyan. The defect is present in all four colors.
Y
N
Replace the developer material for the problem color.
NOTE: After replacing developer material, go to IQ47 ATC Sensor RAP, Appendix 1. ATC
set-up procedure.
If the problem is still present, replace the Developer Housing for the problem color (PL
6.6).
Run ADJ 9.1.1 Max Setup. The Setup runs successfully.
Y
N
Go to the RAP for the Fault Code indicated to troubleshoot the problem.
Xerographic Hard Stop Procedure
1.
Remove the Paper Handling Module Cover.
2.
3.
4.
5.
Press Start.
6.
7.
8.
9.

Y
N
The problem is in the Xerographic Module, the 1st BTR, or the ROS. Complete the steps below
until the problem is resolved
Image Quality
IQ 8 Residual Image RAP, IQ 9 Uneven Density RAP
1/05
3-14
Check the photoreceptor, the corotron wire, and the corotron grid for defects or damage. If
any component is questionable, replace the Drum CRU Machine Consumables.
Go to the IQ 41 1st BTR HVPS RAP. If the 1st BTR Power Supply is good, replace the 1st
BTR (PL 7.6).
Reissue
DocuColor 12/DCCS50
IQ 10 Low Image Density RAP
Replace the ROS (PL 4.1).
Low Image Density RAP. This RAP is used when the output image shows image density that is
lower than the specification.
Initial Actions
This problem can be caused by the following:
Low toner concentration.
Out of specification paper, especially low quality, or heavy weight paper.
Faulty IOT Drive PWB (PL 9.2).
Drum past end of life.
Developer past end of life. Check the HFSI counters for the Developers. Refer to Detailed
Maintenance Activities in Service Call Procedures.
Faulty ADC Sensor.
If Tag #14 is marked off, go to IQ 47 ATC Sensor RAP.
Replace the paper presently being used with new 24 lb. Xerox COLOR Xpressions (NASG), or
90 GSM Colortech + (ESG) paper and run test copies. If the images reproduced are still of low
density, continue with this RAP.
Registration
Drive Gear
Procedure
Clean the ADC Sensor and run ADJ 9.1.1, Max Setup. The Setup runs successfully.
Y
N
Reissue
DocuColor 12/DCCS50
1/05
3-15
Image Quality
IQ 9 Uneven Density RAP, IQ 10 Low Image Density
IQ 11 High Image Density RAP
IOT High Image Density RAP. This RAP is used when the output image shows image density
the is higher than the specification.
Bands, Lines, Smears, or Streaks RAP. This RAP is used when the output image shows bands,
lines, or streaks in the lead edge to trail edge, or the front to rear direction.
Initial Actions
Initial Actions
This problem can be caused by the following:
High toner concentration.
Faulty ADC Sensor.
Drum, Developer or Corotrons past end of life.
Faulty IOT PWB
If the machine has Tag 14, refer to the IQ 47 ATC Sensor RAP.
NOTE: If the image defect looks like an ADC Patch Printout (see Defect Sample 27), go to IQ
8 Residual Image RAP to begin troubleshooting.
NOTE: The table for Banding Intervals and Causes is referenced in the paragraph below. The
measurements cited in this table are based on copies made at 100% magnification.
Using the 150 mm scale, measure the position and interval of the defect. Refer to Banding
Intervals and Causes (Table 1), and Checks for Front-to-Rear Banding Causes (Table 2) of this
RAP to isolate the cause of the defect. If the cause of the defect is not found in the table, continue with this RAP.
Procedure
Clean the ADC Sensor and run ADJ 9.1.1 Max Setup. The Setup runs successfully.
Y
N
Procedure
The Xerographic Subsystems are in spec. Use Tools to set the desired density level if required.
2.
3.
Hard Stop Procedure

1. Remove the Paper Handling Module Cover
4.
5.
Press Start.
6.
7.
8.
9.
Remove the two screws that secure the IBT Front Frame and turn the IBT handle down.

Y
N
The problem is in the 2nd BTR, or the Fuser. Perform the Xerographic Hard Stop again.
This time, wait until the paper is on the Vacuum Transport before removing the interlock
cheater. There are Bands, Lines, Smears, or Streaks on the copies on the Vacuum
Transport.
Y
N
The problem is in the Fuser. Disassembly the fuser and carefully inspect the following parts for damage or toner buildup.
Fuser Pressure Roll
Fuser Heat Roll.
Fuser Cleaning Blade
Go to the IQ 40 2nd BTR HVPS RAP. If the 2nd BTR Power Supply is good, check the
2nd BTR contamination or damage. If contaminated, clean with lint free cloth. If damaged,
replace the 2nd BTR (PL 9.2). If the problem continues, replace the IBT Belt (PL 7.5).
Remove the IBT Cleaning Assembly. Check for damage on the IBT Cleaner Blade or the Film
Seal. The Cleaner Assembly is good.
Image Quality
IQ 11 High Image Density RAP, IQ 12 Bands, Lines,
1/05
3-16
Reissue
DocuColor 12/DCCS50
N
Replace the Cleaner Assembly (PL 7.1)
Table 2 Checks For Other Banding Causes.
Check the IBT Belt for scratches lines or band. The IBT Belt is good.
Y
N
Replace the IBT Belt (PL 7.5).
Problem to check for
Corrective Action
White deletion streak from

lead edge to trail edge
Check for trimmer gap blockage on developer mag rolls.
Poor Developer Bias Contact Clean/Replace the Bias

Brush (PL 6.1)
Choose IOT Test Pattern #11 from the UI, or Test Pattern # 99 from the PWS, and make a
black, yellow, magenta, and cyan print of the test pattern. The defect appears in all four colors.
Y
N
Replace the Developer for the problem color (PL 6.6). If the problem continues, replace
the Developer Housing (PL 6.6).
Check the photoreceptor, the corotron wire, and the corotron grid for defects or damage. If
any component is questionable, replace the Drum CRU (Machine Consumables).
Check the Erase Lamp for dark spots. If the lamp is questionable, Replace the Erase
Lamp (PL 5.1).
Clean the ROS of obstructions or contamination. If the problem continues, replace the
ROS (PL 4.1).
Table 1 Banding Intervals and Causes
Banding Interval in mm Component

0.51
ROS
1.02
ROS
6.6
Drum Motor (PL 1.1), Main Motor

(PL 1.2)
39.14
Gears associated with Mag Roll
40.84
Gears associated with Mag Roll
52.78
Gears associated with IBT Roll
105.77
IBT Drive Assy which includes

double-gear 22/64T (PL 1.1),
Drum Idler Gear (PL 1.1), and
IBT Drive Roll (PL 7.6)
Registration
Drive Gear
Table 2 Checks For Other Banding Causes.

Problem to check for
Corrective Action
Dirty Drum Gear
Clean the Drum Gear
Loose Drum Flange
Tighten Drum Flange
Dirty Corotron Wire/Corotron Clean with brush or replace

Grid
Drum CRU Machine Consumables
Streak on IBT
Hard stop to verify. Change

IBT Belt if defective
Streak on back side of copy.
Check 2nd BTR Roll for damage or contamination
Reissue
DocuColor 12/DCCS50
1/05
3-17
Image Quality
A
Inspect the IBT Belt for contamination, dents or flaws that would cause the defect. The
Belt has dents or flaws that caused the defect.
Y
N
Gently clean the IBT Belt with a soft lint free cloth

IOT White, Black or Colored Spots RAP. This RAP is used when the IOT output print has white,
black, or colored spots.
Initial Actions
NOTE: If the image defect appears as a white spot (or deletion) with a Toner agglomerate near
the middle of the spot (see Defect Sample 19), go to IQ 17 Deletions RAP and troubleshoot the
defect as a Debris-Centered Deletion.
NOTE: If the image defect has the appearance of a small barcode symbol that is read by a barcode scanner (see Defect Sample 25), replace the Drum CRU (Machine Consumables).
IBT
Check/clean or replace the IBT Cleaning Blade (PL 7.8)
Clean the 1st BTR (PL 7.6).
Clean the 2nd BTR (PL 7.9).
Remove the Drum. Check the Drum for damage or excessive contamination caused
by failed cleaning brush or blade, If damage or cleaning failure is present, replace
the Drum CRU (Machine Consumables).
Replace the IBT Belt (PL 7.5).
This failure can be caused by the following:
Developer Problems
Toner Dispense Problems
Failure in the Drum Cleaning system
Flaws on the Drum
Flaws on the IBT Film
Bead Carryout
Failure of the IBT Cleaning Blade
Clean the Document Glass.
Clean the Lens and Mirrors.
Clean/vacuum all Paper path areas.
Clean/ vacuum all related xerographic components.
Procedure
Y
N
There is Bead Carry out on the faulty print.
Y
N
Run 5 copies in each color of Test Pattern #11 UI or Test Pattern #99 PWS. Inspect
the samples for isolated defects in a specific color. Inspect the Developer Housing of
the problem color for leaks, spills, damage or flaws. The Developer Housing has
leaks, spills, damage or flaws.
Y
N
Replace the developer material for the faulty color (Machine Consumables).
Replace the Developer Housing for the faulty color (PL 6.6).
Perform ADJ 9.1.1 Max Setup. After Max Setup is completed, check the high density
areas of the output copies. If the high density areas are not dark enough, perform a manual tone up. Also, inspect the Developer Bias Brush for contamination or wear. Clean or
replace the Brush (PL 6.1) (REP 6.1.4) as required.
A
Image Quality
1/05
3-18
Reissue
DocuColor 12/DCCS50
IQ 14 IOT Solid Black (or Color) Copy RAP
IQ 15 Background RAP
IOT Solid Black Copy RAP. This RAP is used when the copy is solid black with no original document image seen in the copy.
IOT RAP. This RAP is used when the output image shows background greater than the specification.
Initial Actions
NOTE: After replacing developer material, go to IQ47 ATC Sensor RAP, Appendix 1. ATC setup procedure.
Because the ROS exposes the areas of drum that will receive toner, or writes the four colors,
this failure can be caused by the following in order of probability:
Failure to charge the drum. Caused by faulty Charge Corotron, IOT PWB, or PTC and CC
HVPS.
Failure of the Developer Bias power Supply.
Overexposure of the Drum. Caused by faulty IOT PWB, or ROS Assembly.
Procedure
Run IOT Test Pattern #9 from UI, or Test Pattern #102 from PWS in 4 color mode. Background is present.
Y
N
Perform ADJ 9.1.2.
Both of these failures will cause the output copy to be completely black, with no image visible from the original document.
Perform ADJ 9.1.1 Max Setup. Max setup completed successfully.

Y
N
Go to the RAP for the Fault Code indicated to troubleshoot the problem
Mispositioned mirror or lens
Background is present.
Y
N
Go to Final Actions.
Procedure
Go to the IQ 37 Developer Bias HVPS RAP. If the Developer Power Supply is good, go to the
IQ 38 Charge Corotron HVPS RAP. If the Charge Corotron Power Supply is good, replace the
Drum CRU (Machine Consumables). If the problem remains, this indicates there is a problem
in the ROS circuits. Replace the following components in the order shown. After each replacement, make a copy to check the operation of the copier:
ROS Assembly (PL 4.1).
Background is present in all four colors

Y
N
Replace the developer material for the faulty color. If the problem continues, replace the
Developer Housing for the faulty color.
Perform ADJ 12.3.3 DADF Height. Background is still present.
Y
N
Go to the IQ 37 Developer Bias HVPS RAP. The Developer HVPS is good.
Y
N
Replace the Developer HVPS (PL 9.1).
Enter Tools and return all density settings to nominal. If background is still present, replace the
Drum CRU, (Machine Consumables).
Reissue
DocuColor 12/DCCS50
1/05
3-19
Image Quality
IQ 14 IOT Solid Black (or Color) Copy RAP, IQ 15
A
The problem is in the Xerographic Module, the 1st BTR. Complete the steps below until the
problem is resolved

This RAP is used when the output copy is completely blank, or has extremely low image density.
Initial Actions
Ensure that J572 is firmly connected to the Post IPS PWB and P396 is firmly connected
to the Half Tone PWB.
The ROS does not discharge the drum properly.
Ensure than drive from the Main Motor (PL 1.2) to the Developer Clutch (PL 1.3) is functioning correctly.
Check the photoreceptor, the corotron wire, and the corotron screen for defects or damage. If any component is questionable, replace the Xerographic Module (PL 5.3).
BTR (PL 7.6).
Procedure
There is some image on the copy.
Y
N
Remove the Print/Copy Cartridge (Drum). Wipe a section of one of the mag rolls to
remove the toner/developer. Reinstall the Drum, and run 10 copies/prints. Remove the
wiped
area
Drum again, and examine the mag roll on the developer housing. The
remains free from toner/developer.
Y
N
Ensure that the IBT Drawer is properly positioned.
Go to the IQ 41 1st BTR HVPS RAP.
Check for correct operation of the ROS. Use the procedure in the 14-372 ROS
Motor Fail RAP.
Registration
Drive Gear
Go to Flag 8 on BSD 9.3. Check for an open circuit or a short circuit to ground. If the wires
are OK, replace the Developer Clutch (PL 1.3). If the problem persists replace the IOT
Drive PWB (PL 9.2).
Perform the Xerographic Hard Stop Procedure:
1.
2.
3.
4.
5.
Press Start.
6.
7.
8.
9.

Observe the Image on the IBT. The image density is very low on the IBT.
Y
N
A
Image Quality
1/05
3-20
Reissue
DocuColor 12/DCCS50
IQ 17 Deletions RAP
NOTE: When perform the next step, it is very important that you follow the installation sequence for tightening the four screws of the Inner Dispense Cover.
IOT Deletions RAP. This RAP is used when the output copy is experiencing deletions.
6.
Initial Actions
NOTE: If the deletions look like mottle and are most noticeable in the high density areas of an
image, go to IQ 19 Bead Carryout RAP.
Load some new, dry 24 lb. 11 X17 (A3) Xerox COLOR Xpressions (NASG), or 90 GSM Colortech + (ESG) into Tray 2 and make 5 single-color 20% halftone copies of IOT Pattern 11 (UI)
and 99 (PWS) for each color (Y, M, C, and K). Note: Set aside the best black copy for future use
and mark its lead edge.
Procedure
IBT Belt (dents or spots)

Photoreceptor Drum Module (dents, scratches, or spots)
2nd BTR Roll
Paper Path Rollers or Tray Feeders
Fuser Module Rolls
Remove the problem developer housing following (REP 6.6.1).
2.
Remove the problem developer material (REP 6.6.2).
Replace the developer material (REP 6.6.2) but DO NOT replace the developer
housing at this time.
4.
5.
Four Outer Dispense Housings
Four Inner Dispense Housings and their four bearings (clean with a lint-free
cloth and reinstall)
Block and black spacer
Five white spacers (clean with a lint-free cloth and reinstall)
7.
Reinstall the developer housing(s) (REP 6.6.1).
8.
Run 50 11X17/A3 single-color 20% halftone copies of IOT Pattern 11 (UI) and 99
(PWS) for the problem color(s).
Inspect the Drum for any defects or damage. The Drum is OK.
Y
N
Clean or replace the Drum CRU (Machine Consumables).
Inspect the ROS opening in the frame, above the Drum, for blockage and debris. The frame
opening is clean and not blocked.
Y
N
Clear or clean the opening.
NOTE: Before replacing the developer material, vacuum any residual developer
from the housing to ensure complete removal of the problem material.
3.
Inner Dispense Cover
Load the largest-size, fresh paper available in all the remaining trays, including the Paper
Bypass Tray. Place the black copy you set aside earlier on the platen glass with the its lead
edge facing away from the registration edge. Make several black copies from each tray with the
Lighten / Darken Image Quality selection at its Darkest setting and mark each copy set with the
corresponding tray it was fed from. The defect occurred on copies from all four trays and
the Paper Tray Bypass.
Y
N
Repair or replace any faulty components of the Feeder Assembly for the problem paper
supply.
NOTE: Examine and identify the color of the agglomerate/grit contained in the center of
the deletion(s) of a halftone image. The color(s) within the center of the deletion shall be
called the problem color or component.
1.
Outer Dispense Cover, screw and spring
Inspect the IBT Belt for any foreign materials or dents. The IBT Belt is OK.
Y
N
Clean IBT Belt with soft lint free cloth, or replace the IBT Belt (PL 7.5).
The deletions occur with all four colors

Y
N
Deletions are Debris-Centered (that is, it has a Toner agglomerate near the center).
Y
N
Perform ADJ 9.1.1 Max Setup.
If the problem remains, inspect the following parts for damage or contamination:
If the problem remains, inspect the Developer Bias Roll Shaft for contamination or wear.
Clean or repair it as required (PL 7.6). Also, inspect the Developer Bias Brush for contamination or wear. Clean or replace the Brush (PL 6.1) (REP 6.1.4) as required.
The defect is still present with the new paper.

Y
N
The paper was the problem. Tell the customer that new, dry, 24 lb. Xerox COLOR Xpressions (NASG), or 90 GSM Colortech + (ESG) paper is the specified paper for use in the
DocuColor 12 copier.
Using (REP 6.7.1) as a guide, replace the Inner/Outer Dispense Housings (PL 6.5)
for all four colors, including the following parts, except where noted (PL 6.5),

1.
2.
Remove the Rotary Dispense Assembly (REP 6.7.1).
3.
Remove, vacuum and clean the problem rotary auger(s) (REP 6.7.1).
4.
5.
Press Start.
6.
A
Reissue
DocuColor 12/DCCS50
1/05
3-21
Image Quality
IQ 17 Deletions RAP
7.
8.
9.

Y
N
The problem is in the IBT, the 2nd BTR, or the Fuser. Perform the Xerographic Hard Stop
again. This time, wait until the paper is on the Vacuum Transport before removing the
interlock cheater. The defect is present on the copy that is on the Vacuum Transport.
Y
N
The problem is in the Fuser. Disassemble the fuser and carefully inspect the following parts for damage or toner buildup.
Pressure Roll (PL 8.3).
Heat Roll Stripper Fingers (PL 8.3),
Heat Rolls (PL 8.3).
Cleaning Roll (PL 8.5).
Registration
Drive Gear
The problem is in the Xerographic Module, the 1st BTR, or the ROS. Complete the steps below
until the problem is resolved
If the problem is density or background related, perform a ADJ 9.1.1 Max Setup. If any
Fault Codes are generated during the setup, use the RAPs for those Fault Codes to troubleshoot the problem.
Check the photoreceptor, the corotron wire, and the corotron screen for defects or damage. If any component is questionable, replace the Xerographic Module (PL 5.3).
BTR (PL 7.6).
Replace the ROS (PL 4.1).
Image Quality
IQ 17 Deletions RAP
1/05
3-22
Reissue
DocuColor 12/DCCS50
IQ 18 IOT Missing Colors RAP
IOT Missing Colors RAP. This RAP is used when the output copy exhibits a consistent loss of
one of the Cyan, Magenta, Yellow, or Black toners.
Bead Carryout RAP. This RAP is used when the copy is experiencing bead carryout (BCO).
This defect looks like mottle and is most noticeable in the high density areas. BCO is caused by
low toner concentration.
Initial Actions
Check that connectors P/J140 on the TR0 Sensor and P/J139 on the ADC Sensor are
IBT Belt is correctly installed and IBT drive appears to be normal.
copy/print.
Initial Actions
Procedure
NOTE: If the BCO problem occurs with the color black and the IOT s/w version is 6.00.2 or
higher, go to IQ 46 Black Bead Carryout RAP. If the problem occurs with the color black and
the IOT s/w version is lower than 6.00.2, continue with this RAP.
Run the # 9 IOT Test Pattern from the UI, or the 102 Test Pattern from the PWS in 4 color
mode. One of the colors is missing.
Y
N
Run IPS Test pattern # 22 from the UI or PWS. One of the colors is missing
Y
N
Run IPS Test Pattern #21 from the UI or PWS. The copy should look similar to Figure
3 in 3.2.4 IOT/IPS Internal Test Patterns of the Image Quality Supplement. The
Copy looks similar to Figure 3.
Y
N
Replace the Pre IPS PWB (PL 3.5)
NOTE: For a high 4-color background / bead carryout problem (see Defect Sample 10), go to
IQ 37 Developer Bias HVPS RAP to begin troubleshooting.
Ensure that the paper presently being used is fresh 24 lb. Xerox COLOR Xpressions (NASG),
or 90 GSM Colortech + (ESG) paper or paper which is included in the customers Materials
Usage Guide and Recommended Paper List. Run test copies. If the copies reproduced still
have Bead Carryout, continue with this RAP.
Replace the Mem Sys PWB (PL 3.5).

If the machine has Tag 14 ATC Sensor, refer to IQ 47 ATC Sensor RAP.
Enter dC920 and move each of the housings to the development location. The Rotary Developer places each housing in the proper development location.
Y
N
Go to the 9-363 Rotary Home Position Fail RAP.
Procedure
NOTE: This procedure must be performed using UI diagnostics because some of the required
NVM locations cannot be accessed from the PWS.
Replace the problem Developer Housing (PL 6.6). If the problem continues, replace the Half
Tone PWB (PL 9.2).
NOTE: While referring to Table 1, make a drawing of this table on a sheet of 8 1/2 x 11 / A4
LEF paper. Then make a copy of your drawing. These two tables will be used to collect and
analyze data when performing this procedure.
NOTE: Ensure that 8 1/2 X 11 / A4 LEF paper is installed in Tray 2 before continuing.
Enter the diagnostic mode from the UI and select MAX Setup. Select TRC Set UP/Toner Concentration Adjustment. Select TRC Control (dC922). Make a ProCon test pattern by pressing
the Start button. Examine the copy for mottle-like or non-uniform (spotty) density in the highdensity patches. One of these defects is present in the 100% patch (top row) in any color.
Y
N
Go to IQ 2 Defect Listing and choose one or more of the following defects to continue
troubleshooting: mottle, high image density, deletions, or spots.
Select Close three times to take you back to the main menu. Select NVM Read/Write. NVM
locations 773-021 through 773-028 are set to 1.
Y
N
Select MAX Setup. Select and run ADC AGC Setup (dC934) and VH/VM Setup (dC933)
in Max Setup (dc929) and investigate any system failure that is declared.
NVM 773-004 is set to 1;
Reissue
DocuColor 12/DCCS50
1/05
3-23
Image Quality
IQ 18 IOT Missing Colors RAP, IQ 19 Bead Carryout
A
Reselect MAX Setup. Select TRC Set UP/Toner Concentration Adjustment. Select TRC Control (dC922). Make a ProCon test pattern by pressing the Start button. Examine the copy for
mottle-like or non-uniform (spotty) density in the high-density patches. One of these defects
is present in the 100% patch (top row) for the problem color(s).
Y
N
The BCO problem is resolved.
N
Set NVM to 1.
The value in NVM location 773-121 is between 5 and 95 (this number represents the percentage of room humidity).
Y
N
Replace the Humidity Sensor (PL 7.1).
NOTE: If the lower limit(s) for the problem color(s) location(s) has already been reached, go
directly to the end of this RAP and perform the corrective action steps.
Record the ADC Target values from NVM locations 773-266 through 773-269 in Column 1 of
the table you prepared. If the Y, M, C, and K values are EQUAL to or LESS than 230, 230,
250, and 160 respectively, answer Yes. If the value(s) are HIGHER than 230, 230, 250
and 160 respectively, answer No.
Y
N
Set NVM locations 773-266, 267, 268, and 269 to 230, 230, 250, and 160 respectively.
Then make 50 full-color copies of the top half of the Color Test Pattern on 8 1/2 X 11/A4
paper to stabilize the IOT.
NOTE: DO NOT set the new value(s) for the ADC Targets below the following lower limits: 773266 = 150, 773-267 = 150, 773-268 = 170, and 773-269 = 100.
Enter a new value(s) for the problem color(s) in the appropriate NVM location(s) that is 30 bits
less (C,M,Y) or 10 bits less (K) than the current value(s) of the ADC Targets. Then record the
new value(s) in Column 1 on one of the remaining tables you prepared. Make 50 full-color copies of the top half of color test patter 82E10810 to stabilize the IOT. Next, record the Humidity
Adjusted ADC Target value(s) for the problem color(s) from NVM locations 773-281 through
773-284 in Column 2 and the ADC Patch Readings from NVM locations 773-606 through 773609 in Column 3. The value(s) in Column 3 is within +/- 30 bits from the values in Column
2 for the problem color(s).
Y
N
Make 50 full-color copies of the top half of the Color Test Pattern on 8 1/2 X 11 / A4 LEF
paper. Repeat as necessary until the ADC Patch value(s) for the problem color(s) is within
+/- 30 bits of the Humidity Adjusted ADC Targets. If the value(s) is not within this range
after making 250 copies, go to IQ 10 Low Image Density RAP.
Record the Humidity Adjusted ADC Target value(s) for the problem color(s) from NVM locations 773-281 through 773-284 in Column 2 and the ADC Patch Readings from NVM locations
773-606 through 773-609 in Column 3. The value(s) in Column 3 is within +/- 30 bits from
the values in Column 2 for the problem color(s).
Y
N
Y
N
Y
N
NOTE: Before performing the corrective action steps below, re-enter the original value(s) of the
ADC Targets for the problem color(s) in the appropriate NVM location(s). Make 50 full-color
copies of the top half of the Color Test Pattern on 8 1/2 X 11 / A4 LEF paper. Repeat as necessary until the ADC Patch value(s) for the problem color(s) is within +/- 30 bits of the original
Humidity Adjusted ADC Targets.
NOTE: DO NOT set the new value(s) for the ADC Targets below the following lower limits: 773266 = 150, 773-267 = 150, 773-268 = 170, and 773-269 = 100. For example, if reducing the
value of NVM location 773-266 by 50 bits would result in a value less than 150, you must not
exceed the 150 limit for that location.
Enter a new value(s) for the problem color(s) in the appropriate NVM location(s) that is 50 bits
less than the current value(s) of the ADC Targets. Then record the new value(s) in Column 1 on
one of the remaining tables you prepared. Make 50 full-color copies of the top half of color test
patter 82E10810 to stabilize the IOT. Next, record the Humidity Adjusted ADC Target value(s)
for the problem color(s) from NVM locations 773-281 through 773-284 in Column 2 and the
ADC Patch Readings from NVM locations 773-606 through 773-609 in Column 3. The
value(s) in Column 3 is within +/- 30 bits from the values in Column 2 for the problem
color(s).
Y
N
A
Image Quality
Perform the following corrective action steps in order until the problem is resolved.
Check the Toner dispense system for any blockage or obstruction that could limit the
amount of Toner reaching the Developer Housing.
1/05
3-24
Replace the developer material for the problem color (Machine Consumables)
Reissue
DocuColor 12/DCCS50
IQ 20 IOT Graininess RAP
Replace the problem Developer Housing (PL 6.6)
IOT Graininess RAP. This RAP is used when the output copy shows graininess, or a sandy, textured appearance.
Table 1 Data Collection

ADC
Targets
Column 1
Humidity
Adjusted
ADC
Targets
Column 2
ADC Patch
Readings
773-266
773-281
773-606
773-267
773-282
773-607
773-268
773-283
773-608
773-269
773-284
773-609
Procedure
Column 3
Paper outside the specified weight and quality range can increase graininess. Heavy
weight papers are particularly susceptible.
Replace the paper currently in use with new, 24 lb. Xerox COLOR Xpressions (NASG), or
90 GSM Colortech + (ESG) paper. If the paper change does not fix the problem, go to
Detailed Maintenance Activities in Section 1. Check the expected life of the Yellow,
Magenta, Cyan and Black Developer. If the developer material is past expected life,
replace it.
Replace the Developer Bias Brush, if damaged (REP 6.1.4)
Replace the Developer Housing, if damaged (PL 6.6).
Go to IQ 37 Developer Bias HVPS RAP.

NOTE: After replacing developer material, go to IQ47 ATC Sensor RAP, Appendix 1. ATC
set-up procedure.
Reissue
DocuColor 12/DCCS50
1/05
3-25
Image Quality
IQ 19 Bead Carryout RAP, IQ 20 IOT Graininess
IQ 22 Mottle RAP
Images that are not clear, or appear out of focus.
This RAP is to be used when the output image shows Mottle.
Initial Actions
Initial Actions
Clean the top and bottom of the Document Glass, Lens and Mirrors with a lint free cloth and
lens and mirror cleaner. If the defect occurs only in the 3-Color Mode and appears to match the
Toner Explosion defect sample, recommend that the job be run in 4-Color Mode. Otherwise,
continue with the Procedure below.
Replace the paper presently being used with new 24 lb. Xerox COLOR Xpressions
(NASG), or 90 GSM Colortech + (ESG) paper and run test copies. If the copies reproduced still have Mottle, continue with this RAP.
Procedure
If the defect occurs when running internal test pattern #84 on 11x17, single color from the PWS
perform the following until the problem is resolved:
Perform ADJ. 3.4.1 Full Rate/Half Rate Carriage Position Adjustment.
Clean the Ros Lenses.
Replace the Ros Assembly (PL 4.1).
Inspect the Drum surface for damage or contamination.
Inspect the Charge Corotron Wire and Grid for damage or contamination.
Clean both sides of the Platen Glass and ensure that the Platen Glass is seated firmly.
Perform ADJ. 3.4.1 Full Rate/Half Rate Carriage Position Adjustment.
Clean the Ros Lenses.
Replace the Ros Assembly (PL 4.1).
Ensure that IBT is positioned correctly in relation to the Copy/Print Cartridge (Xero Drum).
Check the Plate (PL 7.6) that supports the outboard end of the IBT Backup Roll for damage.
Procedure
Perform ADJ 9.1.1, Max Setup. Mottle is still present
Y
N
If the defect occurs when running the Color Test Pattern from the platen perform the following
until the problem is resolved:
This problem can occur when using lower quality paper, paper which is not in specification
for this machine (refer to the customers Materials Usage Guide and Recommended Paper
List), or in paper that has a high moisture content.
The Defect is present only in the high density areas of the copy.
Y
N
Go to the IQ 37 Developer Bias HVPS RAP The Developer HVPS is good
Y
N
Replace the Developer HVPS (PL 9.1). If problem continues, replace developer
material, (Machine Consumables).
If the defect continues go to IQ 7 IDFE / Network Checkout Procedure.
1.
2.
3.
4.
5.
Press Start.
6.
7.
8.
9.

Y
N
Go to the IQ 40 2nd BTR HVPS RAP. If the 2nd BTR Power Supply is good, replace
the 2nd BTR (PL 9.2). If the problem continues, replace the IBT Belt (PL 7.5).
The problem is in the Xerographic Module, the 1st BTR. Complete the steps below until
the problem is resolved
Check the photoreceptor, the corotron wire, and the corotron grid for defects or damage. If any component is questionable, replace the Xerographic Module (PL 5.3).
A
Image Quality
IQ 21 Blurred or Fuzzy Image RAP, IQ 22 Mottle RAP
1/05
3-26
Reissue
DocuColor 12/DCCS50
IQ 23 Poor Color Balance RAP
Go to the IQ 41 1st BTR HVPS RAP. If the 1st BTR Power Supply is good, replace
the 1st BTR (PL 7.6).
Procedure
The problem is present in all four colors

Y
N
This appears to be a mottle-like bead carryout problem (see Defect Sample 28), go to IQ
19 Bead Carryout RAP to continue troubleshooting.
Perform ADJ 9.1.1 Max Setup. If any Fault Codes are generated during the setup, use the
RAPs for those Fault Codes to troubleshoot the problem. If the high density areas of the copy
appear to light, perform a manual tone up and refer to the IQ 19 RAP.
Registration
Drive Gear
Reissue
DocuColor 12/DCCS50
1/05
3-27
Image Quality
IQ 22 Mottle RAP, IQ 23 Poor Color Balance RAP
IQ 24 Back Side or Side Two Copy Contamination RAP
IQ 25 Hollow Character RAP
Procedure
Small circular-shaped deletions within a character that can occur when the image density is
low or a transparency is used.
Clean all Paper / Copy transports.
Clean/replace the IBT Belt.
Clean/inspect 2nd BTR roll
Clean/inspect Vacuum Transport Assembly
Procedure
Check the following items:
Clean or replace the following parts:
Heat Roll (PL 8.3)
If the problem is with Transparencies, ensure that the customer is running the correct
Transparencies. Transparencies must be run out of Tray 5, and Transparencies must be
selected under Paper Type. If the transparencies have white strips, ensure that the white
strip is facing downward in the tray.
Inspect the IBT Belt for wear, damage or IBT Belt over HFSI threshold. Replace IBT Belt
(PL 7.5) as needed.
Check for Developer over threshold.
External Heat Roll (PL 8.8)
Donor Roll Assembly (Oil System Kit) (REP 8.2.1)
Advance the web manually to a clean area.
Image Quality
IQ 24 Back Side or Side Two Copy Contamination
1/05
3-28
Reissue
DocuColor 12/DCCS50
IQ 27 Color-to-Color Misregistration RAP
Procedure
Procedure
Clean both sides of the Document Glass.
Replace developer material if near or over HFSI threshold. (Machine Consumables)
Check for IBT Belt loosing a pitch and ensure that the tensioner is engaged.
Perform ADJ 9.1.1 Max Setup
Timing of the TR0 signal,
Inspect the TRO Sensor. Ensure it is clean and not damaged.
Ensure that the IBT Belt is not riding on the ridge on the outside edge of the Steering and
Drive rollers.
Perform ADJ 9.1.1 MAX Setup.
Reissue
DocuColor 12/DCCS50
1/05
3-29
Image Quality
IQ 26 Low Contrast Reproduction RAP, IQ 27 Color-
IQ 28 Moire RAP
IQ 29 Newton Rings RAP
Moire can occur when the original is a halftone or contains a halftone. The halftone screen in
the original can interfere with the halftone screens being generated by the copier.
Procedure
Clean the Document Glass with Anti Static Fluid.
Procedure
Place a transparency between the photo and the Document Glass.
NOTE: Newton Rings usually occur when copying high gloss photos in Photo/Photograph
mode.
For Original Type of either Photo & Text or Photo, be certain to select Halftone for Photo
Type.)
Change the orientation of the original by rotating it 90 degrees.
Decrease the Sharpness level (Softer, Softest).
Reduce or enlarge the copy slightly (for example 95% or 105%).
Change Original Type to Graphics & Maps (appearance may change -- some CQ adjustments may be necessary).
Image Quality
IQ 28 Moire RAP, IQ 29 Newton Rings RAP
1/05
3-30
Reissue
DocuColor 12/DCCS50

Toner that was not cleaned off the Heat Roll offsets onto the front or back side of copies.
Perform the Fuser Nip (dC701) ADJ 8.1.1. If the nip width is very low at one end, check
that the Heat and Pressure Roll Bearings are correctly positioned. Also check that the
Pressure Roll Lift mechanism is functioning properly. Ensure that the 2 screws holding the
upper and lower Fuser Frames together are tight.
Y
N
Check the Web Motor (PL 8.4) for an open circuit. If it is OK, replace the Web Drive
PWB (PL 8.4).
In some cases, highly contaminated fuser oil can lead to offsetting, especially with transparencies and black copies. This situation is possible under the following circumstances:
The machine has a low oil supply (i.e., oil bottle is empty oil tank is low/add oil message is displayed).
Oil level on the copies is low (indicated by the lack of oil streaks).
The machine has high copy volume (more than 100K) and the oil in the tank is milky/
dirty.
Low Humidity environments may increase the likelihood of offsetting.
Enter DC330 [10-032] Web Motor. Press the Start button. The voltage at
P/J413A-2
decreases from +24 VDC to less than +1.0 VDC.
Y
N
Replace the IOT Drive PWB (PL 9.2). Install the Web CRU, Front Cover and Oil Cartridge.
If this is suspect, replace the Oil Tank and Oil Pipe (PL 8.7) and the Oil Wick and Oil Filter
(PL 8.7), then go to the GP 1 Fuser Break-In Procedure.
Check for indications that the Web Supply Roll is rotating normally. If there is a buildup of
toner across the entire length of the web, perform the Web Motor Checkout.
Y
N
Y
N
Initial Actions
Run the Fuser Break-in Procedure GP 1 Fuser Break-In Procedure.
Web Motor Checkout
NOTE: Offsetting is most likely to occur when running long jobs of high area coverage, transparencies or coated papers. High AC transparencies should be run using paper interleaves.
Offsetting is also likely to occur when running heavy paper in the normal paper mode. Offsetting is more likely to occur as the Heat Roll ages.
Replace the Web Drive PWB (PL 8.4). If that does not correct the problem, replace the Web
Motor (PL 8.4).
Excessively high Fuser temperature is a primary cause of Fuser contamination. This

problem is prevalent when the machine is run in Extra Heavyweight mode, and increases
when high area coverage images are run frequently. If this is suspect, change the default
values for the NVM locations in Table 1 to the values listed in the New values column.
Table 1 Fuser temperature NVM values

NVM loc.
Procedure
Remove the Fuser Assembly. Check the following components. Clean excess toner from the
components using the Cleaning Procedures in Section 1. Replace the components if contamination remains or if offsetting continues after cleaning.
Heat Roll (PL 8.3)
External Heat Roll (PL 8.8)
Donor Roll (PL 8.9)
Pick Up Roll (PL 8.9). If Roll is replaced, also replace the Metering Blade (PL 8.9).
Oil Wick (PL 8.7)
Perform the actions indicated below:
Check the Oil Bottle, if empty, replace (Machine Consumables).
Check the Oil supply system is functioning. Go to the OF10-2 Fuser Oil Pump RAP.
Check that the load springs and bearings for the Donor Roll Assembly are properly positioned.
Advance the web manually to a clean area. Access NVM location 777-079 and increase
the value by 7,000 for each 25mm/one inch that the web was advanced.
Reissue
DocuColor 12/DCCS50
1/05
3-31
Default value New value
NVM loc.
777-001
160
155
777-137
190
183
777-003
178
170
777-138
183
180
777-005
150
145
777-139
195
188
777-010
165
161
777-166
164
156
777-013
158
153
777-194
185
165
777-016
180
170
777-195
182
165
777-017
193
183
777-196
190
170
777-018
165
156
777-256
1050
18000
777-019
187
167
777-257
1050
25000
777-020
193 (NASG)
185 (ESG)
172
777-272
165
161
777-021
162
156
777-276
160
155
777-023
163
151
777-280
156
151
777-026
161
155
777-299
193
175
777-027
164
155
777-300
10
777-028
162
150
777-301
168
161
777-098
163
155
777-309
168
161
777-135
193
188
777-310
169
163
Image Quality
Table 1 Fuser temperature NVM values

NVM loc.
777-136

167
161
NVM loc.
777-312

168
Process direction streaks that show up first on transparencies or coated paper as low gloss
streaks in solid areas. In severe cases, oil streaks can show up on paper as low density streaks
in large halftone areas.
159
Initial Actions
NOTE: The primary cause of oil streaks is contamination of the oil Metering Blade.
While the Fuser is still warm, clean the External Heat Roll using the Cleaning Procedures in
Section 1. If the toner buildup cannot be removed, replace the roll (PL 8.8).
Check the HFSI counter for Oil System in the Detailed Maintenance Activities. If the count is
at or near 80,000, Install a new Oil System Repair Kit, (includes Donor Roll Assembly, Wick
and Oil Filter) (includes Tag P12 and TAG P21). After Installing a new Oil System Kit, reset
HSFI Counters 10-811 and 10-814.
Procedure
NOTE: Carefully observe the orientation of the Metering Blade to the Pickup Roll before disassembling it. Notice that there is an F stamped into the front frame of the Metering Blade and
the Donor Roll Assembly Frame. When reassembling the Metering Blade, ensure that the two
Fs are located at the front of the Donor Roll Assembly.
NOTE: If the Metering Blade has less than 10,000 copies/prints on it, removing and cleaning
the Metering Blade/Oil System Roll, and Donor Roll with a lint-free cloth (600S1276) and fuser
oil should correct the problem. If the Metering Blade/Oil System has between 10,000 and
70,000 copies on it, perform the following steps:
Image Quality
IQ 30 Fuser Offsetting RAP, IQ 31 Fuser Oil Streak
1/05
3-32
1.
Replace the Metering Blade REP 8.2.1 (PL 8.9), being careful to avoid contaminating the
blade edge during replacement. While replacing the blade, clean the Donor Roll and
Pickup Roll with a lint-free cloth (600S1276) and fuser oil. Before installing the blade, wipe
the edge with a lint-free cloth and oil. Finally, wipe the edge of the blade with a clean finger.
2.
Tear off the corner from a sheet of 24#, (90 gsm) copy paper. After assembling the Metering Blade to the Pickup Roll, slide one of the clean edges of the paper between the blade
and the roll, inboard to outboard, to clean off any remaining contamination.
3.
Inspect the Oil Wick and wipe off the surface with a lint-free cloth.
4.
Clean or replace the following parts as required:
Heat Roll (PL 8.3)
5.
Ensure that the Donor roll and Pickup Roll are in contact with each other after the Donor
Roll Assembly has been installed (REP 8.2.1).
6.
Advance the Web manually to a clean area. Enter Diagnostics. Access NVM Location
777-079 and increase the value by 7,000 for each 25mm/one inch that the web was
advanced.
7.
Perform the Standard Fuser Break-In Procedure (GP 1 Fuser Break-In Procedure).
Reissue
DocuColor 12/DCCS50
IQ 32 ROS Borders RAP
IQ 33 Solid Area Reproduction RAP
Intentional border deletions that exceed specifications (refer to ROS Borders for details).
Initial Actions
Procedure
Load some new, dry 24 lb 11X17/A3 Xerox COLOR Xpressions (NASG), or 90 GSM Colortech
+ (ESG) into the paper tray. Make full color copies and check the Solid Area Reproduction.
Perform the ADJ 9.1.10 Side/Lead Edge Registration (dC129: System Registration).
Procedure
Reissue
DocuColor 12/DCCS50
1/05
3-33
Replace the developer if the developer is near or over HFSI threshold.
Replace the IBT Belt if the IBT Belt is over HFSI threshold.
Check for Mottle/BCO IQ 22 Mottle RAP.
Check the 1st BTR HVPS IQ 41 1st BTR HVPS RAP.
Check the 2nd BRT HVPS IQ 40 2nd BTR HVPS RAP
Image Quality
IQ 32 ROS Borders RAP, IQ 33 Solid Area Repro-
When using the Original Type options of Photo and Text or Text, the copier attempts to discriminate between text and photo areas within the original. It then applies the appropriate image
processing to each area. Text is reproduced at 600 lines per inch while photos are reproduced
at 200 lines/dots per inch. On occasion, the defect may appear where an area is classified
incorrectly and text is treated as photo or vise-versa.
This defect occurs at the transition point between a high density area and a low density area of
the same color. A localized area of the mag brush becomes starved for toner due to development fringe field effects. Starvation tends to worsen at low triboelectric levels (high toner concentration).
Initial Actions
Procedure
Rotate the original 90 degrees.
Reduce or enlarge slightly.
In Photo & Text mode, change Photo Type from Half Tone to Photograph
Under Tools - System Image Quality - Image Recognition, the Key operator can adjust
Text & Photo Recognition and or Text & Photo Balance. It should be noted that these
parameters are not intended to be adjusted on a job to job basis. These adjustments are
trade-offs and should be treated with care.
Change Original Type to Photo or to Graphic & Maps. (Appearance may change - some
CQ adjustments may be necessary.
Change the orientation of the original by rotating it 90 degrees or 180 degrees.

If the machine shows a starvation problem and has Tag 14 ATC Sensor, refer to the IQ 47 ATC
Sensor RAP.
Procedure
Y
N
Ensure that developer housing for the problem color is not damaged. Replace the developer if the developer is near or over HFSI threshold.
NOTE: If the machine is showing objectionable starvation, and has an ATC Sensor and the
sensor is activated, go to the IQ 47 ATC Sensor RAP to check for proper operation.
Image Quality
IQ 34 Text / Image Separation RAP, IQ 35 Toner Star-
1/05
3-34
Reissue
DocuColor 12/DCCS50
IQ 36 Unfused Copy RAP
IQ 37 Developer Bias HVPS RAP
Unfused Image usually occurs because of lack of heat/pressure in the Fuser, or because of
excess toner on the copy.
This RAP is used to isolate the cause of missing or out-of-specification voltages.
Procedure
Initial Actions
Ensure that the correct Paper Mode (i.e Normal, Heavyweight or Extra Heavyweight) has
been selected for the paper being run.
For electronic images, ensure that toner coverage has been limited to a total of less than
280% or less than 70% each color.
WARNING
Measure the Developer Bias output from the DB HVPS:
Switch off the copier.
Procedure
Go to ADJ 8.1.1 Fuser Nip Adjustment. Nip width near the maximum (10.6 mm) will provide the best fusing.
Ensure that output image density is not too high. Compare the output image density to the
density of the original. If output density is too high, go to IQ 11 High Image Density RAP to
achieve the correct image density.
Connect the DMM (+) lead to the developer bias terminal that attaches to the developer
housing.
Connect the DMM (-) lead to the copier frame.
Set the DMM to measure 1 KVDC.
Switch on the copier.
Enter DC330 [09-076], press Start and observe the voltage measurement.
There is a steady voltage of approximately -550 VDC at this point.

Y
N
Press Stop. Enter DC330 [09-077] and press Start. There is a steady voltage of
approximately 415 VAC at this point.
Y
N
Press Stop. Connect the DMM (+) lead to the output terminal of the Developer Bias
HVPS. Press Start. There is approximately -550 VDC at this point.
Y
N
Press Stop. +24 VDC is measured at P/J91-1 on the Developer Bias HVPS.
Y
N
Go to Flag 1 on BSD9.3 and check the wiring for an open circuit.
(If two or more input signal are missing, -550 VDC and 415 VAC outputs will not
be present.) Go to Flag 4 on BSD9.3and check the wiring for an open circuit. If
OK, replace the Developer Bias HVPS (PL 9.1). If the problem remains, replace
Go to Flag 3 BSD9.3 and check the Developer Bias Lead for an open circuit.
Press Stop. Enter dC330 [09-076] and press Start. Approximately +2.7 VDC is measured at J[418]-A9 on the IOT Drive PWB.
Y
N
Approximately +2.7 VDC is measured at P/J91-5 on the Developer Bias HVPS.
Y
N
Go to Flag 5 BSD9.3 and check for an open circuit.
Replace the Developer Bias HVPS (PL 9.1).
Press Stop. Enter DC330 [09-077] and press Start. There is a steady voltage of approximately 415 VAC at this point.
Reissue
DocuColor 12/DCCS50
1/05
3-35
Image Quality
IQ 36 Unfused Copy RAP, IQ 37 Developer Bias
IQ 38 Charge Corotron HVPS RAP
N
Press Stop. Approximately +3.2 VDC is measured at P/J418A-10 on the IOT Drive
PWB when Start is pressed.
Y
N
This RAP is used to isolate the cause of missing or out-of-range voltages and current.
Procedure
WARNING

Y
N
Enter dC330 [09-070]. Press Start. Observe the B Monitor (Red) LED on the CC/PCC HVPS.
The LED is lit or flickering.
Y
N
+24 VDC is measured at P/J82-1 on the CC/PCC HVPS.
Y
N
Approximately +1.0 VDC is measured at P/J82-1 on the CC/PCC HVPS.
Y
N
Approximately +4.5 VDC is measured at P/J418A-11 on the IOT Drive PWB.

Y
N
Y
N
Replace the Developer Bias HVPS (PL 9.1).
Ensure that the following are OK:
Fingers in front Developer Rotor End Frame (PL 6.7)
Developer Bias Brush and Plate (PL 6.1)
Wire from Bias Plate to Developer Roll (PL 9.1)
N
Go to Flag 1 BSD9.1 and check for an open circuit. If OK, replace the IOT
Drive PWB (PL 9.2).
Go to Flag 1 BSD9.1 and check the wire for an open circuit. If OK, replace the
CC/PCC HVPS (PL 9.1).
Go to Flag 4 BSD9.1 and check the Charge output circuit, including the Charge
Corotron wire (PL 5.4), for an open circuit. If OK, replace the CC/PCC HVPS (PL
9.1).
Approximately +3.5 VDC is measured at P/J92-3.
Y
N
Go to Flag 2 BSD9.1 and check for an open circuit. If OK, replace the IOT Drive
PWB (PL 9.2).
The LED is on steady (not flickering).
Y
N
Y
N
Check for an open connection between P/J82-1 and P/J82-1. If OK, replace the
Press Stop. Enter dC330 [09-081]. Press Start. Approximately +3.5 VDC is measure at P/
J92-4.
Y
N
Go to Flag 5 BSD9.1 and check for an open circuit. If OK, replace the IOT Drive PWB (PL
9.2).
A
Image Quality
IQ 37 Developer Bias HVPS RAP, IQ 38 Charge
1/05
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DocuColor 12/DCCS50
A
Press Stop. Perform the following:
Set the meter to measure micro amps.
Disconnect the Charge output connector from the CC/PCC HVPS.
Connect one meter lead to the supply side of the connector and the other lead to the harness side.
Enter dC330 [09-070]. Press Start.
IQ 39 Preclean Corotron HVPS RAP

Procedure
WARNING
Approximately 600 to 800 micro amps is measured.

Y
N
Ensure that NVM location [774-031] is set at 3 and location [774-029] is set at 130. Enter and
operate DC330 [09-068]. Observe the G Monitor (Red) LED on the CC/PCC HVPS. The LED
is lit.
Y
N
Enter and operate DC330 [09-070] and observe the B Monitor (Red) LED on the CC/PCC
HVPS. The LED is lit.
Y
N
The Charge Corotron HVPS checks out OK. Check the following:
Charge Corotron Assy (PL 5.4).
Charge Corotron connector (PL 5.2).
N
Go to Flag 2 BSD9.13 and check for an open circuit. If OK, replace the IOT
Drive PWB (PL 9.2).
Check for an open connection between P/J92-1 and P/J92-1. If OK, replace the
Approximately +1.85 VDC is measured at P/J92-6.
Y
N
PWB (PL 9.2).
Check for an open connection at P/J92-6. If OK, go to Flag 4 BSD9.13 and check the
Preclean output circuit, including the Preclean Corotron wire (PL 5.4) for and open circuit.
If OK, replace the CC/PCC HVPS (PL 9.1).
Set your meter to measure micro amps. Disconnect the Preclean output connector from the
CC/PCC HVPS (PL 9.1). Connect one meter lead to the supply side of the connector and the
other lead to the harness side. Make another full-color copy. Approximately 200 to 400
micro amps is measured.
Y
N
The Preclean Corotron HVPS checks out OK. Check the following:
Preclean Corotron (PL 5.4).
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Preclean Corotron connector (PL 5.2).
Image Quality
IQ 38 Charge Corotron HVPS RAP, IQ 39 Preclean
A
Approximately +11.5 is measured at P/J95-6 on the 2nd BTR HVPS during standby.
Y
N
Go to Flag 6 BSD9.9 and check for an open connection at P/J95-6. If OK, replace the
2nd BTR HVPS (PL 9.2).

Procedure
WARNING
Approximately +11.5 is measured at P/J95-5 on the 2nd BTR HVPS during standby.
Y
N
Set your meter to measure micro amps. Disconnect the output connector from the 2nd BTR
HVPS (PL 9.2). Connect one meter lead to the supply side of the connector and the other lead
to the harness side. Make one full-color copy. Approximately -50 to -70 micro amps is measured momentarily near the end of the copy cycle.
Y
N
Approximately -20 to -30 micro amps is measured momentarily.
Y
N
Approximately 0 micro amps is measured.
Y
N
(This indicates that the measurement is between -1 and -19 micro amps, or -71
micro amps or higher.) Replace the 2nd BTR HVPS (PL 9.2).
Make one full-color copy. Voltage decreases from approximately +11.5 VDC to +0.03 VDC
momentarily near the end of the copy cycle.
Y
N
9.2).
The 2nd BTR HVPS checks out OK. Check the following:
2nd BTR Roll (PL 7.10).
Earth Plates (PL 7.10).
Wire Harness (PL 7.10).
High Voltage Lead from the IBT Assy to the 2nd BTR Roll.
Reconnect the output connector from the 2nd BTR HVPS. +24 VDC is measured
at P/J95-1 on the 2nd BTR HVPS during Standby.
Y
N
PWB (PL 9.2).
Make one full-color copy. Approximately +1.5 VDC is measured momentarily at
P/J95-3 on the 2nd BTR HVPS near the end of the copy cycle.
Y
N
PWB (PL 9.2).
Check for an open connection at P/J95-3, and at P/J95-1. If OK, go to Flag 3
BSD9.9 and check for an open in the output circuit. If OK, replace the 2nd BTR
HVPS (PL 9.2).
Make another full-color copy. Approximately +4.0 VDC is measured momentarily at
P/J95-7 on the 2nd BTR HVPS near the end of the copy cycle.
Y
N
Check for an open connection at P/J95-7. If OK, replace the 2nd BTR HVPS (PL
9.2).
9.2).
Reconnect the output connector to the 2nd BTR HVPS. Approximately +11.5 is measured
at P/J95-4 on the 2nd BTR HVPS during standby.
Y
N
A
Image Quality
1/05
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Reissue
DocuColor 12/DCCS50

This RAP is used to isolate the cause of missing or out-of-range voltages.
Procedure
WARNING
Failure to operate ALL the dC330 output components listed below will result in permanent damage to the photoreceptor.
Enter and stack the following dC330 components in the order listed: Drum Motor [04-021];
Erase Lamp [09-050]; Charge Corotron Wire [09-070]; Charge Corotron Grid [09-81]; and 1st
BTR HVPS [09-047]. Approximately +3.0 VDC is measured at P/J416A-A4 on the IOT
Drive PWB.
Y
N
+24 VDC is measured at P/J416A-A1 on the IOT Drive PWB.
Y
N
Check for an open connection at P/J416A-A1. If OK, replace the IOT Drive PWB PL
9.2.
Approximately +3.5 VDC is measured at P/J416A-A3.
Y
N
Check for an open connection at P/J416A-A3. If OK, replace the IOT Drive PWB PL
9.2.
Go to Flag 1, Flag 2, and Flag 3 BSD9.8 and check for an open circuit. If OK, replace the
1st BTR HVPS PL 7.6.
Check for an open connection at P/J416A-A4 on the IOT Drive PWB. If OK, go to Flag 4 and
check for an open circuit. If OK, the 1st BTR HVPS checks out OK. Check the following:
Bias Roll (PL 7.6).
High Voltage Lead from the HVPS to the Bias Roll. Replace the BTR HVPS if damaged
(PL 7.6).
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1/05
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Image Quality
IQ 42 DTS HVPS RAP
IQ 43 Paper Feed Checkout Procedure
This RAP is used to isolate the cause of missing voltages.
This Procedure is used to isolate the cause of Paper Feed problems for which no faults are
declared.
Procedure
Initial Actions
Make one full-color copy. Approximately +3.8 VDC is measured at P/J419A-7 on the IOT
Drive PWB near the end of the copy cycle.
Y
N
Y
N
Check for an open connection at P/J419A-11. If OK, replace the IOT Drive PWB (PL
9.2).
Check for bent or damaged baffles and guides in the paper feed area.
Check for loose, missing or stretched springs in the paper feed area.
Procedure
For Trays 1-4, check the following parts for wear, slipping, damage, or contamination. Replace
any parts that are questionable in the order listed until the problem is resolved.
Approximately +1.5 VDC is measured at P/J419A-9.

Y
N
Check for an open connection at P/J419A-9. If OK, replace the IOT Drive PWB (PL
9.2).
Feed/Nudger Roll Assembly (PL 2.5)
Retard Roll (PL 2.6)
Go to Flag 1, Flag 2, and Flag 3 BSD9.9 and check for an open circuit. If OK, replace the
DTS HVPS PL 2.14.
High Voltage Lead from the HVPS to the DTS.
Image Quality
IQ 42 DTS HVPS RAP, IQ 43 Paper Feed Checkout
Friction Clutch (PL 2.6)
T/A Roll (PL 2.7B)
T/A Feed Clutch (PL 2.7A)
For Tray 5, check the following parts for wear, slipping, damage, or contamination. Replace
Check for an open connection at P/J419A-7 on the IOT Drive PWB. If OK, go to Flag 4 and
check for an open circuit. If OK, the DTS HVPS checks out OK. Check the following:
Wire Harness (PL 7.10).
1/05
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Feed Roll (PL 2.9)
Retard Roll (PL 2.12)
Nudger Roll (PL 2.11)
Friction Clutch (PL 2.12)
T/A Pinch Roll (PL 2.10)
Pinch Roll (PL 2.10)
Registration Guide (PL 2.13)
Side Guide (PL 2.13)
Reissue
DocuColor 12/DCCS50
IQ 44 Registration Checkout Procedure
IQ 45 Wrinkle RAP
This procedure is used to isolate the cause of Registration problems for which no faults are
declared.
This procedure is used when the copy/print contains wrinkles or closely spaced waves.
Initial Actions
Initial Actions
Check for bent or damaged baffles and guides in the Registration area.
Check for loose, missing or stretched springs in the Registration area.
NOTE: Wrinkles (or waves) occur when there is non-uniform stress in the paper while it passes
though the Fuser Assembly. These stresses can be caused by the following: paper type or condition (old light-weight paper is worse), uneven oil distribution front to rear (OB to IB), differences in contact arc front to rear (OB to IB), and the type of image density (dark solid area
images, especially 2-sided copies/prints are worse).
Procedure
For Trays 1-5, check the following parts for wear, slipping, damage, or contamination. Replace
Registration Roll (PL 2.15)
Pinch Roll(PL 2.16)
Pre Registration Roll (PL 2.16)
Pre Registration Chute (PL 2.16)
Ensure that the customer is using a fresh supply of copy paper.
If oil streaks are present, go to the IQ 31 Fuser Oil Streak RAP.
If the problem occurs only when printing, ensure that the image density is being controlled
at a maximum of 70% for each color.
Rotate the original 180 degrees.
Procedure
NOTE: When performing the Fuser Nip adjustment, attempt to make both rear (IB) and front
(OB) values equal to each other.
Perform the Fuser Nip Adjustment ADJ 8.1.1. If the problem remains, perform this adjustment
again and reset the nip to the low end of the specification at both ends. If the problem still
remains, perform the following actions until the problem is resolved:
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1/05
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Check the HFSI status of the following fuser components: Heat Roll, Pressure Roll, External Heat Roll, and the Oil System (Donor Roll Assembly). Replace any item that is over
threshold.
Ensure that the Color Gradation Check located in the Image Quality Specification section
of the Image Quality Supplement is within specification. If it is not, perform ADJ 9.1.1 Max
Setup.
If the problem occurs when the copy paper is being fed LEF, try feeding the paper SEF.
Try using fresh 24 lb Xerox COLOR Xpressions paper (NASG) or 90 gsm Colortech +
paper (ESG). If the problem is resolved, recommend it to the customer.
If the problem occurs only when making 2-sided copies with high solid area density
images on both sides, it may be necessary to make single-sided copies to minimize or
eliminate the problem.
If the problem occurs only when using plain or coated light-weight paper, it is recommended that a heavier weight paper be used to minimize the problem.
Image Quality
IQ 44 Registration Checkout Procedure, IQ 45 Wrin-
IQ 46 Black Bead Carryout RAP
If the problem continues, perform the following corrective action steps in order until the problem
is resolved.
If the density is still light, check the Toner dispense system for any blockage or obstruction
that could limit the amount of Toner reaching the Developer Housing.
This RAP is used when the copy is experiencing bead carryout (BCO) for the color black. This
defect looks like mottle and is most noticeable in the high density areas. BCO is caused by low
toner concentration.
copy/print.
Initial Actions
This RAP assumes IOT s/w version 6.00.2 or higher is installed. If not, go to IQ 19 Bead Carryout RAP to begin troubleshooting.
Enter dC922 (TRC Control) from dC929 (Max Setup). Manually tone up black by setting
the Tone Interval to 12. If the problem is resolved, refer to Table 1 and set NVM 775-664
to 70 and NVM 775-669 to 65.
Replace the Developer Bias Brush, if damaged (REP 6.1.4)
Replace the Developer Housing, if damaged (PL 6.6).
Go to IQ 37 Developer Bias HVPS RAP.

Table 1 NVM Settings
Ensure that the paper presently being used is fresh 24 lb. Xerox COLOR Xpressions (NASG),
or 90 GSM Colortech + (ESG) paper or paper which is included in the customers Materials
Usage Guide and Recommended Paper List. Run test copies. If the copies reproduced still
have Bead Carryout, continue with this RAP.
Procedure
NOTE: Ensure that 8 1/2 X 11 LEF paper is installed in Tray 2 before continuing.
Enter the diagnostic mode from the UI and select MAX Setup. Select TRC Set UP/Toner Concentration Adjustment. Select TRC Control (dC922). Make a ProCon test pattern by pressing
the Start button. Examine the copy for mottle-like or non-uniform (spotty) density in the highdensity patches. One of these defects is present in the 100% patch (top row) in black.
Y
N
Go to IQ 2 Defect Listing and choose one or more of the following defects to continue
troubleshooting: mottle, high image density, deletions, or spots.
NVM Location
NVM Value
773-223
200
773-269
160
775-681
775-664
65
775-669
60
775-673
100
775-914
100
775-924
100
Select Close three times to take you back to the main menu. Select NVM Read/Write. NVM
locations 773-021 through 773-028 are set to 1.
Y
N
Select MAX Setup. Select and run ADC AGC Setup (dC934) and VH/VM Setup (dC933)
in Max Setup (dC929) and investigate any system failure that is declared.
NVM 773-004 is set to 1;
Y
N
Set NVM to 1.
The value in NVM location 773-121 is between 5 and 95 (this number represents the percentage of room humidity).
Y
N
Replace the Humidity Sensor (PL 7.1).
Refer to Table 1 to ensure that all the NVM settings indicated are correct. If any NVM value
needs to be changed, replace the developer material (REP 6.6.2). If all NVM values are correct
but it has been less than 2,000 copies since the IOT s/w 6.00.2 was installed, replace the
developer material (REP 6.6.2).
Image Quality
IQ 46 Black Bead Carryout RAP
1/05
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DocuColor 12/DCCS50
Table 1
The purpose of the Automatic Toner Concentration Sensor, ATC, is to detect toner concentrations within the color developer housings (Y, M, and C). The DC12 process controls use the
input from the ATC Sensor to maintain TC in the 5-10% range (as described below) minimizing
TC related defects such as BCO and Starvation. BCO or Bead Carry Out commonly occurs
when the TC drops below 5%. BCO appears as mottle or white spots in high-density areas.
Starvation can occur when the TC exceeds 10%. Starvation appears as a deletion at the
boundary between a high and low-density area.
The ATC Sensor consists of; ATC Sensor Assembly, wire harness (J\P 423 on the IOT Drive
PWB), Plate assembly, and an assisting IOT Drive PWB. Troubleshooting the functionality of
the ATC Sensor is mainly executed through NVM read and write. dC330 component control
has been implemented.
Appendix 1 is the set-up procedure to turn ATC Sensor on for machines with software v7.5.3.
SOFTWARE (NVM) REPAIRS:

The machine must have software version V6.00.2 or higher installed.
Make sure NVM 775-731=1on (ATC function 0=OFF / 1=ON)
3.
Check the value of NVM 775-815 (TC set average). Software v6.2.0 has default 250 without ATC Sensor set-up. Software v6.00.x has default 0 without ATC Sensor set-up. (See
Appendix 3c). The value can also be affected by the space between the ATC Sensor and
the Developer Housing Mag- Roll. See Appendix 1 for re-setup instructions. After a successful set-up, NVM 775-815 should be between 150 230.
4.
M_TC measured value failure at setup
775-749
C_TC measured value failure at setup
775-750
Setup failure, any of the above failures
Table 2
For Black, the machine monitors a 60% and 100% ADC patch. Since the ATC Sensor cannot
measure Black TC, the 100% Black ADC patch was implemented in software 6.002 or Tag#16.
2.
Content
Recovery procedure at NVM Failure
In the DC12 (DCCS50), 65% Y, M, C ADC process control patches are periodically read by the
ADC Sensor and compared to ADC Targets. If the readings are not within a specified range of
the targets, the machine will tone up or down as required. The machine is constantly adjusting
the ADC Targets based on input from the Humidity Sensor and ATC Sensor. The process controls attempt to maintain densities across different environments while maintaining TC in the 510% range.
1.
NVM
775-748
NVM Value
1 = OK
0 = NG
Content
NG action
(perform
action
below)
775-741
Dark current failure
775-742
Reference plane output failure
3, 2, 1
775-743
Y_TC measured value failure
4, 2, 1
775-744
M_TC measured value failure
4, 2, 1
775-745
C_TC measured value failure
4, 2, 1
775-746
Shutter open/close failure
775-747
Y_TC measured value failure at setup
4, 2, 1
775-748
M_TC measured value failure at setup
4, 2, 1
775-749
C_TC measured value failure at setup
4, 2, 1
775-750
Setup failure (any of the above failures
3, 2, 1
Action 1: Replace the ATC Sensor and verify the connection.

Action 2: Verify shutter operation. dC330 component controls 009-039 shutter operation.
(See step 8).
Action 3: Ensure the Sensor/reference plane is free from contamination.
Action 4: Verify correct installation of the ATC Sensor Assembly.
5.
Check the following NVM. 775-761 (Measurement TC Sensor Dark Current) value should
be less than 200. Check 775-762 (Measurement of TC Reference Plane) value range
200 ~ 600. If NVM are not within given range, perform step 8 (dC330 component control). If NVM are not within range after dC330 (step 8), ensure the ATC Sensor and shutter is free from contamination. If problem continues perform steps b) through g) of
Appendix 1. If problem continues refer to the Hardware Repairs.
6.
ADC Targets. Check the NVM and change to given value if necessary. The ADC Targets
must be set to nominal values. 773-266=230; 773-267=230; 773-268=250; 773-269=160.
If any of the NVM values are not set to nominal, correct values and perform steps b)
through g) of Appendix 1.
7.
When ATC Sensor is installed, specified developer is noted by NVM. Machines from manufacturing should have all new color developers. If ATC Sensor was installed in field, then
the developer that is replaced must be specified by NVM. Check the NVM and ensure it
corresponds with specified developer. (775-737 see Appendix 1e).
8.
dC330 (Component Control) after the ATC Sensor is implemented.
Using Table 1, confirm that the following NVM values are 1. If any of the values are 0,
repeat steps b) through g) of Appendix 1. After steps b) through g) are completed, refer
back to Table 1 and confirm that the values are all 1. If any values are 0, refer to the recovery procedure listed for the corrective action.
Table 1
NVM
Content
775-741
Dark current failure
775-742
Reference plane output failure
775-743
Y_TC measured value failure
775-744
M_TC measured value failure
775-745
C_TC measured value failure
775-746
Shutter open/close failure
775-747
Y_TC measured value failure at setup
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The following dC330 routines have been added according to the ATC Sensor implementation:
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Image Quality
009-038 (ATC_LED): actuates the LED ON/OFF.

NVM designation
Chain
Link
SET value
Measurement of the TC: NVM 775-982 (This function requires that the desired developer
housing is facing the ATC Sensor. Perform the following steps:
TC_OUT_Hilimit2[Y]
775
825
15
TC_OUT_Hilimit2[M]
775
826
15
TC_OUT_Hilimit2[C]
775
827
15
TC_OUT_Lolimit1[Y]
775
829
20
TC_OUT_Lolimit1[M]
775
830
20
TC_OUT_Lolimit1[C]
775
831
20
TC_CNT_Hi2_MAX
775
839
TC_CNT_Lo2_MAX
775
840
TC_CYAN_OFFSET
775
850
494
TC_RADCS_UP_STEP2
775
859
10
TC_RADCS_DWN_STEP2
775
860
Delta_RADCS_TC_MAX[Y]
775
874
592
Delta_RADCS_TC_MAX[M]
775
875
592
Delta_RADCS_TC_MAX[C]
775
876
592
TC_PV_INT
775
896
Radc_SET_Adj_MIN[K]
775
914
100
Radc_SET_DISP_Adj_MIN[K]
775
924
100
TC_SET_OUT_MAX[Y]
775
966
300
TC_SET_OUT_MAX[M]
775
967
300
TC_SET_OUT_MAX[C]
775
968
300
TC_SET_INIT
775
991
205
a.
Enter sub-system check on the UI and sub-system test on the PWS for machine
diagnostics. Select developer unit check.
b.
For best observation, remove machine Right Upper Cover PL 11.2.
c.
Press Start (if using the UI) or move desired developer into position. Please note the
ATC Sensor is opposite the development position. (UI diagnostics) Select Black,
results in Yellow at ATC Sensor position. Select Magenta, results in Cyan at ATC
Sensor position. Select Cyan results in Black at ATC Sensor position. Select Yellow,
results in Home position. Select Home, results in Magenta at ATC Sensor position.
d.
e.
f.
g.
9.
Table 3
009-039 (Opening/closing of the shutter and TC measurement):
Close developer unit check screen. The desired developer housing remains in
position.
Enter dC330 Component control. Enter 009-039 and press Start. (Shutter activation). Close dC330.
Enter NVM read \ write. NVM 775-982 = TC reading for desired color. (Black is not
detectable with ATC Sensors) Value range 140 ~ 200 for selected color.
If 775-982 is out of given range, perform steps b) through h) of Appendix 1. If problem continues refer to Hardware Repairs.
Check the following NVM and ensure the values are set to given value. Correct values if
needed and repeat steps b) through g) of Appendix 1
Table 3
NVM designation
Chain
Link
SET value
TH2_100_PV_K
773
223
200
K_Delta_VHS_HUM_DWN
773
286
961
K_Delta_VMS_HUM_DWN
773
287
250
K_Delta_BIAS_HUM_DWN
773
289
624
K_Delta_Radc_SET_HUM_K_DWN
773
309
TH1_G100(K)
775
664
65
TH2_G100(K)
775
669
60
Delta_RADCS_100_MAX_K
775
673
100
ATC_CTRL_SW
775
731
TC_OFFSET_OUT_TH
775
773
200
TC_Ref_OUT_MIN
775
776
200
TC_Ref_OUT_MAX
775
777
600
TC_OUT_Adj_MAX
775
779
350
TC_Ref
775
783
420
TC_SET[Y]
775
784
173
TC_SET[M]
775
785
173
TC_SET[C]
775
786
175
TC_OUT_Hilimit1[Y]
775
821
30
TC_OUT_Hilimit1[M]
775
822
30
TC_OUT_Hilimit1[C]
775
823
30
Image Quality
10. dC131 (NVM) after the ATC Sensor is implemented.

11.Check that the following dC131 values have been added according to the ATC Sensor
implementation. NVM are noted if values are judgements or result readings to clarify
some NVM are readings and may vary.
Table 4
1/05
3-44
Chain-Link NVM
No.
Designation
Initial
Value
Set Range
Meaning
775-731
ATC_CTRL_SW
0~65535
ATC Control Switch 1=ON,

0=OFF
775-736
TC_Flag1
0~65535
Calibration Control of the

ATC Sensor for M/C to M/C
variation
1: Execution of the TRC CON
+ Diag.
0: TRC CONT + MINISET by
ATC
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Table 4
Chain-Link NVM
No.
Designation
Initial
Value
Table 6
Set Range
Meaning
0~65535
Color Selection for ATC Control

1: YMC (initial value) 2: only
Y, 3: only M, 4: only C, 5: only
YM, 6: only YC, 7: only MC
Chain-Link NVM
No.
Designation
ATC SENSORS RESULT JUDGMENT OF TC (OK or NG, see step 4)

Table 5
Chain-Link NVM
No.
Designation
Initial
Value
Set Range
Meaning
Initial
Value
Set Range
Meaning
775-752
TC_Ref_OUT_Fai 0
l
0~65535
Frequency of measured TC
value fail with reference
plane (hidden fail)
775-753
TC_OUT_Fail[Y]
0~65535
value fail (hidden fail) [Y]
775-754
TC_OUT_Fail[M]
0~65535
value fail (hidden fail) [M]
775-755
TC_OUT_Fail[C]
0~65535
value fail (hidden fail) [C]
775-756
TC_Ref_OPEN_
OUT_Fail
0~65535
value fail with shutter open
(hidden fail)
775-741
TC_OFFSET_OU 1
T_jd
0~65535
Judgment of TCOFFSET output (1: OK, 0:NG)
775-742
TC_Ref_OUT_jd
0~65535
Judgement of TC reference
plane measurement (1: OK,
0:NG)
775-743
TC_OUT_jd[Y]
0~65535
Judgement of measured TC
value (1: OK, 0:NG) [Y]
Chain-Link NVM
No.
Designation
Initial
Value
Set Range
Meaning
775-744
TC_OUT_jd[M]
0~65535
value (1: OK, 0:NG) [M]
775-791
TC_OUT_Adj[Y]
200
140 ~ 200
TC output adjustment value

[Y]
775-745
TC_OUT_jd[C]
0~65535
value (1: OK, 0:NG) [C]
775-792
TC_OUT_Adj[M]
200
140 ~ 200

[M]
775-746
TC_Ref_OPEN_
OUT_jd
0~65535
value with shutter open (1:
OK, 0:NG)
775-793
TC_OUT_Adj[C]
200
140 ~ 200

[C]
775-747
TC_SET_OUT_jd 1
[Y]
0~65535
value at Diag setup (1: OK,
0:NG) [Y]
775-782
TC_OUT_Daig_A 0
dj
140 ~ 200
Adjustment results of TC
measured value at Diag I/O
check
775-748
TC_SET_OUT_jd 1
[M]
0~65535
0:NG) [M]
TC_SET_OUT_jd 1
[C]
0~65535
TC_SET_ALL_jd
0~65535
775-749
775-750
ATC SENSOR TC READING RESULTS. (see value range description detailed in step 8f).
Table 7
Appendix 1. ATC set-up procedure
0:NG) [C]
General judgement of ATC
control (1: OK, 0:NG)
NVM COUNTER FOR TC MEASUREMENT FAILURE. (see Appendix 3c)

Table 6
Chain-Link NVM
No.
Designation
775-751
Initial
Value
TC_OFFSET_OU 0
T_Fail
Reissue
DocuColor 12/DCCS50
1.
Install at least one new developer. The ATC Sensor must be calibrated from new developer.
2.
Set 775-731 to 1 turns ATC Sensor on. (0 = off).
3.
Confirm NVM 773-266 through 269 are set to 230, 230, 250, 160. (ADC Targets nominal
values).
4.
Set 775-736 to 1. (Value will return to 0 after executing dC922).
5.
Set 775-737 to appropriate value depending on developer material replaced for set-up.
1 = replacement of YMC
2 = replacement of Y
3 = replacement of M
4 = replacement of C
Set Range
Meaning
5 = replacement of YM
0~65535
Frequency of TCOFFSET
output fail (hidden fail)
6 = replacement of YC
7 = replacement of MC
1/05
3-45
Image Quality
6.
A
Enter dC330 [9-038] ATC LED. Open and close the shutter. The LED changes state.
Y
N
+5 VDC is measured between P/J 423-4 and DC COM.
Y
N
Check the IOT Drive PWB for damage and loose mounting. Replace the IOT Drive
PWB (PL 9.2) as required.
Mix developer by executing three (3) internal test pattern #10 from the UI diagnostics or
Test Pattern #99 other halftones 0% Cin (blank print) from PWS.
7.
Execute dC922 TRC Control Ignore Tone-up or down result.
8.
Check 775-741 through 750 = 1 for successful setup. See step #4 of the Software
Repairs and perform action if required.
Appendix 2 Necessity of Re-Setup
+ 5 VDC is measured between P/J 750-4 and DC COM.

Y
N
Go to Flag 8 on BSD 9.2 and check the wires for an open. If the wires check OK,
replace the ATC Sensor Assy (PL 9.1).
ATC Sensor is required to be re-setup per the Setup Procedure in Appendix 1 in the following
cases.
When one or more developers are replaced.
When the sensor or sensor assembly is replaced (not required for simple removal of
bracket).
When position of the sensor installed is obviously displaced (distortion of the bracket,
installation error etc).
Inspect the LED and ensure that it is clean and free of contamination. Replace the ATC
Sensor Assy (PL 9.1) as required.
The circuit appears to be functional. If the problem continues, inspect the LED and ensure that
it is clean and free of contamination. Replace the ATC Sensor Assy (PL 9.1) as required.
Appendix 3
1.
If an ATC Sensor is installed in a machine and NOT calibrated (i.e. 775-736 is not set to 1
and dC922 is not executed) the default value for 775-815 (calibration reference) is
250(SW V6.1X) or 0(SW V6.00.X).
2.
ATC Sensor takes readings every 5th copy based on A3 or 11 x 17 inch paper. The
machine maintains a running average of the last 3 readings.
3.
Installing sw 6.12 or higher to a machine WITHOUT an ATC Sensor, 775-731 MUST BE

TURNED OFF TO 0 MANUALLY. If the ATC Sensor remains on, the NVM fail counter will
continue to count, but poses no problem to ATC related density. When upgrading software
to sw6.12 or higher (machine that has ATC Sensor turned on), value 775-815 must be
transferred to current machine NVM read and write.
Hardware Repairs
Initial Actions
Ensure that wire harness P\J500 is connected from the ATC Sensor Assembly to P/J423
the of IOT DRV PWB.
Inspect the ATC Sensor Assembly for shutter damage, LED/shutter for contamination, .
Make sure the assembly is installed correctly
If the shutter is contaminated wipe with soft cloth.
Procedure
Check function of the shutter by dC330 009-039 closes and opens the shutter, 009-038 actuates the LED on and off. The ATC shutter operates.
Y
N
+24 VDC is measured between P/J278-2 and P/J278-3 on the ATC Sensor Assy.
Y
N
+24 VDC is measured between P423-1 and P423-3 on the IOT Driver PWB.
Y
N
Go to Flag 7 on BSD 9.2 and check the wires for a short circuit. If the wires are
Go to Flag 7 on BSD 9.2 and check the wires for an open circuit.
Replace the ATC Sensor Assy (PL 9.1)
A
Image Quality
1/05
3-46
Reissue
DocuColor 12/DCCS50

Refer to the hard copy supplement for Image Quality Specifications (701P15670).
Reissue
DocuColor 12/DCCS50
1/05
3-47
Image Quality
Image Quality
1/05
3-48
Reissue
DocuColor 12/DCCS50

Refer to the hard copy supplement for Image Quality Defects (701P15670).
Reissue
DocuColor 12/DCCS50
1/05
3-49
Image Quality
Image Quality
1/05
3-50
Reissue
DocuColor 12/DCCS50
4 Repairs & Adjustments

REPAIRS
REP 3.3.1 Carriage Cables .............................................................................................

REP 3.3.2 Carriage Motor ...............................................................................................
REP 3.4.1 Exposure Lamp..............................................................................................
REP 3.4.2 Lamp Wire Harness .......................................................................................
REP 3.5.1 IPS Chassis ...................................................................................................
1. DRIVE
REP 1.3.1 Belt (Developer Drive) ...................................................................................
REP 1.4.1 Belt (2nd BTR, Auger) ...................................................................................
REP 1.5.1 Tray 5/Regi. /Tray 1 Take Away Drive...........................................................
REP 1.6.1 Exit Drive .......................................................................................................
REP 1.6.2 Fuser Drive ....................................................................................................
REP 1.6.3 Exit/Fuser Nip Drive Assembly ......................................................................
4-3
4-5
4-8
4-9
4-11
4-13
4. ROS
REP 4.1.1 ROS ...............................................................................................................
REP 5.1.1 Erase Lamp....................................................................................................
REP 5.3.1 Drum Unit.......................................................................................................
REP 5.3.3 Cleaning Brush ..............................................................................................
REP 5.3.4 Cleaning Blade...............................................................................................
REP 5.4.1 Charge Corotron ............................................................................................
REP 5.4.2 PCC Wire .......................................................................................................
REP 5.5.1 Waste Toner Auger........................................................................................
REP 5.5.2 Auger Belt ......................................................................................................
4-17
4-17
4-18
4-19
4-20
4-21
4-22
4-22
4-24
4-24
4-26
4-27
4-28
4-29
4-30
4-32
4-33
4-35
4-36
4-37
4-38
4-38
4-39
4-40
4-41
4-42
4-43
4-45
4-47
4-48
4-48
4-49
Reissue
DocuColor 12/DCCS50
4-67
4-68
4-69
4-70
4-71
4-71
4-73
4-74
6. DEVELOPMENT
REP 6.1.1 Rotary PWB ...................................................................................................
REP 6.1.2 Rotary Home Position Sensor........................................................................
REP 6.1.3 Rotary Latch Lever.........................................................................................
REP 6.1.4 Bias Brush......................................................................................................
REP 6.2.1 Toner Cartridge Unit ......................................................................................
REP 6.3.1 Toner Cartridge Housing (Cyan, Magenta, Yellow, Black) ............................
REP 6.3.2 Cartridge/Dispense Motor (Cyan, Magenta, Yellow, Black)...........................
REP 6.4.1 Dispense PWB...............................................................................................
REP 6.6.1 Development Housing....................................................................................
REP 6.6.2 Developer Replacement ................................................................................
REP 6.7.1 Rotary Auger (Cyan, Magenta, Yellow, Black)...............................................
REP 6.7.2 Trickle Auger..................................................................................................
4-77
4-78
4-79
4-82
4-83
4-84
4-85
4-86
4-87
4-89
4-92
4-96
7. IBT
REP 7.1.1 IBT .................................................................................................................
REP 7.1.2 IBT Cleaner....................................................................................................
REP 7.5.1 IBT Belt ..........................................................................................................
REP 7.6.1 Bias Roll.........................................................................................................
REP 7.6.2 Drive Roll .......................................................................................................
REP 7.6.3 Back-up Roll...................................................................................................
REP 7.6.4 Contact Roll ...................................................................................................
REP 7.9.1 2nd BTR.........................................................................................................
REP 7.10.1 2nd BTR Roll................................................................................................
4-99
4-101
4-102
4-104
4-106
4-108
4-109
4-109
4-111
8. FUSER
3. IIT
REP 3.1.1 Platen Glass ..................................................................................................
REP 3.1.2 IIT Opening/Closing .......................................................................................
REP 3.2.1 CCD PWB ......................................................................................................
4-65
5. XEROGRAPHICS
2. PAPER TRANSPORT
REP 2.1.1 Tray 1 Set Sensor..........................................................................................
REP 2.1.2 Tray 2/3/4 Size Sensor ..................................................................................
REP 2.4.1 Tray 1/2/3/4 Feeder .......................................................................................
REP 2.5.1 Tray 1/2/3/4 Feed/Nudger Roll Assembly ......................................................
REP 2.6.1 Feed Lift Motor...............................................................................................
REP 2.6.2 Retard Roll.....................................................................................................
REP 2.7.1 Tray 2-4 Take Away Drive .............................................................................
REP 2.7.2 Tray 2/3/4 Feed T/A Clutch............................................................................
REP 2.7.3 T/A Motor .......................................................................................................
REP 2.8.1 Tray 1 Feed-out Sensor, T/A Sensor.............................................................
REP 2.8.2 Tray 2/3/4 Feed-out Sensor...........................................................................
REP 2.9.1 Tray 5.............................................................................................................
REP 2.11.1 Tray 5 Nudger Roll.......................................................................................
REP 2.11.2 Tray 5 Feed Roll ..........................................................................................
REP 2.12.1 Tray 5 Lift Motor...........................................................................................
REP 2.12.2 Tray 5 Retard Roll........................................................................................
REP 2.14.1 Regi. Unit .....................................................................................................
REP 2.15.1 Regi. Sensor ................................................................................................
REP 2.15.2 Regi. Roll .....................................................................................................
REP 2.15.3 Regi. Motor ..................................................................................................
REP 2.16.1 Pre Regi. Sensor .........................................................................................
REP 2.16.2 Pre Regi. Roll...............................................................................................
REP 2.17.1 Vacuum Transport .......................................................................................
REP 2.17.2 Vacuum Transport Belt ................................................................................
REP 2.21.1 Duplex Path Sensor .....................................................................................
REP 2.21.2 Duplex Out Sensor ......................................................................................
REP 2.21.3 Duplex Belt 1/2 ............................................................................................
REP 2.23.1 Inverter 1......................................................................................................
REP 2.23.2 Inverter 2......................................................................................................
REP 2.24.1 Inverter Motor ..............................................................................................
REP 2.24.2 Release Solenoid.........................................................................................
REP 2.26.1 Exit Roll........................................................................................................
4-55
4-60
4-61
4-62
4-63
REP 8.1.1 Fuser Unit ......................................................................................................

REP 8.2.1 Donor Roll Assembly .....................................................................................
REP 8.3.1 Heat Roll ........................................................................................................
REP 8.3.2 Heat Roll Heater Rod.....................................................................................
4-51
4-52
4-54
1/05
4-1
4-115
4-116
4-117
4-120
Repairs and Adjustments
REP 8.3.3 Pressure Roll .................................................................................................

REP 8.3.4 Pressure Roll Heater Rod..............................................................................
REP 8.3.5 Heat Roll Stripper Finger ...............................................................................
REP 8.4.1 Web Motor/EXT-HR Retract Motor ................................................................
REP 8.7.1 Oil Pump ........................................................................................................
REP 8.7.2 Oil Wick..........................................................................................................
REP 8.8.1 External H/R Heater Rod ...............................................................................
REP 8.8.2 External Heat Roll..........................................................................................
REP 8.10.1 Pressure Roll Stripper Finger ......................................................................
4-122
4-125
4-127
4-128
4-131
4-132
4-133
4-136
4-137
REP 13.14.1 Decurler Stepping Motor ............................................................................
14. OCT
REP 14.1.1 Offset Motor .................................................................................................
3. IIT
4-139
4-139
4-141
4-143
4-145
4-146
4-148
4-149
ADJ. 3.4.1 Full Rate/Half Rate Carriage Position............................................................
4-193
4-193
8. FUSER
ADJ 8.1.1 Fuser Nip (DC701) .........................................................................................
ADJ 8.8.1 External Heat Roll Nip Adjustment .................................................................
4-151
4-152
4-197
4-197
9. ELECTRICAL
ADJ 9.1.1 MAX SET UP (dC929)....................................................................................
ADJ 9.1.2 IIT Calibration (dC945) ...................................................................................
ADJ 9.1.3 ADC AGC Setup (dC934)...............................................................................
ADJ 9.1.4 VH/VM Setup (dC933)....................................................................................
ADJ 9.1.5 IOT Highlight Setup (dC918) ..........................................................................
ADJ 9.1.6 TRC Control/Toner Density (dC922) ..............................................................
ADJ 9.1.7 TRC Adjust (dC924)/TRC Check PG (dC939) ...............................................
ADJ 9.1.8 Color Balance Setup (dC919: Copier/Printer) ................................................
ADJ 9.1.10 IOT Registration Series (dC129) ..................................................................
ADJ 9.1.14 IIT Lead Edge Registration...........................................................................
ADJ 9.1.15 IIT Side Edge Registration............................................................................
ADJ 9.1.16 IIT Horizontal Magnification/Vertical Magnification (IIT Machine).................
ADJ 9.1.17 Tray 5 Guide (dC740)...................................................................................
ADJ 9.1.18 Touch Panel Starting Point Correction .........................................................
ADJ 9.1.19 Tray 2, 3, and 4 for 12 x 18 Paper................................................................
4-153
12. DADF
REP 12.1.1 DADF ...........................................................................................................
REP 12.2.2 Registration Gate Solenoid..........................................................................
REP 12.3.1 Left/Right Counter Balance..........................................................................
REP 12.3.2 DADF Control PWB .....................................................................................
REP 12.4.1 Feed Motor ..................................................................................................
REP 12.4.2 Nudger Roll..................................................................................................
REP 12.4.3 Feed Roll .....................................................................................................
REP 12.5.1 Document Feed Lower Chute ......................................................................
REP 12.5.2 Retard Roll...................................................................................................
REP 12.5.3 Set Gate Solenoid........................................................................................
REP 12.5.4 Registration Sensor .....................................................................................
REP 12.5.5 Size Sensors 1/2 (Rear/Front) .....................................................................
REP 12.6.1 DADF Belt Motor..........................................................................................
REP 12.7.1 Duplex Sensor .............................................................................................
REP 12.8.1 Registration Pinch Roll ................................................................................
REP 12.9.1 Exit Motor.....................................................................................................
REP 12.10.1 Platen Belt .................................................................................................
4-189
6. DEVELOPMENT
ADJ 6.1.1 Rotary Home Position Sensor ........................................................................
ADJ 6.6.1 Rotary Development Housing Position...........................................................
11. COVER
REP 11.1.1 Platen Cushion ............................................................................................
4-187
4-188
4-188
ADJUSTMENTS
10. AIR SYSTEM

REP 10.2.1 Fuser Fan ....................................................................................................
REP 10.2.2 Suction Blower Motor...................................................................................
4-185
19. IDFE
REP 19.1 Removing the IDFE.........................................................................................
REP 19.2 Token Ring PWB (IDFE).................................................................................
REP 19.3 DIMMs on the Motherboard (IDFE).................................................................
9. ELECTRICAL
REP 9.2.1 Opening/Closing the IOT Control PWB Chassis............................................
REP 9.2.2 IOT Drive PWB ..............................................................................................
REP 9.2.3 Half Tone PWB ..............................................................................................
REP 9.3.1 Power Chassis...............................................................................................
REP 9.3.2 IOT LVPS.......................................................................................................
REP 9.3.3 B3/B3H (ESS) LVPS......................................................................................
REP 9.5.1 Control Panel .................................................................................................
REP 9.6 Billing Data PWB Replacement ........................................................................
4-184
4-155
4-156
4-156
4-158
4-159
4-160
4-161
4-162
4-163
4-164
4-165
4-166
4-167
4-168
4-170
4-172
4-173
4-199
4-199
4-200
4-200
4-201
4-201
4-202
4-203
4-203
4-207
4-208
4-209
4-211
4-212
4-213
12. DADF
ADJ 12.1.1 DADF Side Registration ...............................................................................
ADJ 12.3.1 Left/Right Counter Balance ..........................................................................
ADJ 12.3.2 DADF Parallelism .........................................................................................
ADJ 12.3.3 DADF Height ................................................................................................
ADJ 12.4.1 DADF Lead Edge Registration .....................................................................
4-215
4-216
4-217
4-218
4-221
13. MAIL BOX SORTER

REP 13.3.1 Decurler .......................................................................................................
REP 13.5.1 Vertical LED/Sensor ....................................................................................
REP 13.5.2 Bin Tray 1 ....................................................................................................
REP 13.6.1 Bin Trays 2 - 10 ...........................................................................................
REP 13.13.1 Decurler Rolls 1/2 ......................................................................................
REP 13.13.2 Gear and Cam ...........................................................................................
4-175
4-176
4-177
4-179
4-180
4-182
1/05
4-2
Reissue
DocuColor 12/DCCS50
REP 1.3.1 Belt (Developer Drive)
3. Remove the main motor.
Parts List on PL 1.3

Removal
WARNING
1.
Remove the IOT Rear Cover (PL 11.3).
2.
Remove the Toner Waste Bottle.
3.
Open the IOT Control PWB Chassis (REP 9.2.1).
4.
Remove the flywheel and flange (Figure 1).

1. Remove the screws (2).
2. Remove the Flywheel.
3. Loosen the screws (2).
4. Remove the flange.
Figure 2 Removing the Main Motor

7.
Remove the Main Motor Bracket (Figure 3).

2. Remove the bracket.
Figure 1 Removing the Flywheel

5.
Remove the Waste Toner Auger (REP 5.5.1).
6.
Remove the Main Motor (Figure 2).

1. Disconnect the connectors (2).
Reissue
DocuColor 12/DCCS50
1/05
4-3
REP 1.3.1
Figure 3 Removing the Main Motor Bracket

8.
Remove the Rotary Developer Duct (Figure 4).

2. Remove the VSEL rear bracket.
4. Remove the Rotary Developer Duct.
Figure 4 Removing the Rotary Developer Duct

9.
Remove the belt (Figure 5).

1. Remove the spring.
2. Loosen the screw.
5. Remove the belt.
REP 1.3.1
1/05
4-4
Reissue
DocuColor 12/DCCS50
REP 1.4.1 Belt (2nd BTR, Auger)

Removal
WARNING
1.
Remove the IOT Rear Cover (PL 11.3 Item 7)
2.
Remove the Toner Waste Bottle.
3.
4.
Remove the Flywheel and flange (Figure 1).

2. Remove the Flywheel.
4. Remove the flange.
Figure 5 Removing the Belt
Installation
1.
Reinstall the parts in the reverse order of disassembly.

Figure 1 Removing the Waster Toner Auger
5.
Remove the Waster Toner Auger (REP 5.5.1).
6.
Remove the Main Motor (Figure 2).

Reissue
DocuColor 12/DCCS50
1/05
4-5
REP 1.3.1, REP 1.4.1
Remove the Main Motor.
Figure 3 Removing the Main Motor Bracket

Figure 2 Removing the Main Motor
7.
8.
Remove the Main Motor Bracket (Figure 3).
Remove the Auger Drive (Figure 4).

2. Remove the E-clip.
3. Remove the gear.

5. Remove the Auger Drive.
6. Disconnect the connector.
7. Remove the bearing.
REP 1.4.1
1/05
4-6
Reissue
DocuColor 12/DCCS50
Figure 4 Removing the Auger Drive

9.
Figure 5 Removing the Belt
Remove the belt (Figure 5).
Installation
1. Loosen the screws (2) and the belt tension.
1.

3. Remove the gear pulley.
4. Remove the gear pulley.
5. Remove the belt.
Reissue
DocuColor 12/DCCS50
1/05
4-7
REP 1.4.1
REP 1.5.1 Tray 5/Regi. /Tray 1 Take Away Drive

Removal
WARNING
1.
2.
Remove the Left Upper Rear Cover (PL 11.3 Item 2)
3.
Remove the Tray 5/Regi. and Tray 1 Take Away Drive (Figure 1).
3. Release the clamp and remove the harness.
6. Remove the drive.
Figure 1 Removing the Drives
Installation
1.
REP 1.5.1
1/05
4-8
Reissue
DocuColor 12/DCCS50
REP 1.6.1 Exit Drive

Removal
WARNING
1.
2.
Remove the Filter Unit Cover (PL 11.2 Item 4)
3.
4.
Move the wire harness (Figure 1).

1. Release the clamps (2).
2. Move the harness.
3. Remove the clamp.
Figure 1 Moving the Harness

5.
Remove the duct (Figure 2).

2. Remove the duct.
Reissue
DocuColor 12/DCCS50
1/05
4-9
REP 1.6.1
Figure 2 Removing the Duct

6.
Remove the Exit Drive (Figure 3).

1. Remove the screw.
2. Remove the Motor Cover.
5. Remove the motor.
7. Remove the Exit Drive.
Figure 3 Removing the Exit Drive
Installation
1.
REP 1.6.1
1/05
4-10
Reissue
DocuColor 12/DCCS50
REP 1.6.2 Fuser Drive

Removal
WARNING
1.
Remove the following covers:

1.
IOT Rear Cover (PL 11.3 Item 7)
2.
Tray Module Rear Cover (PL 11.3 Item 11)
3.
Filter Unit Cover (PL 11.2 Item 4)
4.
Pull out Tray 1.
5.
Remove the Auger Sensor and the 2nd BTR HVPS (Figure 1).
3. Remove the sensor.
5. Pull out the connector.
6. Remove the screws (3)
7. Remove the 2nd BTR HVPS.
Figure 1 Removing the Auger Sensor

6.

2. Release the hook and remove the duct.
Reissue
DocuColor 12/DCCS50
1/05
4-11
REP 1.6.2

7.
Remove the Filter Case (Figure 3).

1. Remove the filter.
2. Remove the duct.
4. Remove the Filter Case.
Figure 3 Removing the Filter Case

8.
Remove the Fuser Drive (Figure 4).

1. Disconnect the connector (2).
3. Remove the Fuser Drive.
REP 1.6.2
1/05
4-12
Reissue
DocuColor 12/DCCS50
REP 1.6.3 Exit/Fuser Nip Drive Assembly

Removal
1.
2.
3.
IOT Rear Cover (PL 11.3 Item 7)
Tray Module Rear Cover (PL 11.3 Item 11)
Filter Unit Cover (PL 11.2 Item 4)

Figure 4 Removing the Fuser Drive
Installation
1.

4.
Remove the Filter Case (PL 10.2 Item 3) (Figure 2).

1. Remove the filter.
2. Remove the duct by lifting up and out of the Filter Case.
4. Remove the Filter Case.
Reissue
DocuColor 12/DCCS50
1/05
4-13
REP 1.6.2, REP 1.6.3

7.
Remove Inverter 2 (REP 2.23.2).
8.
Remove Inverter 1 (REP 2.23.1).

NOTE: Exit/Fuser Nip Drive Assembly is mounted on the rear frame at the top of the
inverter opening
9.
Remove the Exit/Fuser Nip Drive Assembly (Figure 4 and Figure 5).
Figure 2 Removing the Filter Case

5.
Lower the IOT Control PWB Chassis (REP 9.2.1).
6.
Remove the Filter Duct (PL 10.2 Item 2) (Figure 3)

2. Remove the duct.
REP 1.6.3
1/05
4-14
Reissue
DocuColor 12/DCCS50
Installation
NOTE: Ensure that the Exit/Fuser Nip Drive Assembly is seated correctly. If assembly is not in
the correct position, the K-clips cannot be installed.
1.
1
Remove screws (2)
from bracket (inside of
machine)
Figure 4 Removing the Exit/Fuser Nip Drive Assembly - Inside of Machine
3
Unplug Clutch,
release harness
clamps (2)
1
Remove
Screw
2
Remove K-clips (2)
Figure 5 Removing the Nip Clutch - Rear Frame of Machine
Reissue
DocuColor 12/DCCS50
1/05
4-15
REP 1.6.3
REP 1.6.3
1/05
4-16
Reissue
DocuColor 12/DCCS50
REP 2.1.1 Tray 1 Set Sensor
REP 2.1.2 Tray 2/3/4 Size Sensor

Removal

Removal
WARNING
NOTE: This page describes how to remove the Tray 2 Sensor.

1.
Remove trays 1 and 2 to allow easy access (PL 2.1 Item 4).
2.
Remove the Tray 1 Set Sensor (Figure 1).
WARNING

1.
Remove Trays 1 through 4 to allow easy access (PL 2.1 Item 4).
2.
Remove the Tray 2 Size Sensor (Figure 1).

3. Remove the Tray 1 Sensor.

3. Remove the Tray 2 Size Sensor.
Figure 1 Removing the Tray 1 Set Sensor
Installation
1.
Figure 1 Removing the Tray 2 Size Sensor
Installation
1.
Reissue
DocuColor 12/DCCS50
1/05
4-17
REP 2.1.1, REP 2.1.2
REP 2.4.1 Tray 1/2/3/4 Feeder
4.
Remove the Tray 1 Feeder (Figure 2).


Removal
2. Remove the KL-clip.

NOTE: The KL-clip exists only in trays 2/3/4. (Tray 1 does not have a KL-clip.)
NOTE: This page describes how to remove the Tray 1 Feeder.
3. Remove the stud.
NOTE: If the Feeder Assembly must be replaced, make sure to reset the HFSI counter.
1.
Tray 1: DC135(008-801)
2.
Tray 2: DC135(008-802)
3.
Tray 3: DC135(008-803)
4.
Tray 4: DC135(008-804)
4. Remove the Tray 1 Feeder.
WARNING
1.
Open the Left Lower Cover.
2.
Pull out Tray 1.
3.
Pull out the Tray 1 Feeder (Figure 1).

2. Pull out the Tray 1 Feeder.
Figure 2 Removing the Tray 1 Feeder
Installation
1.
Figure 1 Pulling out the Tray 1 Feeder
REP 2.4.1
1/05
4-18
Reissue
DocuColor 12/DCCS50
REP 2.5.1 Tray 1/2/3/4 Feed/Nudger Roll Assembly
4.
Remove the Feed/Nudger Roll Assembly (Figure 2).

1. Push the pins on both sides.

Removal
2. Remove the Feed/Nudger Roll Assembly.
NOTE: Replace the Feed/Nudger Roll Assembly and the Retard Roll at the same time.
NOTE: After replacing the Feed Nudger Roll Assembly, reset the HFSI counter.
1.
Tray 1: DC135(008-801)
2.
Tray 2: DC135(008-802)
3.
Tray 3: DC135(008-803)
4.
Tray 4: DC135(008-804)
NOTE: This page describes how to remove the Tray 1 Feed/Nudger Roll Assembly.
WARNING
1.
Pull out Tray 1.
2.
3.
Pull out the Tray 1 Feeder (Figure 1).

Figure 2 Removing the Feed/Nudger Roll Assembly
Installation
1.

Reissue
DocuColor 12/DCCS50
1/05
4-19
REP 2.5.1
REP 2.6.1 Feed Lift Motor

Removal
NOTE: This page describes how to remove the Tray 1Feed Lift Motor.
WARNING
1.
Pull out the Tray 1 Feeder (REP 2.4.1).
2.
Remove the bracket (Figure 1).

3. Remove the E-clip and bearings.
Figure 2 Removing the Feed Lift Motor
Installation
NOTE: Do not mistake the solenoid mounting screw for the bracket mounting screw.
1.
Figure 1 Removing the Bracket

3.
Remove the Feed Lift Motor (Figure 2).

2. Remove the Feed Lift Motor.
REP 2.6.1
1/05
4-20
Reissue
DocuColor 12/DCCS50
4.
Remove the Tray 1 Retard Roll (Figure 2).

1. Push in the pins on both sides.

Removal
2. Remove the Retard Roll.
NOTE: Replace the Retard Roll and Feed/Nudger Assembly at the same time.
NOTE: After replacing the Retard Roll, reset the HFSI counter.
1.
Tray 1: DC135 (008-801)
2.
Tray 2: DC135 (008-802)
3.
Tray 3: DC135 (008-803)
4.
Tray 4: DC135 (008-804)
NOTE: This page describes how to remove the Tray 1 Retard Roll.
WARNING
1.
Pull out Tray 1.
2.
3.
Pull out Tray 1 Feeder (Figure 1).

Figure 2 Removing the Tray 1 Retard Roll
Installation
1.

Reissue
DocuColor 12/DCCS50
1/05
4-21
REP 2.6.2
REP 2.7.1 Tray 2-4 Take Away Drive
REP 2.7.2 Tray 2/3/4 Feed T/A Clutch
Parts List on PL 2.7B

Removal
Parts List on PL 2.7A

Removal
WARNING
NOTE: This page describes how to remove the Tray 2 Feed T/A Clutch.

1.
2.
WARNING
Remove the following parts:

a.
IOT LVPS (REP 9.3.2).
b.
LVPS bracket (PL 9.3 Item 4)
Remove the Tray 2-4 Take Away Drive (Figure 1).
1.
Remove the Tray 2-4 Take Away Drive (REP 2.7.1).
2.
Disconnect the connector (Figure 1).

2. Remove the wire from the saddle edge.

3. Remove the Tray 2-4 Take Away Drive.
Figure 1 Disconnecting the connector

3.
Figure 1 Removing the Tray 2-4 Take Away Drive
Remove the Tray 2 Feed T/A Clutch (Figure 2).

Installation
2. Remove the gear.
1.
4. Remove the shaft. (Push the release button on the clutch.)

5. Remove the Tray 2 Feed T/A Clutch.
REP 2.7.1, REP 2.7.2
1/05
4-22
Reissue
DocuColor 12/DCCS50
Figure 2 Removing the Tray 2 Feed T/A Clutch
Figure 3 Reassembly
Installation
NOTE: When you reinstall the parts, make sure to insert the bracket stopper into the clutch tab
(Figure 3).
1.
Reissue
DocuColor 12/DCCS50
1/05
4-23
REP 2.7.2
REP 2.7.3 T/A Motor
REP 2.8.1 Tray 1 Feed-out Sensor, T/A Sensor
Parts List on PL 2.7A

Removal

Removal
WARNING
WARNING
1.
Remove the Tray 2-4 Take Away Drive (REP 2.7.1).
1.
2.
Remove the T/A Motor (Figure 1).
2.
Move the baffle in the direction shown and remove it (Figure 1).
1. Remove the baffle.
2. Remove the springs (2).
3. Remove the T/A Motor.
Figure 1 Removing the Baffle

Figure 1 Removing the T/A Motor
3.
Move the sensor with the bracket (Figure 2).
Installation
1.
REP 2.7.3, REP 2.8.1
1/05
4-24
Reissue
DocuColor 12/DCCS50
Figure 2 Moving the Sensor

4.
Figure 3 Removing the Tray 1 Feedout Sensor and T/A Sensor
Installation
Remove the Tray 1 Feedout Sensor and T/A Sensor (Figure 3).
1.

3. Remove the sensors (2).
Reissue
DocuColor 12/DCCS50
1/05
4-25
REP 2.8.1
REP 2.8.2 Tray 2/3/4 Feed-out Sensor

Removal
NOTE: This page describes how to remove the Tray 2 Feed-out Sensor.
WARNING
1.
2.
Move the baffle in the direction shown and remove it (Figure 1).
1. Remove the baffle.

4.
Remove the Tray 2 Feed-out Sensor (Figure 3).

1. Remove the Tray 2 Feed-out Sensor.
Figure 1 Removing the Baffle

3.
Remove the sensor (the whole bracket) (Figure 2).

REP 2.8.2
1/05
4-26
Reissue
DocuColor 12/DCCS50
REP 2.9.1 Tray 5

Removal
NOTE: After replacing Tray 5, clear the HFSI counter [08-810].
WARNING
1.
Remove Tray 5 (Figure 1).

1. Move Left Middle Cover downward.
2. Pull the hooks (2) outward.
3. Lift Tray 5 and remove it.
Figure 3 Removing the Tray 2 Feed-out Sensor
Installation
1.
Figure 1 Removing Tray 5
Installation
1.
Reissue
DocuColor 12/DCCS50
1/05
4-27
REP 2.8.2, REP 2.9.1
REP 2.11.1 Tray 5 Nudger Roll

Removal
NOTE: After replacing the Nudger Roll, clear the HFSI counter [08-810].
NOTE: Replace the Tray 5 Nudger, Feed and Retard Rolls at the same time.
WARNING
1.
Open the Tray 5 Assembly (Figure 1).

1. Pull the lever up and open the Upper Tray 5 Assembly.
Figure 2 Removing the Tray 5 Nudger Roll
Installation
1.
Figure 1 Opening the Tray 5 Assembly

2.
Remove the Tray 5 Nudger Roll (Figure 2).

2. Push in the plunger.
3. Remove the Nudger Roll.
REP 2.11.1
1/05
4-28
Reissue
DocuColor 12/DCCS50
REP 2.11.2 Tray 5 Feed Roll

Removal
NOTE: After replacing the Feed Roll, clear the HFSI counter. DC135(008-810) Diag. Screen
NOTE: Replace the Tray 5 Feed, Nudger and Retard Rolls at the same time.
WARNING
1.
Open the Upper Tray 5 Assembly (Figure 1).

1. Pull the lever up and open the Upper Tray 5 Assembly.
Figure 2 Removing the Tray 5 Feed Roll
Installation
1.
Figure 1 Opening the Upper Tray 5 Assembly

2.
Remove the Tray 5 Feed Roll (Figure 2).

1. Remove the chute.
2. Remove the collar.
3. Remove the Feed Roll.
Reissue
DocuColor 12/DCCS50
1/05
4-29
REP 2.11.2
REP 2.12.1 Tray 5 Lift Motor

Removal
WARNING
1.
Open the Upper Tray 5 Assembly (Figure 1), or for ease of access, remove the Tray 5
Assembly from the machine (REP 2.9.1).
1. Pull up the lever and open the Upper Tray 5 Assembly.

3.


2.

1. Pull outward to extend the tray, then pivot the tray up.
3. Remove the lower cover.
5. Remove the wire from the hooks (3).
REP 2.12.1
1/05
4-30
Reissue
DocuColor 12/DCCS50

4.
Figure 4 Removing the Tray 5 Lift Motor
Installation
Remove the Tray 5 Lift Motor (Figure 4).

1.
2. Remove the switch bracket.

4. Remove the Tray 5 Lift Motor.
Reissue
DocuColor 12/DCCS50
1/05
4-31
REP 2.12.1
REP 2.12.2 Tray 5 Retard Roll

Removal
NOTE: After replacing the Retard Roll, clear the HFSI counter. DC135(008-810) Diag.Screen
NOTE: Replace the Tray 5 Retard, nudger and feed rolls at the same time.
WARNING
1.
Open the upper Tray 5 Assembly (Figure 1).

1. Pull up the lever and open the Upper Tray 5 Assembly.
Figure 2 Removing the Tray 5 Retard Roll

2.
Remove the Tray 5 Retard Roll (Figure 2).

1. Remove the Tray 5 Retard Roll.
2. Remove the collars (2).
3. Remove the shaft.
REP 2.12.2
1/05
4-32
Reissue
DocuColor 12/DCCS50
Installation
REP 2.14.1 Regi. Unit
NOTE: When installing the Tray 5 Retard Roll, make sure that the marking is at the rear (Figure
3).

Removal
WARNING
1.
Open the Front Door.
2.
Push the lever down and pull out the drawer assembly.
3.
Pull the drawer assembly out to a maintenance position. (Figure 1)

1. Push the stoppers on both sides.
2. Pull out the drawer assembly.
Figure 3 Reassembly
1.
Figure 1 Opening the Drawer

4.
5.

a.
Drawer Cover (PL 2.18)
b.
Knob (PL 2.22 Item 9)
c.
Oil Cartridge (PL 8.1 Item 5)
d.
Cartridge Guide (PL 8.1 Item 4)
Remove the ground wire (Figure 2).

Reissue
DocuColor 12/DCCS50
1/05
4-33
REP 2.12.2, REP 2.14.1
2. Remove the plate.

3. Release the clamp and remove the wire.
5. Pull out the ground wire from the hole.
Figure 3 Removing the Regi. Unit
Installation
1.
Figure 2 Removing the Ground Wire

6.
Remove the Regi. Unit. (Figure 3)

2. Remove the Regi. Unit.
REP 2.14.1
1/05
4-34
Reissue
DocuColor 12/DCCS50
REP 2.15.1 Regi. Sensor

Removal
WARNING
1.
2.
3.
Pull the drawer assembly out to a maintenance position (Figure 1).

2. Pull out the drawer assembly.
Figure 2 Removing the Regi. Cover

5.
Remove the Regi. Sensor (Figure 3).

3. Remove the Regi.Sensor.

4.
Remove the Regi. Cover (Figure 2).

2. Remove the Regi. Cover.
Reissue
DocuColor 12/DCCS50
1/05
4-35
REP 2.15.1
REP 2.15.2 Regi. Roll

Removal
WARNING
1.
2.
Remove the Regi. Unit (REP 2.14.1).
3.
Remove the Regi. Roll (Figure 1).

2. Remove the gear.
4. Move the bearings (2).
5. Remove the Regi. Roll.
Figure 3 Removing the Regi. Sensor
Installation
1.
Figure 1 Removing the Regi. Roll
Installation
1.
REP 2.15.1, REP 2.15.2
1/05
4-36
Reissue
DocuColor 12/DCCS50
REP 2.15.3 Regi. Motor

Removal
WARNING
1.
2.
3.
Remove the Regi. Motor (Figure 1).

2. Release the clamps (2) and remove the wire.
3. Remove the wire from the edge saddle.
5. Remove the Regi. Motor.
Figure 1 Removing the Regi. Motor
Installation
1.
Reissue
DocuColor 12/DCCS50
1/05
4-37
REP 2.15.3
REP 2.16.1 Pre Regi. Sensor
REP 2.16.2 Pre Regi. Roll

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
Remove the Pre-Regi. Sensor with the bracket (Figure 1).
3.
Lower the chute (Figure 1).
2. Remove the coupling.
4. Lower the chute.
Figure 1 Removing the Pre-Regi. Sensor
Figure 1 Lowering the Chute
Installation
1.
4.
Remove the Pre-Regi. Roll (Figure 2).

2. Move the bearing in the direction of the arrow.

3. Remove the Pre-Regi. Roll.
REP 2.16.1, REP 2.16.2
1/05
4-38
Reissue
DocuColor 12/DCCS50
REP 2.17.1 Vacuum Transport

Removal
WARNING
1.
2.
3.
Pull the drawer assembly out to a maintenance position (Figure 1).

2. Pull out the Drawer Assembly.
Figure 2 Removing the Pre-Regi. Roll
Installation
1.

4.
Remove the Vacuum Transport (Figure 2).

2. Remove the Vacuum Transport.
Reissue
DocuColor 12/DCCS50
1/05
4-39
REP 2.16.2, REP 2.17.1
REP 2.17.2 Vacuum Transport Belt

Removal
WARNING
1.
2.
Remove the Vacuum Transport (REP 2.17.1).
3.
Release the hook from the duct (Figure 1).
Figure 2 Removing the Vacuum Transport
Installation
1.
Figure 1 Releasing the Hook

4.
Remove the Vacuum Transport Belt (Figure 2).

1. Remove the Idler Roll.
2. Remove the Vacuum Transport Belt.
REP 2.17.1, REP 2.17.2
1/05
4-40
Reissue
DocuColor 12/DCCS50
REP 2.21.1 Duplex Path Sensor

Removal
WARNING
1.
2.
Remove the Vacuum Transport (REP 2.17.1).
3.
Remove the Duplex Path Sensor with the bracket (Figure 1).
Figure 2 Removing the Vacuum Transport Belt
Installation
NOTE: When installing the Vacuum Transport Belt, make sure the shiny side is inside.
1.

4.
Remove the Duplex Path Sensor from the sensor bracket (Figure 2).
1. Remove the Duplex Path Sensor.
Reissue
DocuColor 12/DCCS50
1/05
4-41
REP 2.17.2, REP 2.21.1
REP 2.21.2 Duplex Out Sensor

Removal
WARNING
1.
2.
3.
Remove the Duplex Out Sensor with the bracket (Figure 1).
Figure 2 Removing the Duplex Path Sensor
Installation
1.

4.
Remove the Duplex Out Sensor from the sensor bracket (Figure 2).
1. Remove the Duplex Out Sensor.
REP 2.21.1, REP 2.21.2
1/05
4-42
Reissue
DocuColor 12/DCCS50
REP 2.21.3 Duplex Belt 1/2

Removal
WARNING
1.
2.
3.
a.
2nd BTR (REP 7.9.1).
b.
Vacuum Transport Unit (REP 2.17.1).

Figure 2 Removing the Duplex Out Sensor
Installation
1.

4.
Remove the joint (Figure 2).

1. Remove the E-clips (2).
2. Remove the pulley.
3. Remove the bearing and shaft.
5. Remove the joint.
Reissue
DocuColor 12/DCCS50
1/05
4-43
REP 2.21.2, REP 2.21.3
Figure 2 Removing the Joint

5.
Figure 3 Removing the Duplex Belt 1
Remove the Duplex Belt 1 (Figure 3).
6.
Remove the Duplex Belt 2 (Figure 4).
2. Move the bearings (2) in the direction of the arrow.
3. Remove the Aligner Rolls 2/3.
3. Remove the Aligner Roll 1.
4. Remove the Duplex Belt 1.
4. Remove the Duplex Belt 2.
REP 2.21.3
1/05
4-44
Reissue
DocuColor 12/DCCS50

Removal
WARNING
1.
Remove the Right Upper Cover (PL 11.2 Item 1)
2.
Open the Inverter 2.
3.
Remove the Inverter Cover (Figure 1).

2. Lift the Inverter Cover and remove it.
Figure 4 Removing the Duplex Belt 2

7.
Figure 1 Removing the Inverter Cover

4.
Pull out the Drawer Assembly.
5.

Reissue
DocuColor 12/DCCS50
1/05
4-45
REP 2.21.3, REP 2.23.1
Figure 3 Removing the Inverter 1

6.
Installation
Remove the Inverter 1 (Figure 3).
1.
2. Lift the Inverter 1 and remove it.
REP 2.23.1
1/05
4-46
Reissue
DocuColor 12/DCCS50

Removal
WARNING
1.

a.
Right Upper Cover (PL 11.2 Item 1)
b.
Exit Tray (PL 2.23 Item 11)
2.
Open the Inverter 2.
3.
Remove the Inverter Cover (Figure 1).

2. Lift the Inverter Cover and remove it.
Figure 2 Removing the Inverter 2

NOTE: Ensure that the 5 tabs on the cover correctly latch into the Inverter before tightening the mounting screws.
5.
Figure 1 Removing the Inverter Cover

4.
Remove the Inverter 2 (Figure 2).

3. Remove the Inverter 2.
Reissue
DocuColor 12/DCCS50
1/05
4-47
REP 2.23.2
REP 2.24.1 Inverter Motor
REP 2.24.2 Release Solenoid

Removal

Removal
WARNING
WARNING
1.
Remove the Inverter 1 (REP 2.23.1).
1.
2.
Remove the Inverter Motor (Figure 1).
2.
Remove the Release Solenoid (Figure 1).
2. Remove the cable tie.
2. Cut off the cable tie.
4. Remove the Inverter Motor.
4. Remove the Release Solenoid.
Figure 1 Removing the Inverter Motor
Figure 1 Removing the Release Solenoid
Installation
Installation
1.
1.
REP 2.24.1, REP 2.24.2
1/05
4-48
Reissue
DocuColor 12/DCCS50

Removal
WARNING
1.
2.
Remove the Exit Roll (Figure 1).

1. Raise the chute.
5. Remove the Exit Roll.
Figure 1 Removing the Exit Roll
Installation
1.
Reissue
DocuColor 12/DCCS50
1/05
4-49
REP 2.26.1
REP 2.26.1
1/05
4-50
Reissue
DocuColor 12/DCCS50
REP 3.1.1 Platen Glass
Installation

Removal
NOTE: Press the Platen Glass in the direction of arrow A; Press the Right Side Plate in the
direction of arrow B (Figure 2).
CAUTION
Ensure that Tag 8, IIT Support Weld Brace Kit, is installed before the following removal procedure is performed.
WARNING
1.
Open the Platen Cover.
2.
Remove the Platen Glass (Figure 1).

2. Remove the Right Side Plate.
3. Remove the Platen Glass.
Figure 2 Reassembly
Figure 1 Remove the Platen Glass
Reissue
DocuColor 12/DCCS50
1/05
4-51
REP 3.1.1
REP 3.1.2 IIT Opening/Closing

2. Remove screw

Removal
CAUTION
Ensure that Tag 8, IIT Support Weld Brace Kit, is installed before the following removal procedure is performed.
WARNING
NOTE: Remove the DADF if the unit is so equipped. (REP 12.1.1).
1.

a.
IIT Left Cover (PL 11.3 Item 16)
b.
Right Upper Cover (PL 11.2 Item 1)
2.
Slide the Control Panel toward the front (see Figure 1 of REP 9.5.1).
3.
Remove the stopper (Figure 1).

2. Remove the stoppers (2)
Figure 2 Disconnecting the connectors

5.
Open the IIT (Figure 3).

2. Open the IIT
3. Insert the brace into the hole.
4. Lock the screw removed in step 5.1.
Figure 1 Removing the Stoppers

4.
Disconnect the connectors (Figure 2).
REP 3.1.2
1/05
4-52
Reissue
DocuColor 12/DCCS50
Installation
NOTE: When the stopper is installed, set it by pressing it toward the arrow. (Figure 4)
Figure 4 Reassembly
1.
Figure 3 Opening the IIT
Reissue
DocuColor 12/DCCS50
1/05
4-53
REP 3.1.2
REP 3.2.1 CCD PWB

Removal
WARNING
1.
2.
Remove the Platen Glass (REP 3.1.1).
3.
Remove the Right Upper Cover (PL 11.2 Item 1).
4.
Remove the Lens Cover (PL 3.2 Item 11).
5.
Remove the Cable Stoppers (Figure 1).

1. Remove the screws, two per stopper (4 total).
2. Remove the Cable Stoppers (2).
Figure 2 Disconnecting the Connector

7.
Remove the CCD PWB (Figure 3).

2. Remove the CCD PWB.
Figure 1 Removing the Cable Stoppers

6.

2. Remove the connector.
REP 3.2.1
1/05
4-54
Reissue
DocuColor 12/DCCS50
REP 3.3.1 Carriage Cables

Removal
NOTE: This page describes how to remove the Rear Carriage Cable.
WARNING
Turn power off disconnect the power plug.
NOTE: Do not replace both cables at the same time. Remove the front and rear cables separately.
1.
Remove the Platen Cover or DADF (REP 12.1.1).
2.
3.
Platen machines: Remove the Blind Cover (PL 11.1 Item 7).
4.
Remove the Top Cover (PL 11.1 Item 1).
5.
Platen machines: Remove the Registration Guide (Figure 1).

2. Remove the Registration Guide.
Figure 3 Removing the CCD PWB
Installation
NOTE: Ensure that the two locating holes line up with the semi-perf locating pin.
1.
Figure 1 Removing the Registration Guide

6.
Reissue
DocuColor 12/DCCS50
1/05
4-55
DADF machines: Remove the registration gate and plate (Figure 2).
REP 3.2.1, REP 3.3.1

2. Remove the Registration Gate.
Figure 3 Positioning the Half Rate Carriage

9.
Remove the Carriage Cable (Figure 4).

2. Separate the spring and the cable.
Figure 2 Removing the Registration Gate and Plate
3. Pull out the ball from the hole.

7.
Remove the Full Rate Carriage from the IIT Frame (REP 3.4.2). Keep the lamp wire harness connector connected.
8.
Move the Half Rate Carriage so that the position of the Carriage Cable Ball on the Capstan is one of the following: (Figure 3)
4. Remove the cable.
1. Two Carriage Cable Rolls in front and rear.

2. The Carriage Cable Ball is directly above.
REP 3.3.1
1/05
4-56
Reissue
DocuColor 12/DCCS50
Figure 4 Removing the Carriage Cable
Figure 5 Winding the Carriage Cable
Installation
2. Wind the cable (spring hook side) onto the pulley for 2.5 turns (Figure 6).
1.
3. Tape and lock the cable (on the spring hook) on the frame (Figure 6).
Wind the Carriage Cable into the pulley (Figure 5).

1. Insert the Carriage Cable Ball into the groove of the pulley.
Reissue
DocuColor 12/DCCS50
1/05
4-57
REP 3.3.1
Figure 6 Locking the Cable
Figure 7 Locking the Cable
4. Wind the cable (ball side) onto the pulley for 2.4 turns (Figure 7).
6. The following figure shows the number of carriage cable windings (front/rear) (Figure 8).
5. Tape and lock the cable wound on the pulley (Figure 7).
REP 3.3.1
1/05
4-58
Reissue
DocuColor 12/DCCS50
Figure 9 Installing the Carriage Cable (ball side)

3.
Install the Carriage Cable (spring hook side) (Figure 10).

1. Hook the cable to the pulley (from bottom to top).
2. Hook the cable to the small pulley in the Half Rate Carriage (from bottom to top).
3. Hook the cable to the stud (from bottom to top).
4. Install the spring on the cable (spring hook side).
5. Hook the spring onto the frame.
Figure 8 Carriage Cable Windings

2.
Install the Carriage Cable (ball side) (Figure 9).

1. Hook the cable to the pulley (from bottom to top).
2. Hook the cable to the large pulley in the Half Rate Carriage (from top to bottom).
3. Insert the ball into the frame hole.
Reissue
DocuColor 12/DCCS50
1/05
4-59
REP 3.3.1
REP 3.3.2 Carriage Motor

Removal
WARNING
1.
2.
3.
Platen machine: Remove the Blind Cover (PL11.1). PL 11.1 Item 7
4.
Remove the Top Cover (PL 11.1 Item 1)
5.
Remove the IIT Rear Cover (PL 11.3 Item 15)
6.
Remove the Carriage Motor (Figure 1).

5. Remove the Carriage Motor.
Figure 10 Installing the Carriage Cable (spring hook side)

4.
Remove the tape from the cable.
5.
Install the Full Rate Carriage in the IIT Frame.
6.
Adjust the positions of the Full Rate/Half Rate Carriages (ADJ. 3.4.1).
7.
Manually move the Full Rate Carriage to make sure it moves smoothly.
8.
Install the remaining parts in the reverse order of disassembly from Step 6.
REP 3.3.1, REP 3.3.2
1/05
4-60
Reissue
DocuColor 12/DCCS50
REP 3.4.1 Exposure Lamp

Removal
WARNING
CAUTION
Avoid touching the exposure lamp with your bare hands during removal or installation. Oil from
your hands will contaminate the surface of the lamp.
1.
Open the Platen Cover or DADF.
2.
3.
Move the Full Rate Carriage to the frame notch.
4.
Remove the Exposure Lamp (Figure 1).

3. Remove the Exposure Lamp.
Figure 1 Removing the Carriage Motor
Installation
1.
Figure 1 Removing the Exposure Lamp
Installation
1.
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DocuColor 12/DCCS50
1/05
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REP 3.3.2, REP 3.4.1
REP 3.4.2 Lamp Wire Harness

Removal
WARNING
1.
2.
3.
Platen machines: Remove the Blind Cover (PL 11.1 Item 7).
4.
Remove the Top Cover (PL 11.1 Item 1).
5.
Disconnect the Lamp Wire Harness connector and release the Clamp Hook (Figure 1).
2. Release the clamp.
3. Remove the clamp.
4. Release the hook.
Figure 2 Removing the Full Rate Carriage

7.
Remove the Lamp Wire Harness from the Full Rate Carriage (Figure 3).
1. Flip the Full Rate Carriage.
3. Remove the guide.
5. Remove the Lamp Wire Harness.
Figure 1 Disconnecting the Lamp Wire Harness

6.
Remove the Full Rate Carriage (Figure 2).

2. Remove the Full Rate Carriage.
REP 3.4.2
1/05
4-62
Reissue
DocuColor 12/DCCS50
REP 3.5.1 IPS Chassis

Removal
WARNING
CAUTION
The IPS chassis is heavy (16lb.). Take care to avoid injury when handling the IPS chassis.
1.
Remove the Right Upper Cover (PL 11.2 Item 1).
2.
Remove the IIT Rear Cover (PL 11.3 Item 15).
3.
Disconnect the connectors at the right side of the IPS chassis (Figure 1).
2. Remove the connector cover.
Figure 3 Removing the Lamp Wire Harness
Installation
1.
NOTE: After reinstalling the parts, adjust the positions of the Full Rate/Half Rate Carriages
(ADJ. 3.4.1).
Figure 1 Disconnecting the Connectors

4.
Disconnect the connectors in the rear side of the IPS chassis (Figure 2).
1. Release the clamp.
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REP 3.4.2, REP 3.5.1
Figure 2 Disconnecting the Connectors

5.
Figure 3 Pulling out the IPS Chassis
Installation
Pull out the IPS chassis (Figure 3).

1.
2. Ensure that the (3) connectors on the right side of the IPS chassis are disconnect.
3. Pull out the IPS chassis.
REP 3.5.1
1/05
4-64
Reissue
DocuColor 12/DCCS50
REP 4.1.1 ROS

Removal
WARNING
CAUTION
The ROS assembly is a precision optical component. Be careful not to damage the unit when
handling it.
1.
Open/close the IIT (REP 3.1.2).
2.
Remove the Half Tone PWB Cover (Figure 1).

2. Remove the Half Tone PWB Cover.
Figure 2 Remove the ROS Top Cover

4.

Figure 1 Remove the Half Tone PWB Cover

3.
Remove the ROS Top Cover (Figure 2).

2. Remove the ROS Top Cover.
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DocuColor 12/DCCS50
1/05
4-65
REP 4.1.1
Figure 4 Remove the ROS
Figure 3 Disconnect the connectors

5.
Installation
Remove the ROS (Figure 4).

NOTE: If installing a new ROS ensure that the tape covering the ROS window is removed.
1.
4. Remove the ROS.
REP 4.1.1
1/05
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Reissue
DocuColor 12/DCCS50
REP 5.1.1 Erase Lamp
Installation

Removal
NOTE: When installing the Erase Lamp, match the rails (on both sides of the Erase Lamp) with
groove A (Figure 2).
WARNING
NOTE: When removing the Drum Unit, do not expose the Drum to direct sunlight or strong
light.
NOTE: Do not touch the Drum surface.
1.
Remove the Drum Unit (REP 5.3.1).
2.
Remove the Erase Lamp (Figure 1).

2. Remove the Erase Lamp.
Figure 2 Reassembly
1.
Figure 1 Remove the Erase Lamp
Reissue
DocuColor 12/DCCS50
1/05
4-67
REP 5.1.1
REP 5.3.1 Drum Unit
Installation

Removal
NOTE: When installing the Drum Unit, match the rails with groove A (Figure 2).
WARNING
light.
1.
2.
Turn the IBT Handle to the left.
3.
Pull the handle and pull out the Drum Unit (Figure 1).
1. Pull the handle.
2. Pull out the Drum Unit.
Figure 2 Reassembly
1.
After reinstallation of the parts, perform the following steps.

a.
After replacing the Drum Unit, make sure that the Image Quality is correct (IQ 1
Image Quality Troubleshooting Entry RAP).
b.
If the Image Quality is not correct, perform the MAX set-up (ADJ 9.1.1).
Figure 1 Pull out the Drum Unit
REP 5.3.1
1/05
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Reissue
DocuColor 12/DCCS50
REP 5.3.3 Cleaning Brush
4. Remove the Cleaning Brush.

Removal
WARNING
light.
1.
2.
Remove the Drum (REP 5.3.1).
3.
Remove the gear (Figure 1).

1. Remove the gear.
Figure 2 Remove the Cleaning Brush
Figure 1 Remove the Gear

4.
Remove the Cleaning Brush (Figure 2).

1. Remove the gear.
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1/05
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REP 5.3.3
Installation
REP 5.3.4 Cleaning Blade
NOTE: When installing the Cleaning Brush, make sure that the long shaft side is to the rear as
shown in the figure below (Figure 3).

Removal
WARNING
light.
1.
2.
Remove the Cleaning Blade (Figure 1).

2. Remove the Cleaning Blade.
Figure 3 Reassembly
1.
Figure 1 Remove the Cleaning Blade
Installation
NOTE: After installing the Cleaning Blade, clean the Cleaning Blade.
1.
REP 5.3.3, REP 5.3.4
1/05
4-70
Reissue
DocuColor 12/DCCS50
REP 5.4.1 Charge Corotron
REP 5.4.2 PCC Wire

Removal

Removal
WARNING
WARNING
light.
light.
1.
1.
2.
Remove the Charge Corotron (Figure 1).
2.
Remove the Pre-Clean Corotron (Figure 1).
2. Remove the Charge Corotron.
2. Remove the Pre-Clean Corotron.
Figure 1 Remove the Charge Corotron
Figure 1 Remove the Pre-Clean Corotron
Installation
3.
1. Remove the Arc Shields on both sides.
NOTE: Do not touch the Corotron Wire during installation.

1.
Reissue
DocuColor 12/DCCS50
Remove the PCC Wire (Figure 2).
3. Remove the PCC Wire.
1/05
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REP 5.4.1, REP 5.4.2
Installation
NOTE: Install the PCC Wire as shown in the figure below (Figure 3).
Figure 2 Remove the PCC Wire
Figure 3 Install the PCC Wire

NOTE: After installing the PCC Wire, clean the PCC Wire.
1.
REP 5.4.2
1/05
4-72
Reissue
DocuColor 12/DCCS50
REP 5.5.1 Waste Toner Auger

Removal
WARNING
NOTE: Protect the floor with a sheet of paper where the removed waste Toner Auger is to be
placed.
1.
Remove the IOT Rear Cover (PL 11.3 Item 7).
2.
Remove the Fly Wheel (PL 1.1 Item 10).
3.
Remove the Waste Toner Auger (Figure 1).

3. Remove the Auger Sensor.
4. Remove the wire from the wire clips.
6. Remove the Waste Toner Auger.
Figure 1 Remove the Waste Toner Auger
Installation
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1.
2.
Ensure that the Drum CRU,IBT Assembly, and the Waste Toner Bottle are removed before
installing the auger.
REP 5.5.1
REP 5.5.2 Auger Belt

Removal
WARNING
NOTE: Protect the floor with a sheet of paper where the removed Waste Toner Auger is to be
placed.
1.
Remove the Waste Toner Auger (REP 5.5.1).
2.
Remove the spring (Figure 1).

2. Remove the bearings (3).
Figure 2 Remove the Auger Belt
Figure 1 Remove the Spring

3.
Remove the Auger Belt (Figure 2).

2. Remove the Auger Assembly.
3. Remove the Auger Belt.
REP 5.5.2
1/05
4-74
Reissue
DocuColor 12/DCCS50
Installation
NOTE: Install the Auger Belt as shown in the figure below (Figure 3).
NOTE: Protect the floor with a sheet of paper where the Waste Toner Auger is to be installed.
Figure 3 Install the Auger Belt

1.
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1/05
4-75
REP 5.5.2
REP 5.5.2
1/05
4-76
Reissue
DocuColor 12/DCCS50
REP 6.1.1 Rotary PWB

Removal
WARNING
1.
Open/close the IOT Control PWB chassis (REP 9.2.1).
2.

Figure 2 Remove the Rotary PWB and Plate

4.
Remove the Rotary PWB (Figure 3).

2. Remove the Rotary PWB.
Figure 1 Remove the Bracket

3.
Remove the Rotary PWB with the plate (Figure 2).

Reissue
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1/05
4-77
REP 6.1.1
REP 6.1.2 Rotary Home Position Sensor

Removal
WARNING
1.
Remove the Rotary PWB (steps 1 -3 of REP 6.1.1).
2.
Remove the Rotary Home Position Sensor with the bracket (Figure 1).
Figure 3 Remove the Rotary PWB
Installation
1.
Figure 1 Remove the Rotary Home Position Sensor
Installation
1.
REP 6.1.1, REP 6.1.2
1/05
4-78
Push the bracket in the direction of the arrow and lock it. (Figure 2).
Reissue
DocuColor 12/DCCS50
REP 6.1.3 Rotary Latch Lever

Removal
WARNING
1.
Remove the Right Upper Cover (PL 11.2 Item 1)
2.
Remove the Rotary PWB (Steps 1 - 3 of REP 6.1.1)
3.

4. Pull out the connector from the hole.
Figure 2 Position the Bracket

2.
Adjust the Rotary Home Position Sensor (ADJ 6.1.1).
Figure 1 Disconnect the Connectors

4.
Hook the bracket hooks (Figure 2).

1. Hook the bracket hooks (2).
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1/05
4-79
REP 6.1.2, REP 6.1.3
Figure 2 Hook the Bracket Hooks

5.
Figure 3 Remove the Rotary Latch Lever
Installation
Remove the Rotary Latch Lever (Figure 3).

1. Remove the connectors (2).
1.
Perform ADJ 6.6.1 Rotary Development Housing Position and install the locating pin to
position the Black Development Housing against the Drum.
2.
If the Solenoid Assy was replaced, install the new Solenoid on the Rotary Latch lever
bracket, and reinstall the Gear. Ensure that the flag on the plunger fully blocks the sensor
when the plunger is pushed in.
3.
Lock the Rotary Latch Lever (Figure 4).

3. Remove the Rotary Latch Lever.
4. If the Solenoid Assy is to be replaced, remove the screws (2).
5. If the Solenoid Assy is to be replaced, remove the Gear.
1. Turn the gear and push in the plunger.
REP 6.1.3
1/05
4-80
Reissue
DocuColor 12/DCCS50
Figure 4 Lock the Rotary Latch Lever

4.
Figure 5 Install the Rotary Latch Lever
Install the Rotary Latch Lever (Figure 5).

1. Push the Rotary Latch Lever in the direction of the arrow.
2. Fasten the screws (2).
5.
Remove the Locating Pin and return it to its storage position.
6.
After installation, check the gear play. Manually lock and release the solenoid. Make sure
that the solenoid is properly locked.
CAUTION
Ensure that the Locating Pin is removed before attempting to run the machine.
Reissue
DocuColor 12/DCCS50
1/05
4-81
REP 6.1.3
REP 6.1.4 Bias Brush
Installation

Removal
NOTE: Make sure that the protruding part of the Bias Brush is in the frame hole (Figure 2).
WARNING
1.

a.
Cover Assembly (PL 6.5 Item 18)
b.
Trickle Toner Bottle (PL 6.5 Item 23)
2.
3.
Remove the Bias Brush (Figure 1).

2. Remove the fasten terminal.
3. Remove the Bias Brush.
Figure 2 Reassembly
1.
Figure 1 Remove the Bias Brush
REP 6.1.4
1/05
4-82
Reissue
DocuColor 12/DCCS50
REP 6.2.1 Toner Cartridge Unit

Removal
WARNING
1.
2.
Remove the Toner Cartridge Cover (PL 6.2 Item 7).
3.
Raise the Toner Cartridge Unit and close the Shutter (Figure 1).
1.
Disconnect the connectors (2).
2.
Close the Shutter.
Figure 2 Remove the Toner Cartridge Unit
Installation
1.
Figure 1 Raise the Toner Cartridge Unit

3.
Remove the Toner Cartridge Unit (Figure 2).

NOTE: Since item 1 hooks onto item 2, push the Toner Cartridge Unit up and remove it
(pull it out) in the forward direction.
3. Remove the Toner Cartridge Unit.
Reissue
DocuColor 12/DCCS50
1/05
4-83
REP 6.2.1
REP 6.3.1 Toner Cartridge Housing (Cyan, Magenta,

Yellow, Black)
Installation
1.

Removal
WARNING
NOTE: This page describes how to disassemble the Black Toner Cartridge Housing.
NOTE: Protect the floor by placing a sheet of paper on the floor.
1.
Remove the Toner Cartridge Unit (REP 6.2.1).
2.
Remove the Toner Cartridge (Yellow/Black) (PL 6.2 Item 1).
3.
Remove the Toner Cartridge Housing (Figure 1).

3. Remove the Toner Cartridge Housing.
Figure 1 Remove the Toner Cartridge Housing
REP 6.3.1
1/05
4-84
Reissue
DocuColor 12/DCCS50
REP 6.3.2 Cartridge/Dispense Motor (Cyan, Magenta,

Yellow, Black)
Removal
NOTE: This page describes how to disassemble the Black Cartridge/Dispense Motor.
WARNING
1.
2.
3.
Remove the Cartridge Motor (Figure 1).

3. Remove the Cartridge Motor.
Figure 1 Remove the Cartridge Motor

4.
Remove the Dispense Motor (Figure 2).

1. Disconnect the terminals (2).
3. Remove the Dispense Motor.
Reissue
DocuColor 12/DCCS50
1/05
4-85
REP 6.3.2
REP 6.4.1 Dispense PWB

Removal
WARNING
1.
2.
Remove the Toner Cartridge Cover (PL 6.2).
3.
Remove the Dispense PWB (Figure 1).

2. Release the hooks (4) and remove the Dispense PWB.
Figure 2 Remove the Dispense Motor

Figure 1 Remove the Dispense PWB
Installation
1.
Installation
1.
REP 6.3.2, REP 6.4.1
1/05
4-86
Reissue
DocuColor 12/DCCS50
REP 6.6.1 Development Housing

Removal
NOTE: After replacing the Development Housing, reset the HFSI counter. Enter the dC135
HFSI Counters Diag. Screen:
a.
Yellow: location NVM 009-851
b.
Magenta: location NVM 009-852
c.
Cyan: location NVM 009-853
d.
Black: location NVM 009-850
WARNING
WARNING
1.
Remove the Right Upper Cover (PL 11.2).
2.


3.
Hook the bracket hook s (Figure 2).

1. Hook the hooks (2).
Reissue
DocuColor 12/DCCS50
1/05
4-87
REP 6.6.1
Figure 2 Hook the Bracket Hook s

4.
Figure 3 Open the Arms
Open the arms (white) (Figure 3).
5.
1. Rotate the Rotary Assembly.
Remove the Development Housing (Figure 4).

1. Remove the development housing.

3. Open the arms (2).
REP 6.6.1
1/05
4-88
Reissue
DocuColor 12/DCCS50
REP 6.6.2 Developer Replacement

Removal
Developer Removal
WARNING
WARNING
NOTE: After replacing the Development Housing, reset the HFSI counter. Enter the dC135
HFSI Counter List Diag. Screen:
a.
Yellow: location NVM 009-851
b.
Magenta: location NVM 009-852
c.
Cyan: location NVM 009-853
d.
Black: location NVM 009-850
1.
Remove the Development Housing (REP 6.6.1).
2.
Place a sheet of paper on the floor or desk. Place the removed Development Housing on
it.
3.
Remove the Upper Cover (Figure 1).

2. Release the hooks (4) and remove the cover.
Figure 4 Remove the Development Housing
Installation
NOTE: If the Development Housing cannot be easily installed, the gears may not be meshed
properly. Rotate the gears clockwise slightly and then install the Development Housing.
1.
NOTE: If the developer material has been replaced, go to IQ47 ATC Sensor RAP, Appendix 1.
ATC set-up procedure
Reissue
DocuColor 12/DCCS50
1/05
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REP 6.6.1, REP 6.6.2
Figure 1 Remove the Upper Cover

4.
Figure 2 Empty the Developer
Turn the Development Housing upside down. Empty the Developer (Figure 2).
5.
NOTE: Be careful that the gear is not contaminated by Developer. If contaminated, clean
the gear and make sure that the gear is moving smoothly.
Add the Developer (Figure 3).

1. Rotate the Magnet Roll Gear in the direction of the arrow, move the Developer
pack right and left, while adding the Developer.
1. Turn the Development Housing in the direction of the arrow.

2. Pour out the Developer.
3. Rotate the Magnet Roll Gear in the direction of the arrow. Pour out the remaining
Developer.
REP 6.6.2
1/05
4-90
Reissue
DocuColor 12/DCCS50
Figure 3 Add the Developer

6.
Figure 4 Position the Hook
Make sure that the Development Housing hook is not up on the Upper Cover (Figure 4).
7.
Restore the machine.
8.
Make 10 copies of the Test Pattern (82E10810) to mix the Developer in the following
mode:
9.
a.
11 x 17 or A3 and 4-color mode (full color)
b.
10 sheets
Perform the MAX Set Up (ADJ 9.1.1).
NOTE: After performing MA Set Up, go to IQ47 ATC Sensor RAP, Appendix 1. ATC set-up procedure.
Reissue
DocuColor 12/DCCS50
1/05
4-91
REP 6.6.2
REP 6.7.1 Rotary Auger (Cyan, Magenta, Yellow, Black)

Removal
NOTE: This page describes how to disassemble the Magenta Rotary Auger.
WARNING
CAUTION
Be careful not to touch the seals or mating surfaces of the rotary dispense parts. Contamination by skin oils can cause toner problems.
NOTE: Since a large amount of toner overflows during this procedure, use a plastic bag to
recover the overflowing toner to prevent contaminating the work area.
1.

a.
Development Housing (REP 6.6.1)
b.
Toner Cartridge Cover (PL 6.2 Item 7)
c.
Trickle Toner Bottle (PL 6.5 Item 23)
d.
Cover Assembly (PL 6.5 Item 18)
e.
Remove the Front Door Interlock Cover (PL 9.1)
2.
3.


4.
Remove the Outer Dispense Cover (Figure 2).

2. Remove the Outer Dispense Cover.
3. Disconnect the sensor.
REP 6.7.1
1/05
4-92
Reissue
DocuColor 12/DCCS50
Figure 2 Remove the Outer Dispense Cover

5.
Figure 3 Remove the Cover
Remove the cover (Figure 3).
6.
Remove the Inner/Outer DIspense Housings (Figure 4).
1.Remove the screws (4).
2. Remove the cover.
2. Remove the bearing (plastic).

3. Remove the Inner/Outer Dispense Housings.
Reissue
DocuColor 12/DCCS50
1/05
4-93
REP 6.7.1
NOTE: Remove the Black, Yellow, Magenta and Cyan Inner/Outer Dispense Housings.
Figure 5 Remove the Spacer

Figure 4 Remove the Inner/Outer DIspense Housings
7.
8.
Remove the spacer (Figure 5).
Remove the Rotary Auger (Figure 6).

NOTE: Mark the Developer Rotary Frame Assembly with the color of the Rotary Auger if
removing more then one Rotary Auger.
1. Remove the block.

2. Remove the spacer.
1. From inside the machine, release the stopper tab on the Rotary Auger (PL 6.7).
2. Push the Rotary Auger toward the front of the machine to remove it from Rotary
Frame.
REP 6.7.1
1/05
4-94
Reissue
DocuColor 12/DCCS50
Figure 6 Remove the Rotary Auger
Figure 7 Tightening Sequence
Installation
a.
g.
Reinstall the parts in the reverse order of disassembly until the installation of the Four (4)
screws that secures the Inner Dispense Cover.
NOTE: The following procedure is instructions for tightening the four (4) screws that
secure the Inner Dispense Assembly.
b.
Because of the Counter Reaction torque from each screw, retighten the screw in the
same sequence by turning each screw 1/4 (one quarter) of a turn (90 degrees).
h.
Repeat step g.
i.
Remove the screws (3) that were installed in step d.
j.
Continue the reassembly process.
This procedure is to EVENLY distribute the torque throughout the Rotary Dispenser.
c.
Do not use Power Screwdrivers.
d.
Install the screws (3) that secure the Outer Dispense Assembly (PL 6.5) (only the screws,
not the Outer Dispense Cover). This will secure the Dispense Assembly and align the
Inner Dispense Assembly.
e.
Hand tighten the screws (4) until the lock washer closes (locks) in the sequence shown
(Figure 7).
f.
DO NOT OVER TIGHTEN
Reissue
DocuColor 12/DCCS50
1/05
4-95
REP 6.7.1
REP 6.7.2 Trickle Auger

Removal
WARNING
1.
Open/close the IOT Control PWB Chassis (REP 9.2.1).
2.
Remove the Flywheel (REP 1.3.1), (See Figure 1).
3.

Figure 2 Remove the Rotary Developer Duct

6.

3.Remove the screws (2).

4.
Remove the Rotary Developer Duct (PL 10.2 Item 4)
5.

REP 6.7.2
1/05
4-96
Reissue
DocuColor 12/DCCS50

7.
Figure 4 Remove the Drives
Remove the Development/BP0 Drive and IBT Cleaner Retract (Figure 4).
8.
Remove the Trickle Auger (Figure 5).

1. Remove the Trickle Auger.
2. Remove the belt.

3. Remove the Development/BP0 Drive and IBT Cleaner Retract.
Reissue
DocuColor 12/DCCS50
1/05
4-97
REP 6.7.2
Installation
NOTE: Place a sheet of paper on the floor when the Trickle Auger is pulled out to protect
the floor from any spilled Developer.
NOTE: When installing the Development/BP0 Drive and IBT Cleaner Retract, make sure the
couplings are properly meshed. Push the Development Clutch in after temporarily locking the
Development BP0 Drive and the IBT Cleaner Retract (Figure 6).
Figure 5 Remove the Trickle Auger
Figure 6 Install the drives
REP 6.7.2
1/05
4-98
Reissue
DocuColor 12/DCCS50
REP 7.1.1 IBT
1. Rotate the lever in the direction of the arrow.

Removal
3. Pull out the IBT.
WARNING
NOTE: When removing the IBT, do not expose the belt to direct sunlight or strong light.
NOTE: When removing the IBT, make sure that the IBT belt does not touch any other part.
NOTE: Carefully place the removed IBT on a flat surface (covered with a sheet of paper).
1.
2.
3.
Remove the Trickle Toner Bottle (PL 6.5).
4.
Lower the lever and pull out the Drawer Assembly.
5.
Pull the Drawer Assembly out to the work position (Figure 1).
1. Push in the stoppers on both sides.
Figure 2 Pull out the IBT

7.
Remove the IBT Inner Cover (Figure 3).

2. Remove the lever.
4. Remove the IBT Inner Cover.
Figure 1 Pull out the drawer

6.
Pull out the IBT (Figure 2).
Reissue
DocuColor 12/DCCS50
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REP 7.1.1
Figure 4 Remove the IBT
Figure 3 Remove the IBT Inner Cover

8.
Remove the IBT (Figure 4).

1. Remove the IBT.
REP 7.1.1
Installation
1.
1/05
4-100
Reissue
DocuColor 12/DCCS50
REP 7.1.2 IBT Cleaner

Removal
NOTE: After replacing the IBT Cleaner, clear the HFSI counter. Enter thedC135 HFSI Counter
List Diag. Screen NVM 009-836.
WARNING
WARNING
Do not put the IBT Cleaner into a fire. If the IBT Cleaner is placed into a fire, it may
explode and cause injury.
NOTE: When removing the IBT, make sure that the IBT Belt does not touch any other part.
NOTE: Place the removed IBT Cleaner on the floor, protected by a sheet of paper.
1.
2.
Remove the IBT (REP 7.1.1).
3.
Remove the IBT Cleaner (Figure 1).

2. Remove the IBT Cleaner.
Figure 1 Remove the IBT Cleaner
Installation
NOTE: Ensure that the inboard side of the IBT Cleaner is fully seated.
1.
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REP 7.1.2
REP 7.5.1 IBT Belt

Removal
5.
Raise the IBT.
6.
Remove the Inlet Plate (Figure 2).

2. Remove the Inlet Plate.
NOTE: After replacing the IBT Belt, clear the HFSI. Enter the dC135 HFSI Counter List Diag.
Screen:
1.
DC 135 (NVM 009-805)
2.
DC135 (NVM 009-806)
WARNING
1.
2.
3.
Remove the IBT Cleaner (REP 7.1.2).
4.
Move the stoppers (2) in the direction of the arrow and lock the roll (Figure 1), front and
rear.
1. Move the stoppers (2), front and rear.
Figure 2 Remove the Inlet Plate

7.
Move the roll and loosen the tension (Figure 3).

4. Hold the bracket and move the roll.
5. Hook the bracket hole to the boss.
Figure 1 Move the Stoppers

REP 7.5.1
1/05
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DocuColor 12/DCCS50
Figure 4 Remove the IBT Belt
Figure 3 Loosen the Tension

8.
Remove the IBT Belt (Figure 4).

1. Remove the IBT Belt.
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REP 7.5.1
Installation
REP 7.6.1 Bias Roll
NOTE: When installing the IBT Belt, make sure that the silver seal is towards the inboard side.

Removal
Also ensure that the Tracking Rings which are located on the inside of the IBT Belt, are not
riding on the ends of the Steering Roll or Drive Roll (Figure 5).
WARNING
NOTE: Carefully place the removed IBT on a flat surface (covered with the sheet of paper).
1.
2.
Remove the IBT Belt (REP 7.5.1).
3.
Release the stoppers (Figure 1).

1. Move the stoppers (2) in the direction of the arrow and release them.
Figure 5 install the IBT Belt

1.
Figure 1 Move the Stoppers

4.
Remove the Bias Roll (Figure 2).

1. Raise the Tension Roll.
2. Remove the Bias Roll.
REP 7.5.1, REP 7.6.1
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Installation
NOTE: When installing the Bias Roll, make sure that the marking on the Bias Roll is towards
the inboard side (Figure 3).
Figure 2 Remove the Bias Roll
Figure 3 Install the Bias Roll
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1/05
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REP 7.6.1
NOTE: Install the bearings at both sides of the Bias Roll in the positions shown in the figure
below (Figure 4).
REP 7.6.2 Drive Roll

Removal
WARNING
NOTE: Carefully place the removed IBT on a flat surface (covered with sheet of paper).
1.
2.
Remove the Drive Roll Cleaning Blade (Figure 1).

1. Remove the Drive Roll Cleaning Blade.
Figure 4 Install the Bearings

1.
Figure 1 Remove the Drive Roll Cleaning Blade

3.

2. Remove the gear.
REP 7.6.1, REP 7.6.2
1/05
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DocuColor 12/DCCS50

4.
Remove the front lever (PL 7.7 Item 15).
5.
Move the Drive Roll in the direction of the arrow and remove it (Figure 3).
1.Remove the screw.
Figure 3 Remove the Drive Roll
Installation
NOTE: To clean the Drive Roll, remove the Drive Roll Cleaning Blade and clean the Drive Roll
with a cloth using Film Remover.
1.
4. Remove the Drive Roll.
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1/05
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REP 7.6.2
REP 7.6.3 Back-up Roll

Removal
NOTE: If replacing the Back-up Roll, clear the HFSI counter. Enter the dC135 HFSI Counter
List Diag. Screen (009-808).
WARNING
1.
2.
Remove the IBT Cleaner (REP 7.1.2).
3.
4.
Remove the Back-up Roll (Figure 1).

NOTE: Do not touch or hold the rubber layer of the Back-up Roll.
3. Remove the Back-up Roll.
Figure 1 Remove the Back-up Roll
Installation
1.
REP 7.6.3
1/05
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DocuColor 12/DCCS50
REP 7.6.4 Contact Roll
REP 7.9.1 2nd BTR

Removal

Removal
WARNING
NOTE: After replacing the 2nd BTR, clear the HFSI counter. Enter the dC135 HFSI Counter
WARNING
1.

a.
IBT (REP 7.1.1).
b.
IBT Cleaner (REP 7.1.2).
c.
IBT Belt (Disassembly 7.5.1) REP 7.5.1).
2.
Remove the Back-up Roll (REP 7.6.3).
3.
Remove the Contact Roll (Figure 1).

1.
2.
Push the lever down and pull out the Drawer Assembly.
3.
Pull the Drawer Assembly out to a maintenance position (Figure 1).

1. Push in the stoppers on both sides.
1. Remove the Contact Roll.

2. Remove the bearings on both sides.
Figure 1 Pull out the Drawer

4.
Figure 1 Remove the Contact Roll
Installation
1.
Reissue
DocuColor 12/DCCS50
5.
Remove the following parts.

a.
Knob (PL 2.22 Item 9)
b.
Drawer Cover (PL 2.18 Item 6)
c.
Oil Cartridge (PL 8.1 Item 5)
Remove the indicator (Figure 2).

1/05
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REP 7.6.4, REP 7.9.1
2. Remove the Cartridge Guide.

3. Remove the indicator.
Figure 3 Remove the 2nd BTR
Installation
CAUTION
Be sure to rotate the drive shaft on the 2nd BTR to move the BTR Roll to the down position
before closing the Drawer Assembly.
1.
Figure 2 Remove the Indicator

6.
Remove the 2nd BTR (Figure 3).

3. Pull out the ground wire from the hole.
5. Remove the 2nd BTR.
REP 7.9.1
1/05
4-110
Reissue
DocuColor 12/DCCS50
REP 7.10.1 2nd BTR Roll

Removal
WARNING
1.
2.
Remove the 2nd BTR (REP 7.9.1).
3.
Remove the cover (Figure 1).

1. Remove the wire from the hooks (3).
5. Remove the plate grounds (2).
Figure 2 Remove the Inlet Plate

5.
Remove the gears (Figure 3).

2. Remove the gears (2).
Figure 1 Remove the Cover

4.
Remove the Inlet Plate (Figure 2).

2. Remove the wire from the hook.
3. Remove the Inlet Plate.
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1/05
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REP 7.10.1
Figure 3 Remove the Gears

6.
Remove the arms (Figure 4).
Figure 4 Remove the Arms

7.
Remove the 2nd BTR Roll (Figure 5).

1. Remove the 2nd BTR Roll.
2. Remove the E-clip and nylon washer.

3. Remove the arms (2).
REP 7.10.1
1/05
4-112
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DocuColor 12/DCCS50
Figure 5 Remove the 2nd BTR Roll
Installation
NOTE: To clean the 2nd BTR Roll, wipe the roll surface with a dry cloth.
CAUTION
Be sure to rotate the drive shaft on the 2nd BTR to move the BTR roll to the down position
before closing the drawer assembly.
1.
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1/05
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REP 7.10.1
REP 7.10.1
1/05
4-114
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DocuColor 12/DCCS50
REP 8.1.1 Fuser Unit
1. Lever (PL 2.22)

2. Drawer Cover (PL 2.18)

Removal
3. Oil Cartridge (PL 8.1)

5.
NOTE: After replacing the Fuser Unit, clear all HFSI counters related to the Fuser.
1. Lower the baffle.

WARNING
CAUTION
5. Remove the Fuser Unit.
Since the Fuser is very hot, wait until the Fuser becomes sufficiently cold.
1.
2.
Push the lever down and pull out the Drawer Assembly.
3.
Pull the Drawer Assembly out to a maintenance position (Figure 1).
Remove the Fuser Unit (Figure 2).
1. Push in the stoppers at both sides.

Figure 2 Remove the Fuser Unit
Installation
NOTE: Make sure to re-connect the connector when the Fuser Unit is installed.
Figure 1 Pull out the Drawer Assembly

NOTE: Spread a drop cloth on the floor before removing the Oil Cartridge, in order to
avoid any spills.
4.
1.
2.
Perform the Full Fuser Break-In Procedure (GP 1 Fuser Break-In Procedure).
3.
Perform the Fuser Nip adjustment (ADJ 8.1.1).
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REP 8.1.1
REP 8.2.1 Donor Roll Assembly
NOTE: Take care not to damage the Donor Roll on the wire ties holding the fuser harness.

Removal
Installation
After replacing the Donor Roll Assembly, reset the HFSI counter. Enter the dC135 HFSI
Counter List Diag. Screen (010-811). If the wick is also replaced, reset HFSI 10-814.
NOTE: If Donor Roll is replaced separately, make sure to reinstall the Donor Roll by placing the
long journal in the rear (Figure 2).
WARNING
NOTE: When replacing only the Metering Blade, clean the Pickup Roll and the Donor Roll with
a lint free cloth (600S1276) and Fuser Oil before installing the blade. Wipe off the edge of the
blade with a lint free cloth and then with a clean finger. After assembling the Metering Blade to
the Pickup Roll, use the corner of a piece of clean copy paper and slide it inboard to outboard
between the blade and the roll to clean any remaining contamination.

CAUTION
1.
2.
Open the drawer to the maintenance position.
3.
4.

a.
Oil Cartridge (PL 8.1)
b.
Front Cover (PL 8.1)
c.
Top Cover (PL 8.2)
Remove the Donor Roll Assembly (Figure 1). Do not remove the Fuser Assembly from
the machine.
2. Remove the KL-clips (2).
4. Remove the gear.
5. Remove the Donor Roll Assembly.
Figure 2 Install the Donor Roll

1.

a.
Ensure that Oil Metering Blade is seated correctly against the wick.
b.
Ensure that springs (2) are located correctly at both ends of Donor Roll Assembly(Figure 1, step 1).
NOTE: If Donor Roll, Pick up Roll, or Oil Metering Blade (PL 8.9) are replaced individually,
perform the Standard Fuser Break-In Procedure (GP 1 Fuser Break-In Procedure).
Figure 1 Remove the Donor Roll Assembly
REP 8.2.1
2.
1/05
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DocuColor 12/DCCS50
REP 8.3.1 Heat Roll

Removal
6.
a.
Heat Roll Heater Rod (REP 8.3.2).
b.
Heat Roll Finger Assembly (REP 8.3.5). (Steps 1 - 3)
Pull out the Stand Plate (Figure 2).

1. Pull out the Stand Plate.
NOTE: After replacing the Heat Roller, reset the HFSI counter. Enter the dC135 HFSI Counter
WARNING
CAUTION
1.
2.
Remove the Fuser Unit (REP 8.1.1).
3.
4.

a.
b.
Top Cover (PL 8.2)
Remove the Web Assembly (Figure 1).

1. Press the latch release button.
2. Remove the Web Assembly.
Figure 2 Pull out the Stand Plate

CAUTION
Be careful when opening the Upper Frame Assembly, because the springs may come off the
Donor Roll Assembly.
7.
Open the Upper Frame Assembly (Figure 3).

2. Open the Upper Frame Assembly.
Figure 1 Remove the Web Assembly

5.
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REP 8.3.1
NOTE: Before removing the Heat Roll, observe the location of the flange on each
bearing. They should be inside the Fuser Frame at each end (Figure 6).
Figure 3 Open the Upper Frame Assembly

8.
Raise the stoppers on both sides (Figure 4).

Figure 4 Raise the Stoppers
2. Raise the stoppers (2).

9.
Remove the Heat Roll (Figure 5).

1. Remove the Heat Roll.
REP 8.3.1
1/05
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Installation
NOTE: Ensure that the bearings are installed with the flanges toward the center of the roll so
that they fit inside the Fuser Frame (Figure 6).
Figure 5 Remove the Heat Roll

10. Wipe off and then inspect the Heat Roll Thermistors (2) for wear or damage and replace
them as needed.
Figure 6 Install the Heat Roll

NOTE: When installing the Heat Roll, press the stoppers down and lock the Heat Roll (Figure
7).
1. Press down the stoppers (2).
2. Tighten the screws (2).
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1/05
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REP 8.3.1
REP 8.3.2 Heat Roll Heater Rod

Removal
WARNING
CAUTION
CAUTION
Do not touch the glass surface of the Heater Rod. If the glass surface is accidentally touched,
wipe it with a dry cloth.
1.
2.
3.
4.

Figure 7 Lock the Heat Roll

CAUTION
After closing the Upper Frame Assembly, ensure that the two load springs are located correctly
at each end of the Donor Roll Assembly, The springs may become loose during service.
1.
2.
3.
Perform the Fuser Nip Adjustment (ADJ 8.1.1).
REP 8.3.1, REP 8.3.2
1/05
4-120
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DocuColor 12/DCCS50
Figure 1 Remove the Bracket (Front of Fuser)

5.
Figure 2 Disconnect the Connector (Rear of Fuser)

6.
Remove the Heat Roll Heater Rod (Figure 3).

1. Remove the Heat Roll Heater Rod.

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REP 8.3.2
REP 8.3.3 Pressure Roll

Removal
NOTE: After replacing the Pressure Roll, reset the HFSI counter. Enter the dC135 HFSI
Counter List Diag. Screen (010-802).
WARNING
CAUTION
1.
2.
Remove the Pressure Roll Heater Rod (REP 8.3.4).
3.
Pull out the Stand Plate (Figure 1).

1. Pull out the Stand Plate.
Figure 3 Remove the Heat Roll Heater Rod
Installation
1.
Figure 1 Pull out the Stand Plate

4.
REP 8.3.2, REP 8.3.3
1/05
4-122
Remove the Fuser Top Cover (PL 8.2).
Reissue
DocuColor 12/DCCS50
CAUTION
Be careful when opening the Upper Frame Assembly; the load springs at each end of the
donor roll assembly may come off.
5.
Open the Upper Frame Assembly (Figure 2).

2. Open the Upper Frame Assembly.
Figure 3 Remove the Pressure Roll

7.
Wipe off, then inspect the Pressure Roll Thermistors (2) for wear or damage and replace
them as needed.
Figure 2 Open the Upper Frame Assembly

NOTE: Before removing the Pressure Roll, observe the location of the flange on each
bearing. They should be inside the Lift Lever Frame (Figure 5).
6.
Remove the Pressure Roll (Figure 3).

1. Remove the Inlet Chute.
3. Remove the Pressure Roll.
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REP 8.3.3
Installation
NOTE: Ensure that the bearings are installed with the flanges inside of the Lift Lever Frame
(Figure 4) and (Figure 5).
Figure 5 Install the Pressure Roll
Figure 4 Install the Pressure Roll
REP 8.3.3
1/05
4-124
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REP 8.3.4 Pressure Roll Heater Rod
NOTE: Install the spring as shown in the figure below (Figure 6).

Removal
WARNING
CAUTION
CAUTION
1.
2.
3.
4.

Figure 6 Install the Spring

CAUTION
After closing the Upper Frame Assembly, ensure that the two load springs are located correctly
at each end of the Donor Roll Assembly, The springs may become loose during service.
1.
2.
3.
Perform the Fuser Nip Adjustment (ADJ 8.1.1).
Figure 1 Remove the Bracket (Front of Fuser)
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REP 8.3.3, REP 8.3.4
5.

Figure 3 Remove the Pressure Roll Heater Rod
Installation
Figure 2 Disconnect the Connector (Rear of Fuser)
6.
1.
Remove the Pressure Roll Heater Rod (Figure 3).

1. Remove the Pressure Roll Heater Rod.
REP 8.3.4
1/05
4-126
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DocuColor 12/DCCS50
REP 8.3.5 Heat Roll Stripper Finger

4. Remove the Heat Roll Stripper Finger.

Removal
WARNING
CAUTION
1.
2.
3.
Remove the Heat Roll Stripper Finger Assembly (Figure 1).

NOTE: Do not damage the Stripper finger tips.
1. Raise the Exit Chute.
4. Remove the Heat Roll Stripper Finger Assembly.
Figure 2 Remove the Heat Roll Stripper Finger
Installation
1.
Install the Heat Roll Stripper Finger (Figure 3).
Figure 1 Remove the Heat Roll Stripper Finger Assembly

4.
Remove the Heat Roll Stripper Finger (Figure 2).

1. Remove the spring tip from the groove.
2. Remove the stud.
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1/05
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REP 8.3.5
REP 8.4.1 Web Motor/EXT-HR Retract Motor

Removal
WARNING
CAUTION
1.
2.
3.
4.
Remove the Web Assembly (Figure 1).

1. Press the Latch Release Buttons (2).
2. Remove the Web Assembly.
Figure 3 Install the Heat Roll Stripper Finger

1.
2.
Figure 1 Remove the Web Assembly

5.

REP 8.3.5, REP 8.4.1
1/05
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Figure 3 Remove the Sensor

6.
7.
Remove the EXT-H/R Retract Motor (Figure 4).

Remove the sensor (Figure 3).
3. Remove the stud screw.
6. Loosen the set screw.

7. Remove the gear.
8. Remove the motor.
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1/05
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REP 8.4.1
Figure 5 Remove the Web Motor
Installation
1.
Figure 4 Remove the EXT-H/R Retract Motor

8.
Remove the Web Motor (Figure 5).

3. Remove the gear.
4. Remove the Web Motor.
REP 8.4.1
1/05
4-130
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DocuColor 12/DCCS50
REP 8.7.1 Oil Pump

Removal
WARNING
CAUTION
1.
2.
3.
4.
Move the clamp in the direction of the arrow (Figure 1).

2. Move the clamps (2) in the direction of the arrow.
Figure 2 Remove the Oil Pump
Installation
1.
2.
Perform the Full Fuser Break-In Procedure (GP 1 Fuser Break-In Procedure).
Figure 1 Move the Clamps

5.
Remove the Oil Pump (Figure 2).

NOTE: After removing the Oil Pump, drain the oil remaining in the tube into the tank.
2. Remove the Oil Pump.
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REP 8.7.1
REP 8.7.2 Oil Wick
5.
Remove the Oil Wick (Figure 2).


Removal
2. Remove the Oil Wick and, if present, the backup plate.
WARNING
CAUTION
NOTE: After replacing the Oil Wick, reset the HFSI counter. Enter the dC135 HFSI Counter
1.
2.
3.
4.

a.
b.
Top Cover (PL 8.2)
Remove the Oil Pipe (Figure 1).

1. Loosen the clamp.
2. Remove the Oil Pipe.
Figure 2 Remove the Oil Wick
Installation
1.
2.
Figure 1 Remove the Oil Pipe
REP 8.7.2
1/05
4-132
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DocuColor 12/DCCS50
REP 8.8.1 External H/R Heater Rod

Removal
WARNING
CAUTION
CAUTION
1.
2.
3.
4.

a.
b.
Top Cover (PL 8.2)

Figure 1 Disconnect the Connectors (Front of Fuser)

5.

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REP 8.8.1
Figure 2 Disconnect the Connectors - Rear of Fuser

6.
Remove the External Heat Roll Assembly (Figure 3).
Figure 3 Remove the External Heat Roll Assembly

7.
Remove the brackets (Figure 4).
3. Remove the External Heat Roll Assembly.
3. Remove the brackets (2).

4. Clean the External Heat Roll Assembly.
REP 8.8.1
1/05
4-134
Reissue
DocuColor 12/DCCS50
Figure 4 Remove the Brackets

8.
Remove the External H/R Heater Rod (Figure 5).

1. Remove the External H/R Heater Rod.
Reissue
DocuColor 12/DCCS50
Figure 5 Remove the External H/R Heater Rod
Installation
1.
1/05
4-135
REP 8.8.1
REP 8.8.2 External Heat Roll

Removal
NOTE: After replacing the External Heat Roll, Enter dC135 HFSI Counter List and reset HFSI
counter 010-803.
WARNING
CAUTION
Since the Fuser is very hot, Wait until the Fuser becomes sufficiently cold.
CAUTION
1.
Open the front door.
2.
Remove the External H/R Heater Rod (REP 8.8.1).
3.
Remove the External Heat Roll (Figure 1 ).

1. Remove the rings (2).
3. Remove the External Heat Roll.
4. Clean and inspect the two External Heat Roll Thermistors.
Figure 1 Remove the External Heat Roll
Installation
REP 8.8.2
1.
2.
3.
Adjust the External Heat Roll Nip (ADJ 8.8.1).
1/05
4-136
Reissue
DocuColor 12/DCCS50
REP 8.10.1 Pressure Roll Stripper Finger

Removal
NOTE: If the Pressure Roll Finger Assembly appears bent or damaged, replace the entire
finger assembly.
5.
1. Remove the spring tip from the groove.
WARNING
2. Remove the stud.
CAUTION
4. Remove the Stripper Finger.
1.
Remove the Pressure Roll Stripper Finger (Figure 2).
2.
3.
4.
Remove the Exit Chute (Figure 1).

NOTE: Do not damage the finger tip.
3. Remove the Exit Chute Assembly.
Figure 2 Remove the Pressure Roll Stripper Finger
Installation
1.
Install the spring as shown (Figure 3).
Figure 1 Remove the Exit Chute
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1/05
4-137
REP 8.10.1
Figure 3 Install the Spring

1.
2.
REP 8.10.1
1/05
4-138
Reissue
DocuColor 12/DCCS50
REP 9.2.1 Opening/Closing the IOT Control PWB Chassis
REP 9.2.2 IOT Drive PWB

Removal

Removal
WARNING
WARNING
1.
1.
2.
Remove the IOT Control PWB Cover (PL 9.2).
2.
Remove the IOT Control PWB Cover (PL 9.2).
3.
Open the IOT Control PWB Chassis (Figure 1).
3.
Remove the IOT CPU PWB (Figure 1).
3. Open the PWB chassis.
3. Remove the IOT CPU PWB.
Figure 1 Open the IOT Control PWB Chassis
Installation
1.
Figure 1 Remove the IOT CPU PWB

4.
Disconnect the IOT Drive PWB connectors (12) (Figure 2).
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1/05
4-139
REP 9.2.1, REP 9.2.2
Figure 3 Remove the IOT Drive PWB
Installation
1.
Figure 2 Disconnect the IOT Drive PWB Connectors

5.
Remove the IOT Drive PWB (Figure 3).

2. Remove the IOT Drive PWB.
REP 9.2.2
1/05
4-140
Reissue
DocuColor 12/DCCS50
REP 9.2.3 Half Tone PWB

Removal
WARNING
1.
Open/close the IIT (REP 3.1.2).
2.
Remove the Half Tone PWB Cover (Figure 1).

2. Open the Half Tone PWB Cover.
Figure 2 Remove the VSEL BT PWB

4.

Figure 1 Remove the Half Tone PWB Cover

3.
Remove the VSEL BT PWB (Figure 2).

4. Remove the VSEL BT PWB.
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1/05
4-141
REP 9.2.3
Figure 4 Remove the Half Tone PWB

5.
Remove the Half Tone PWB (Figure 4).

Installation
1.
Failure to comply with the board replacement procedure in GP 10 Replacing Billing PWBs
, could result in catastrophic NVM corruption.
3. Remove the Half-Tone PWB.

2.
REP 9.2.3

CAUTION
2. Remove the screws (2) and washers (2).
1/05
4-142
Refer to GP 10 Replacing Billing PWBs in order to synchronize the serial number of the
PWB.
Reissue
DocuColor 12/DCCS50
REP 9.3.1 Power Chassis

Removal
WARNING
1.
2.
Remove the following covers.

a.
Tray Module Rear Cover (PL 11.3)
b.
Filter Unit Cover (PL 11.2)
c.
Power Chassis Cover (PL 11.2)

Figure 2 Remove the Suction Blower

4.
Remove the screws (large: 1/small:3) of the AC Drive PWB. Keep the AC Drive PWB connector connected (Figure 3).
1. Remove the screw (large: 1).
2. Remove the screws (small: 2).
Figure 1 Remove the Duct

3.
Remove the Suction Blower (Figure 2).

3. Remove the Suction Blower.
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1/05
4-143
REP 9.3.1
Figure 3 Remove the Screws

5.
Remove the power chassis (Figure 4).

Figure 4 Remove the Power Chassis
Installation
1.
CAUTION
The IOT Control PWB Power Chassis contains the IOT NVM PWB, and the IOT CPU
PWB. Refer to GP 10 Replacing Billing PWBs , when replacing this component.
4. Remove the power chassis.
REP 9.3.1
1/05
4-144
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REP 9.3.2 IOT LVPS

Removal
3. Remove the IOT LVPS.
WARNING
1.
Remove the Tray Module Rear Cover (PL 11.3).
2.
Disconnect the IOT LVPS connectors (11) (Figure 1).
Figure 2 Remove the IOT LVPS
Installation
1.
Figure 1 Disconnect the IOT LVPS Connectors

3.
Remove the IOT LVPS (Figure 2).
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1/05
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REP 9.3.2
REP 9.3.3 B3/B3H (ESS) LVPS

Removal
WARNING
1.
2.

a.
b.
Filter Unit Cover (PL 11.2)
c.
Power chassis cover (PL 11.2)

Figure 2 Remove the Suction Blower

4.
Disconnect the AC Drive PWB connectors (Figure 3).

2. Disconnect the ESS SSR connectors (2).
3. Disconnect the AC Drive PWB connectors (8).
4. Disconnect P/J20.

3.
Remove the Suction Blower (Figure 2).

3. Remove the Suction Blower.
REP 9.3.3
1/05
4-146
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Figure 4 Remove the AC Drive PWB

6.
Remove the B3/B3H LVPS (Figure 5).

4. Remove the B3/B3H LVPS.
Figure 3 Disconnect the AC Drive PWB Connectors

5.
Remove the AC Drive PWB (Figure 4).

1. Remove the screw (large: 1).
2. Remove the screws (small: 3).
3. Remove the AC Drive PWB.
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REP 9.3.3
REP 9.5.1 Control Panel

Removal
WARNING
1.
2.
Remove the Control Panel (Figure 1).

2. Slide the Control Panel to the front. (Release it from the hook.)
Figure 5 Remove the B3/B3H LVPS
Installation
1.
Figure 1 Remove the Control Panel
Installation
1.
REP 9.3.3, REP 9.5.1
1/05
4-148
Reinstall the parts in the reverse order of disassembly. Check/adjust the Touch Panel
Starting Point Correction (ADJ 9.1.18).
Reissue
DocuColor 12/DCCS50
REP 9.6 Billing Data PWB Replacement

Procedure
CAUTION
This procedure is used to maintain the integrity of the serial number and billing data, when one
or more Billing PWBs must be replaced.
To maintain the integrity of the serial number and billing data, never replace all three PWBs at
the same time. If any of the following billing data PWBs needs replacing, only replace them
one at a time according to this procedure:
CAUTION
Failure to comply with the board replacement procedure in GP 10 Replacing Billing PWBs ,
could result in catastrophic NVM corruption.
Whenever any of the following PWBs are replaced, follow the procedure in GP 10 Replacing
Billing PWBs :
IOT NVM PWB (PL 9.2).
IOT CPU PWB (PL 9.2).
Half Tone PWB (PL 9.2).
If two or more serial numbers DO NOT match the M/C label serial number, escalate the service
call to Field Engineering or the NTC.
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1/05
4-149
REP 9.6
REP 9.6
1/05
4-150
Reissue
DocuColor 12/DCCS50
REP 10.2.1 Fuser Fan

Removal
WARNING
1.
Open/close the IOT Control PWB Chassis (REP 9.2.1).
2.
Remove the Fuser Cover (Figure 1).

2. Remove the Fuser Cover.
Figure 2 Remove the Fuser Fan
Installation
1.
Figure 1 Remove the Fuser Cover

3.
Remove the Fuser Fan (Figure 2).

1. Remove the Fuser Fan.
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1/05
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REP 10.2.1
REP 10.2.2 Suction Blower Motor

Removal
WARNING
1.
Remove the following part:

a.
2.

Figure 2 Remove the Suction Blower Motor
Installation
1.

3.
Remove the Suction Blower Motor (Figure 2).

3. Remove the Suction Blower Motor.
REP 10.2.2
1/05
4-152
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DocuColor 12/DCCS50
REP 11.1.1 Platen Cushion

Removal
WARNING
NOTE: The Platen Cushion is fixed in place by double-sided tape.
1.
Peel off the Platen Cushion (Figure 1).

1. Open the Platen Cover.
2. Peel off the Platen Cushion.
Figure 2 Install the Platen Cushion
Figure 1 Remove the Platen Cushion
Installation
NOTE: After peeling off the Platen Cushion, completely remove the tape from the Platen
Cover.
1.
Install the Platen Cushion (Figure 2).

1. Remove the seal.
2. Push the Platen Cushion in the direction of the arrow.
3. Slowly lower the Platen Cover and push it onto the Platen Cushion.
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1/05
4-153
REP 11.1.1
REP 11.1.1
1/05
4-154
Reissue
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REP 12.1.1 DADF

Removal
WARNING
WARNING
1.

Figure 2 Remove the DADF
Installation
1.
Figure 1 Disconnect the Connector

2.
Remove the DADF (Figure 2).

2. Remove the DADF.
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1/05
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REP 12.1.1
REP 12.2.2 Registration Gate Solenoid
REP 12.3.1 Left/Right Counter Balance

Removal

Removal
WARNING

1.
2.
Remove the Registration Gate Solenoid (Figure 1).
WARNING
WARNING
1.
Remove the DADF (REP 12.1.1).
2.
Remove the Rear Cover (PL 12.1).
3.
Remove the Left Counter Balance (Figure 1).
4. Remove the Registration Gate Solenoid.

2. Remove the Left Counter Balance.
Figure 1 Remove the Registration Gate Solenoid

Figure 1 Remove the Left Counter Balance
Installation
1.
4.
Remove the Right Counter Balance (Figure 2).

2. Remove the fastening terminals (2).
3. Remove the Right Counter Balance.
REP 12.2.2, REP 12.3.1
1/05
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Figure 2 Remove the Right Counter Balance
Figure 3 Install the Left/Right Counter Balance
Installation
1.
2.
Reinstall the remaining parts in the reverse order of disassembly.
Make sure to install each counter balance (left/right) on the correct side since the load
applied to each balance is different (Figure 3).
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REP 12.3.1
REP 12.3.2 DADF Control PWB
Installation

Removal
1.
WARNING
1.
2.
Remove the DADF Control PWB (Figure 1).

2. Remove the DADF Control PWB from the PWB supports (3).
Figure 1 Remove the DADF Control PWB
REP 12.3.2
1/05
4-158
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REP 12.4.1 Feed Motor

Removal
WARNING
1.
Remove the Rear Cover (PL 12.1)
2.

Figure 2 Remove the Feed Motor
Installation
1.

3.
Remove the Feed Motor (Figure 2).

2. Loosen the screws and remove the ground wire.
3. Remove the belt.
4. Remove the Feed Motor.
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REP 12.4.1
REP 12.4.2 Nudger Roll

Removal
NOTE: After replacing the Nudger Roll, reset the HFSI counter. Enter the dC135 HFSI
Counters Diag. Screen (NVM 005-80).
NOTE: Replace the Nudger Rolls and the Feed Roll at the same time.
WARNING
1.
Open the DADF Top Cover and remove the Inner Cover (Figure 1).
1. Open the Top Cover.
3. Remove the Inner Cover.
Figure 2 Remove the Nudger Rolls
Installation
NOTE: The Nudger Rolls have a one-way clutch structure. Install them so that they rotate
freely in the clockwise direction.
1.
Figure 1 Remove the Inner Cover

2.
Remove the Nudger Rolls (Figure 2).

2. Remove the Nudger Rolls (2).
REP 12.4.2
1/05
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REP 12.4.3 Feed Roll

Removal
NOTE: After replacing the Feed Roll, reset the HFSI counter. Enter the dC135 HFSI Counters
Diag. Screen (NVM 005-805).
NOTE: Replace the Feed Roll and the Nudger Rolls at the same time.
WARNING
1.
Open the Top Cover and remove the Inner Cover (Figure 1).
3. Remove the Inner Cover.
Figure 2 Remove the Feed Roll Assembly

3.
Remove the Feed Roll (Figure 3).

2. Remove the gear.
4. Remove the Feed Roll.
Figure 1 Remove the Inner Cover

2.
Remove the Feed Roll Assembly (Figure 2).

2. Slide the bearing.
3. Remove the Feed Roll Assembly.
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REP 12.4.3
REP 12.5.1 Document Feed Lower Chute

Removal
WARNING
1.

a.
Entrance Tray (PL 12.1)
b.
2.
Open the Document Feed Upper Chute.
3.
Remove the Document Feed Lower Chute (Figure 1).

3. Remove the Document Feed Lower Chute.
Figure 3 Remove the Feed Roll
Installation
NOTE: The Feed Rolls have a one-way clutch structure. Install them so that they rotate freely
in the clockwise direction.
1.
Figure 1 Remove the Document Feed Lower Chute
Installation
1.
REP 12.4.3, REP 12.5.1
1/05
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DocuColor 12/DCCS50

Removal
NOTE: After replacing the Retard Roll, reset the HFSI counter. Enter the dC135 HFSI
Counters Diag. Screen (NVM 005-805).
WARNING
1.
Remove the Document Feed Lower Chute (REP 12.5.1).
2.
Remove the Retard Roll (Figure 1).

4. Remove the arm.
6. Remove the Retard Roll.
Figure 1 Remove the Retard Roll
Installation
NOTE: The Retard Rolls have a one-way clutch structure. Install them so that they rotate freely
in the clockwise direction.
NOTE: After replacing the Retard Roll, make sure that the Retard Roll Mylar Guard is in the
correct position. (It may be inside the document feed chute.)
1.
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REP 12.5.2
REP 12.5.3 Set Gate Solenoid

Removal
WARNING
1.
2.
Remove the Set Gate Solenoid (Figure 1).

4. Remove the Set Gate Solenoid.
Figure 2 Install the Set Gate Solenoid

2.
Install and lock the Set Gate Solenoid by pressing it in the direction of the arrow (Figure 3)
Figure 1 Remove the Set Gate Solenoid
Installation
1.
Install the Set Gate Solenoid by inserting the pin into the gate (Figure 2).
REP 12.5.3
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REP 12.5.4 Registration Sensor

Removal
WARNING
1.
2.
Disconnect P/J580 and remove the Registration Sensor (Figure 1).

4. Remove the Registration Sensor.
Figure 3 Lock the Set Gate Solenoid

3.
Figure 1 Remove the Registration Sensor
Installation
1.
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When installing the Registration Sensor, lock it by matching the bracket hole with the halfpunch (Figure 2).
REP 12.5.3, REP 12.5.4
REP 12.5.5 Size Sensors 1/2 (Rear/Front)

Removal
WARNING
1.
2.
Remove the Set Gate Solenoid (REP 12.5.3).
3.
Remove the Size Sensors 1/2 (front/rear) (Figure 1).

4. Remove the Size Sensors 1/2.
Figure 2 Installing the Registration Sensor

2.
Figure 1 Remove the Size Sensors 1/2
Installation
1.
REP 12.5.4, REP 12.5.5
1/05
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REP 12.6.1 DADF Belt Motor

Removal
WARNING
1.
2.
Slide the DADF Control PWB (Figure 1).

2. Remove the Control PWB from the PWB supports (3) and slide the Control PWB
in the direction shown.
Figure 2 Remove the DADF Belt Motor
Installation
1.
Install the Belt (Figure 3 - looking from the rear).
Figure 1 Slide the DADF Control PWB

3.
Remove the DADF Belt Motor (Figure 2).

1. Draw a line to mark the location of the motor.
3. Remove the belt.
4. Remove the DADF Belt Motor.
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REP 12.6.1
REP 12.7.1 Duplex Sensor

Removal
WARNING
1.

a.
b.
Rear Cover (PL 12.1)
c.
Top Cover (PL 12.2)
2.
Slide the Feed Motor (REP 12.4.1).
3.
Incline the Invert Chute (Figure 1).

2. Incline the Invert Chute.
Figure 3 Install the Belt

2.
Figure 1 Incline the Invert Chute

4.
Remove the Invert Chute (Figure 2).

2. Remove the Invert Chute.
REP 12.6.1, REP 12.7.1
1/05
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Figure 3 Remove the Duplex Sensor
Figure 2 Remove the Invert Chute

5.
Remove the Duplex Sensor (Figure 3).

Installation
1.
2. Remove the Duplex Sensor.
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REP 12.7.1
REP 12.8.1 Registration Pinch Roll

Removal
WARNING
NOTE: Do not damage or scratch the surface of the Registration Pinch Roll. (Scratches may
cause skewing.)
1.

a.
b.
Rear Cover PL 12.1)
2.
Remove the Registration Gate Solenoid (REP 12.2.2).
3.
Remove the Lower Chute (Figure 1).

2. Remove the pulley.
4. Remove the Lower Chute.
Figure 1 Remove the Lower Chute

4.
Remove the gate (Figure 2).

NOTE: When removing the gate, make sure not to lose the springs (2) since the springs
may jump out.
2. Remove the gate.
REP 12.8.1
1/05
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Figure 2 Remove the Gate

5.
Figure 3 Remove the Registration Pinch Roll
Open the Top Cover. Press the bearing and spring in the rear so that they do not separate
and remove the Registration Pinch Roll (Figure 3).
Installation
1.
2. Remove the C-clip.

3. Remove the C-clip.
6. Remove the Registration Pinch Roll.
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REP 12.8.1
REP 12.9.1 Exit Motor

Removal
WARNING
1.
2.
Remove the Exit Motor (Figure 1).

4. Remove the belt.
5. Remove the Exit Motor.
Figure 2 Install the Exit Motor

2.
Figure 1 Remove the Exit Motor
Installation
1.
Install and lock the motor by pressing it in the direction of the arrow (Figure 2).
REP 12.9.1
1/05
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REP 12.10.1 Platen Belt
2. Move the shaft support in the direction of the arrow.

3. Remove the Platen Belt.

Removal
NOTE: After replacing the Platen Belt, reset the HFSI counter. Enter the dC135 HFSI Counters
Diag. Screen (NVM 005-805).
WARNING
1.
2.
Remove the Document Transport (Figure 1).

NOTE: Remove the Document Transport by holding it in the rear.
2. Remove the Document Transport.
Figure 2 Remove the Platen Belt
Installation
1.
Install the parts in the reverse order of the disassembly, but keep the following in mind:
Figure 1 Remove the Document Transport

CAUTION
Document Handler rises quickly when Platen Belt is removed.
3.
Remove the Platen Belt (Figure 2).

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REP 12.10.1
NOTE: Lock the shaft support by matching the hole with the frame's half-punch (Figure
3).
NOTE: Make sure that both sides of the Platen Belt are correctly set in the pulley (Figure
4).
CORRECT
Figure 3 Lock the shaft support
REP 12.10.1
INCORRECT
Figure 4 Install the Platen Belt

2.
Connect the power cord and switch on the power.
3.
Select and execute the DC330 Component Control Diag. Screen (005-055 Belt Motor
CW). Press the START button.
4.
Rotate the Platen Belt for 15 seconds. Press the STOP button. Check that the Platen Belt
has not shifted to either side.
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4-174
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REP 13.3.1 Decurler

Removal
WARNING
1.
Remove the Decurler Front Cover (PL 13.11).
2.

Figure 2 Remove the Decurler
Installation
1.

3.
Remove the Decurler (Figure 2).

2. Remove the Decurler.
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REP 13.3.1
REP 13.5.1 Vertical LED/Sensor
2. Decline the chute to the right side.
Parts List on PL 13.5 PL 13.9

Removal
4. Remove the Vertical Sensor.
WARNING
1.

a.
b.
Exit Cover (PL 13.4)
c.
Top Cover (PL 13.4)
2.
Open the front cover.
3.
Remove the Vertical LED (Figure 1).

4. Remove the Vertical LED.
Figure 2 Remove the Vertical Sensor
Installation
1.
Figure 1 Remove the Vertical LED

4.
Remove the Vertical Sensor (Figure 2).

1. Remove the screws (4) on the both sides.
REP 13.5.1
1/05
4-176
Reissue
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Removal
WARNING
1.
2.

a.
Stopper (PL 13.1)
b.
c.
Top Cover (PL 13.4)
d.
Left Cover (PL 13.4)

2. Remove the belt from the pulley.
Figure 2 Remove the ACT Cover

4.
Remove the Bin Tray Pawl from the gate (Figure 3).

3.
Remove the ACT Cover (Figure 2).

4. Remove the ACT Cover.
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REP 13.5.2
Figure 4 Remove Bin Tray 1
Figure 3 Remove the Bin Tray Pawl

5.
Remove the Bin Panel (Numbered Panel) (PL 13.4).
Installation
6.
Remove the Bin Tray 1 (Figure 4).
1.

2. Remove Bin Tray 1.
REP 13.5.2
1/05
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REP 13.6.1 Bin Trays 2 - 10

Removal
WARNING
NOTE: This page describes how to disassemble Bin Tray 2.
NOTE: To remove any Bin Tray (n), first remove Bin Trays 1 to (n-1).
1.
Remove the Bin Tray 1 (REP 13.5.2).
2.
Remove the Bin Tray Pawl from the gate (Figure 1).
Installation
1.
Figure 1 Remove the Bin Tray Pawl

3.
Remove the Bin Panel (Numbered Panel) (PL 13.4).
4.
Remove Bin Tray 2 (Figure 2).

3. Remove bin tray 2.
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REP 13.6.1
REP 13.13.1 Decurler Rolls 1/2

Removal
WARNING
1.
2.

a.
Decurler Rear Cover (PL 13.11)
b.
Decurler Top Cover (PL 13.11)
c.
Decurler Inner Cover (PL 13.11)
Remove the bearings (Figure 1).

Figure 2 Remove the Bearings

4.
Remove Decurler Roll 1 (Figure 3).

1. Remove Decurler Roll 1.

3.

REP 13.13.1
1/05
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Figure 3 Remove Decurler Roll 1

5.

Installation
1.
Install Decurler Rolls 1/2. Identify them by their markings (Figure 5).
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REP 13.13.1
REP 13.13.2 Gear and Cam

Removal
WARNING
1.
2.

a.
Decurler rear cover (PL 13.11)
b.
Decurler top cover (PL 13.11)

3. Hook the spring to the wire.
Figure 5 Install Decurler Rolls 1/2

2.

3.

2. Remove the gear.
REP 13.13.1, REP 13.13.2
1/05
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Figure 3 Remove the Cam

4.
Remove the Cam (Figure 3).

Installation
2. Remove the reflector.
This illustration shows installation for the rear side. Install the gear and cam for the front in the
same way as for the rear.
1.
Install the gear and cam. Align the holes in the two parts (Figure 4).

5. Remove the cam.
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REP 13.13.2
REP 13.14.1 Decurler Stepping Motor

Removal
WARNING
1.
2.

a.
Decurler rear cover (PL 13.11)
b.
Decurler top cover (PL 13.11)
Remove the Decurler Stepping Motor (Figure 1).

3. Remove the decurler stepping motor.
Figure 4 Install the Cam and Gear

2.
Figure 1 Decurler Stepping Motor
Installation
1.
REP 13.13.2, REP 13.14.1
1/05
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REP 14.1.1 Offset Motor

Removal
WARNING
1.
Remove the OCT from the Sorter.
2.
Remove the support (view from bottom) (Figure 1).

2. Remove the retaining covers (2).
3. Remove the support.
Figure 2 Remove the Offset Motor
Installation
1.
Figure 1 Remove the Support

3.
Remove the Offset Motor (Figure 2).

5. Remove the Offset Motor.
Reissue
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1/05
4-185
REP 14.1.1
REP 14.1.1
1/05
4-186
Reissue
DocuColor 12/DCCS50
REP 19.1 Removing the IDFE

Removal (Product Code GL2)
NOTE: There are two configurations of the IDFE for this machine. This REP applies generically to both. Where differences between the units exist, the applicable information is specified
by the product code for the IDFE (GL2 or MFY).
Remove the IDFE from the Printer.
9.
If necessary, remove any additional memory from the IDFE (REP 19.3).
NOTE: The IDFE comes 128 MB of memory installed. Customers may have additional
memory kit(s) installed in the IDFE. Remove this memory for installation into the replacement IDFE.
Replacement (Product Code GL2)

Perform the following to replace the GL2 version of the IDFE:
Perform the following to remove the GL2 version of the IDFE:

1.
8.
1.
If necessary, reinstall the Token Ring PWB into the IDFE (REP 19.2).
2.
If necessary, reinstall the customers additional memory kit(s) into the IDFE (REP 19.3).
CAUTION
3.
If any of the following steps are not correctly followed, the IDFE will not shut down properly,
and steps 2-3 of this procedure must be repeated.
If necessary, remove the IDFE Cover from the existing IDFE and install the Cover on the
replacement IDFE.
4.
Install the IDFE on the Printer.
2.
Switch OFF the Main Switch for the Printer/IDFE.
5.
Tighten the 4 mounting screws that secure the IDFE to the Printer.
3.
Wait for 30 seconds.
6.
Install the IDFE wiring harness between the IDFE and the Printer.
CAUTION
NOTE: Allow 30 seconds to ensure complete shutdown of the Hard Disk Drive.
4.
Disconnect all network cables from the IDFE.
5.
Disconnect and remove the 2 DDI Cables from the IDFE to the Printer.
6.
Disconnect the IDFE wiring harness from the Printer and the IDFE.
7.
Loosen the 4 mounting screws that secure the IDFE to the Printer.
8.
Remove the IDFE from the Printer.
9.
If necessary, remove the Token Ring PWB from the IDFE (PL 19.1)
Do not cross the 2 DDI Cables.
Perform the following to remove the MFY version of the IDFE:

and steps 2-3 of this procedure must be repeated.
Switch OFF the Main Switch for the Printer/IDFE.
NOTE: Allow 30 seconds to ensure complete shutdown of the Hard Disk Drive.
4.
Switch on the Main Power to the Printer.
1.
If necessary, install the customers additional memory kit(s) into the IDFE (REP 19.3).
2.
If necessary, remove the IDFE Cover from the existing IDFE and install the Cover on the
replacement IDFE.
3.
Install the IDFE on the Printer.
4.
Tighten the 6 mounting screws that secure the IDFE to the Printer.
5.
Install the IDFE wiring harness between the IDFE and the Printer.
CAUTION
CAUTION
9.
Perform the following to replace the MFY version of the IDFE:
Removal (Product Code MFY)
3.
Connect all network cables to the IDFE.
Replacement (Product Code MFY)
NOTE: The IDFE comes with 128 MB of memory installed. Customers may have additional memory kit(s) installed in the IDFE. Remove this memory for installation into the
replacement IDFE.
2.
Connect the 2 DDI Cables between the IDFE and the Printer.
8.
10. Ask the customer to use the Configuration Report to verify that the printer connectivity
settings are correct.
10. If necessary, remove any additional memory from the IDFE (REP 19.3).
1.
7.
Do not cross the 2 DDI Cables.

6.
Connect the 2 DDI Cables between the IDFE and the Printer.
7.
Connect all network cables to the IDFE.
8.
Switch on the power to the Printer.
9.
Ask the customer to use the Configuration Report to verify that the printer connectivity
settings are correct.
Disconnect all network cables from the IDFE.

NOTE: The 2 DDI Cables removed in the next step will be used on the replacement IDFE.
5.
Disconnect and remove the 2 DDI Cables from the IDFE to the Printer.
6.
Disconnect the IDFE wiring harness from the Printer and the IDFE.
7.
Loosen the 6 mounting screws that secure the IDFE to the Printer.
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REP 19.1
REP 19.2 Token Ring PWB (IDFE)
REP 19.3 DIMMs on the Motherboard (IDFE)

Removal

Removal
NOTE: There are two configurations of the IDFE for this machine. However, this procedure
applies only to the IDFE with the GL2 product code.
CAUTION
Use the ESD Kit and the established ESD procedures when handling PWBAs or accessing
componets within the IDFE.
1.
Remove the IDFE from the IOT (REP 19.1).
2.
Place the IDFE on a clean static-free work surface.
3.
Remove the Cover from the IDFE (PL 19.1).
4.
Remove the 2 screws and the 2 grounding clips for the Token Ring PWB.
5.
Remove the 2 screws from the SCAN IIT PWBA.
6.
Remove the Token Ring PWB from connectors J3 and J4 on the SCAN IIT PWBA.
7.
Remove the 2 standoffs from the Token Ring PWB.
1.
Remove the IDFE from the IOT (REP 19.1).
2.
Place the IDFE on a clean static-free work surface.
3.
Loosen the 9 screws and open the Cover for the IDFE (PL 19.1).
4.
Remove the DIMM(s) (PL 19.1).
Replacement
CAUTION
Use the ESD Kit and the established ESD procedures when handling PWBAs, DIMMs or
accessing components within the IDFE.
Replacement
CAUTION
Use the ESD Kit and the established ESD procedures when handling PWBAs or accessing
components within the IDFE.
1.
CAUTION
Use the ESD Kit and the established ESD procedures when handling PWBAs, DIMMs or
accessing components within the IDFE.
1.
Remove the DIMM(s) from their anti-static packaging.
2.
Install the DIMM(s) into the Motherboard (PL 19.1).
3.
Close the cover and tighten the 9 screws on the IDFE (PL 19.1).
4.
Re-install the IDFE on the IOT (REP 19.1).
Remove the Token Ring PWB from its anti-static packaging.
2.
Install the 2 standoffs and the 2 screws for the Token Ring PWB.
3.
Install the Token Ring PWB into connectors J3 and J4 on the SCAN IIT PWB.
NOTE: Carefully press the Token Ring PWB down onto Connectors J3 and J4 until the
PWB is completely seated on the SCAN IIT PWBA. Do not force the PWB onto the Connectors. If you have difficulty installing the Token Ring PWB, remove it completely and try
again.
NOTE: Do not install the Token Ring PWBA onto Connectors J1 and J2 on the SCAN IIT
PWBA. Connectors J1 and J2 are not functional and the Token Ring PWBA will not operate.
4.
Install the 2 screws for the SCAN IIT PWBA.
5.
Install the 2 grounding clips and the 2 screws.

NOTE: Ensure that the 2 grounding clips touch the Chassis to form a path to ground.
6.
Replace the Cover on the IDFE (PL 19.1).
7.
Reinstall the IDFE on the IOT (REP 19.1).
REP 19.2, REP 19.3
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ADJ. 3.4.1 Full Rate/Half Rate Carriage Position

Purpose
To adjust positional relationships between the Full and Half Rate Carriages.
Adjustment
WARNING
1.
2.
3.
Prepare the positional jigs (Figure 1).

2. Remove the jigs (4).
Figure 2 Align the Half Rate Carriage

5.
Install the jigs on the Half Rate Carriage (front/rear) (Figure 3).
1. Install the jigs (front/rear).
2. Lock the jigs with the screws.
Figure 1 Prepare the Jigs

4.
Align the Half Rate Carriage jig hole with the rail jig hole (front/rear) (Figure 2).
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ADJ. 3.4.1
Figure 3 Install the Half Rate Jigs
Figure 4 Change the Half Rate Pulley Lock Position
NOTE: If the Half Rate Carriage jig hole and the rail jig hole do not match and the jigs cannot
be installed, change the pulley lock position (Figure 4).
6.
7.
Install the jig on the frame jig hole. Check that the jig holes of the frame and the Full Rate
Carriage match (front/rear) (Figure 5).
1. Install the jig (front/rear).
Perform the following to match the jig holes:
2. Lock them with the screw.
1. Loosen the set screws (2), rotate the pulley and match the jig holes.
2. Match the jig holes.
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Figure 5 Install the Full Rate Jigs
Figure 6 Change the Full Rate Carriage Position
NOTE: If the Full Rate Carriage jig hole and the rail jig hole do not match and the jigs cannot
be installed, loosen the lock screw of the carriage cable and match the holes (front/rear) (Figure 6).
1.
Loosen the screw, move the Full Rate Carriage, and match the holes (front/rear).
2.
Match the holes (front/rear).
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ADJ. 3.4.1
ADJ. 3.4.1
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ADJ 6.1.1 Rotary Home Position Sensor
ADJ 6.6.1 Rotary Development Housing Position

Purpose

Purpose
This procedure sets the correct NVM values for the Rotary Home Position Sensor.
To properly position the Rotary Development Housings when performing various set ups.
Adjustment
Adjustment
1.
WARNING
Perform ADJ 6.6.1 to set the Rotary Assembly to the Cyan position.
CAUTION
Ensure that the Locating Pin is removed before attempting to run the machine.
1.
2.
2.
Without moving the Rotary Assembly, remove the locating pin and return it to its storage
position.
NOTE: After 776-064 is executed, the value is reset to 0 automatically. There is no need to
reset the NVM value.
a.
Toner Trickle Bottle (PL 6.5)
b.
Right Upper Cover (PL 11.2)

CAUTION
3.
Enter dC131 NVM Read/Write and change the value in NVM location 776-064 Home
Sensor Adjustment Mode to 1.
Ensure that the Locating Pin is removed and returned to its storage position before attempting
to run the machine.
4.
Enter dC330 Component Control. Execute 009-034 (Dispense Motor C).
3.
While the housing moves from the Cyan position to the Home position, the machine automatically measures and corrects the moving pulses.
Remove the Locating Pin (Figure 1).

2. Remove the pin.
Figure 1 Remove the Locating Pin
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ADJ 6.1.1, ADJ 6.6.1
4.

Figure 3 Hook the Bracket Hooks

6.
Remove the plate (Figure 4).


5.
Hook the bracket hooks (2) as shown in the figure below (Figure 3).
1. Hook the bracket hooks (2).
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Figure 4 Remove the Plate

7.
Rotate the Rotary Assembly until the appropriate development housing and the drum are
facing each other (Figure 5).
Figure 5 Rotate the Rotary Assembly

8.
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Match the front notch of the Rotary Assembly with the frame hole (Diameter 8).
ADJ 6.6.1
9.
Insert the locating pin into the frame hole (Diameter 8) and lock it with the screw (Figure
6).
1. Insert the locating pin.
2. Lock the screw.
Figure 6 Insert the Locating Pin

CAUTION
Ensure that the Locating Pin is removed and returned to its storage position before attempting
to run the machine.
10. Return to ADJ 6.1.1 to adjust the Rotary Home Position Sensor.
ADJ 6.6.1
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ADJ 8.1.1 Fuser Nip (DC701)
ADJ 8.8.1 External Heat Roll Nip Adjustment
Purpose
Purpose
To make a copy for checking and adjusting the Fuser Nip Width.
The purpose of this adjustment is to ensure correct Heat Roll-to-External Heat Roll contact,
which will aid in proper fusing and minimize web wrapping.
Check
NOTE: Use Tray 5 for making a measurement copy and a nip width measurement.
The paper used for the nip width measurement differs depending on the market:
XE, FX: A4L (90GSM Colotech+)
XC, XCL, AO: Letter L (24# Color Expressions)
1.
Enter dC701 Fuser Nip Measurement.
2.
Place the specified paper in Tray 5.
Check
1.
Enter DC701 (PWS Tool) or Subsystem Check / Fuser Nip Measurement from the UI
diagnostic screen.
2.
Place 24lb (90gsm) 8.5 x 11 LEF paper in Tray 5.
3.
Select Nip Adjustment Black Copy and make 1 copy.
4.
Cut the copy to make 6 - 70 mm x 60mm test strips as shown in Figure 1.
(PC-Diag. screen: Adjustment/Other Adjustment/Set Fuser Nip Adjustment)

3.
Follow the instructions on the screen and print three measurement copies.
4.
Place the copies just made back into Tray 5, face up.
5.
Select Make width measurement repeat this three times.
6.
Check that the nip width is an average of 10.3 +/- 0.3mm, front to rear.
Adjustment
1.
Adjust the screw (located on side requiring nip width adjustment) (Figure 1).
1. Rotate in the A direction (CCW): nip width becomes smaller.
2. Rotate in the B direction (CW): nip width becomes larger.
NOTE: 1/2 turn = approximately 0.5mm nip width change.
Figure 1 dC701 Test Page
Figure 1 Adjust the Nip

2.
Repeat the check and adjustment until the Nip Width is within specification.
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5.
Fold each test strip along the edge where the black and white portions meet.
6.
Open the Front Door and pull the Drawer Assembly out to the maintenance position (REP
8.1.1).
7.
Remove the Fuser Top Cover (PL 8.2 item 1).
8.
Install a cheater in the Front Door Interlock, and allow the machine to come to Ready.
NOTE: If strips will not fit between Heat and External Heat Roll, close copy drawer for approximately. 3 seconds and open drawer to install strips. If, after doing this several times, you cannot position the strips, replace the assembly because the frame is bent.
9.
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Insert 2 folded test strips (Figure 2) between Heat Roll and External Heat Roll approximately 50 mm from ends of rolls.
ADJ 8.1.1, ADJ 8.8.1
Adjustment
NOTE: If there is no fused transfer area, or if the difference between sides is excessive, preset
the height of the External Heat Roll Springs (PL 8.8 Item 18) to 24 mm (Figure 4).
TEST STRIPS
ADJUSTMENT SCREWS
Figure 2 Test Strip/Adjustment Screw locations
10. Close the Copy Drawer. The External Heat Roll Retract Motor will cam and uncam External Heat Roll. This will take approximately 3 seconds.
11. Open the drawer and remove the Test Strips.
12. Unfold the Test Strips slowly and check for a 3mm 0.5 fused transfer area on both strips
(Figure 3).
Figure 4 Spring Height
3 0.5mm
1.
2.
Adjust screws (Figure 2) to achieve 3mm 0.5 fused transfer area on both strips.
To increase nip turn screw counterclockwise.
To decrease nip turn screw clockwise.
Repeat Check/Adjustment until nip is within specification.
Figure 3 Fused Transfer Area

13. If the measurement is not within specification, perform the Adjustment.
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ADJ 9.1.1 MAX SET UP (dC929)
ADJ 9.1.2 IIT Calibration (dC945)
Purpose
Purpose
To conduct a check of the machine and set it up so that excellent copy quality can be consistently obtained by stabilizing the development potential and copy density.
1.
Calculate and set the white reference correction factor.
2.
Correct the IIT sensitivity dispersion.
Adjustment
Check
1.
Enter the PWS Diag. Screen for dC929.
2.
Do the MAX SETUP according to the following procedure:
1.
Enter the PWS Diag.Screen for dC945.

NOTE: Before performing the following procedure, be sure that the values for dC919
Color Balance Setup (IIT installed machine only) = 4 and the values for dC924 TRC
Adjust / dC939 TRC Check PG =128 (change all values for low, medium, and high settings).
a.
ADJ 9.1.2 IIT Calibration (dC945)
b.
ADJ 9.1.3 ADC AGC SET UP (dC934)
c.
ADJ 9.1.4 VH/VM SET UP (dC933)
d.
ADJ 9.1.5 Highlight SET UP (dC918)
e.
ADJ 9.1.6 TRC Control/Toner Density (dC922)
f.
ADJ 9.1.7 TRC Adjust (dC924)/TRC Check PG (dC939) - NOT TO BE USED AT

THIS TIME
g.
ADJ 9.1.8 Color Balance Setup (dC919: Copier/Printer)
2.
White Reference Adjustment:

a.
Put ten sheets of 11 x 17 Color Xpressions paper (NASG) or ten sheets of A3 Colotech+ paper (XE) on the Platen Glass, evenly covering the glass and registered
against the registration edges.
b.
Select White Reference Adjustment.
c.
Select Start.
d.
Follow the instructions on the screen. (Refer to step a above.)
e.
The Red, Green, and Blue values in the White Reference Set Values box will automatically update.
NOTE: After completing the Max Setup, check for background. If there is persistent
background in the image area on machines equipped with a DADF, manually reduce
NVM locations 715-091, 715-092, and 715-093 by five units each, until background
is acceptable. Do not exceed a maximum of ten units for each setting.
3.
4.
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CCD Calibration:
a.
Place the lead edge of the Color Test Pattern against the left registration edge of the
Platen Glass.
b.
Select CCD Calibration.
c.
Select Start.
d.
Follow the instructions on the screen. (Refer to step a above.)
e.
If OKs are displayed for the b* Judgement and Reflection Ratio Judgement, proceed
to step 4.
f.
If an NG is displayed, check the lower left corner of the screen for faults. Correct the
faults and repeat the adjustment.
Perform (ADJ 9.1.3) ADC AGC Setup (dC934 ADC/AGC Setup).
ADJ 9.1.1, ADJ 9.1.2
ADJ 9.1.3 ADC AGC Setup (dC934)
ADJ 9.1.4 VH/VM Setup (dC933)
Purpose
Purpose
To adjust the ADC gain to obtain the specified Vclean and to measure the Vclean non-uniformity on the belt.
To set the output values of the VG, LD light amount, development bias, and ASG bias.
Adjustment
Adjustment
1.
1.
2.
Select Start.
2.
Select Start.
3.
If OKs are displayed in the Judgement column, proceed to step 5.
3.
If OKs are displayed in the Set Value Judgement column, proceed to Step 5 below.
4.
4.
If an NG is displayed, check the lower left corner of the screen for Faults. Correct the
If an NG is displayed, check the lower left corner of the screen for faults. Correct the
5.
Perform (ADJ 9.1.5) IOT Highlight Setup (dC918 IOT Highlight Setup).
5.
Perform (ADJ 9.1.4) VH/VM Setup (dC933 VH/VM Setup).
ADJ 9.1.3, ADJ 9.1.4
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ADJ 9.1.5 IOT Highlight Setup (dC918)
ADJ 9.1.6 TRC Control/Toner Density (dC922)
Purpose
Purpose
a.
To make the Highlight density reproduction starting points uniform for K, Y, M and C.
1.
b.
To make the In/Out Highlight density uniform.
Measure the gradient patch by the ADC sensor and create the IOT TRC correction LUT. If
the measurement result is not within the margin, display the Tone Up/Down evaluation.
c.
To set the ESV/ADC control target values.
2.
Display the two patch densities for each color on the IBT belt.
Check/Adjustment
Adjustment
1.
1.
2.
Check the In(board)/Out(board) density difference.
2.
Select Tray: 11 x 17 or A3.
a.
Select Tray: 11 x 17 or A3.
3.
Select Start.
b.
Select Screen: 300
4.
Check the TRC Judge column:
c.
Select Start.
If all boxes display OK, proceed to step 5.
d.
Visually check the density differences between the inboard (rear) and the outboard
(front) side of the output print. If there is no density difference from the outboard to
the inboard side, for all colors, go to step 3.
If an NG is displayed, return to ADC AGC Setup (ADJ 9.1.3).
e.
If adjustment is necessary, select the In/Out box of the color to adjust and perform
one of the following:
NOTE: The density of the inboard side of the output print is fixed, and the outboard
side is adjusted to match the inboard.
f.
3.
To lighten the outboard density, increase the value using the (+) button and
press Save to store the value.
To darken the outboard density, decrease the value using the (-) button and
press Save to store the value.
NOTE: The TRC Judgement is based on the Measurement vs. Target Table for TRC
Patches #1 and #2 at the bottom of the screen. Patch #1 is 30% Cin for all four colors,
while Patch #2 is 65% Cin for YMC and 60% Cin for K.
5.
Check the RADC Judge Column:
If an NG is displayed, return to ADC AGC Setup (ADJ 9.1.3).
NOTE: The RADC Judgement is based on RADC patches: 65% Cin for YMC and 60%
Cin for K. (Separate patches from the TRC patches.)
6.
Repeat Step 2 until the inboard and the outboard densities are equal.
Check the Tone Judge column.

a.
Check the CMYK Highlight densities.
b.
If an Up or Down is displayed for a given color, that color requires toning up or down.
a.
c.
Select Run to start the tone up/down routine. The Tone Interval column automatically displays the required quantity.
Using the print made in step 2, visually check the densities of the color squares
(from left to right: Mono K, C, M, Y, and Process K):
The Mono K, C, M, and Y squares in the fourth row down should be barely visible.
The Mono K, C, M, and Y squares in the eighth row down should not be visible.
b.
If the print meets specification, go to step 4.
c.
If the print does not meet specification, select the appropriate color in the Adjustment
box in the 300 Lines column. Adjust the value using the +/- buttons and select Save.
(Increasing the value increases the density.)
d.
Select Tray (11 x 17 or A3), Screen (300) and Start. Repeat step 3 using this output print.
4.
Change the values in the 600 Lines column to match the numbers in the 300 Lines column (if they do not already match) and select Save.
5.
Perform (ADJ 9.1.6) TRC Control (dC922 TRC Control/Toner Density Adjustment).
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NOTE: No output prints are generated.

d.
Return to step 2 when the routine is completed. If the Tone Judge and Tone Interval
results do not change after several attempts at the tone up/down routine, go to IQ 10
Low Image Density RAP.
NOTE: The Tone Judge column is based on the RADC patch measurements vs the
RADC targets as follows:
Machines without ATC Sensors: The RADC targets shown on dC922 TRC Control/
Toner Density Adjustment screen are humidity adjusted ADC targets that Correspond to NVMs 773-281 thru 773-284.
If the RADC Measurement is within 30 bits of the RADC Target, the density of the
patch is close to the target density. No tone up or down is required.
If the RADC Measurement is more than 30 bits from the RADC Target, but is within
100 bits of the RADC Target for YMC (80 for K), the density of the patch is lighter
or darker than the target, but output densities will be corrected automatically by
LUTs. No tone up or down is required.
ADJ 9.1.5, ADJ 9.1.6
7.
If the RADC Measurement is more than 100 bits from the RADC Target for YMC
(more than 80 bits for K), LUTs cannot compensate, and toning up or down is
required. If one color is out of range, the other colors may display an Up or Down in
the Tone Judge column to move closer to their targets, even though they are within
the appropriate range.
ADJ 9.1.7 TRC Adjust (dC924)/TRC Check PG (dC939)
Machines with ATC Sensors: The RADC targets shown on the dC922 TRC Control/
Toner Density Adjustment screen are humidity adjusted ADC targets that correspond
to NVMs 773-281 thru 773-284. They are not the final TC adjusted ADC targets that
the RADC measurements are being compared to with this configuration. The final
TC adjusted ADC targets can only be found in NVMs 773-961 thru 773-964. using
these final TC adjusted ADC targets, the same 100 bits for YMC (80 bits for K) tone
up/down criteria as above applies.
NOT TO BE USED AT THIS TIME.
Purpose
To manually fine adjust the low/medium/high densities (TRC) for each color.
NOTE: Although it appears that the densities can be adjusted independently for different
screen types, this is not the case. An adjustment for one screen type will affect all of the
screens (300, 150C, 200R, and 600). Also, there is quite a bit of overlap among the low,
medium, and high densities. For these reasons, it is recommended that dC924/939 not be
used.
Perform (ADJ 9.1.8) Color Balance Setup dC919 Color Balance Setup (IIT installed
machine only) only if required by the customer.
ADJ 9.1.6, ADJ 9.1.7
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ADJ 9.1.8 Color Balance Setup (dC919: Copier/Printer)
ADJ 9.1.10 IOT Registration Series (dC129)
Purpose
Purpose
To set the system highlight densities and highlight gray balance.
The purpose is to adjust the position of the image on the page. This is done by changing the
value in the appropriate NVM location in dC129. This controls where the ROS writes the
image.
NOTE:
1.
This function should be done when the customer has requested further adjustment of low
end density reproduction.
2.
Before executing this function, the dC918 Highlight Setup (ADJ 9.1.5) must be done correctly.
Introduction
This series consists of 3 procedures:
Lead Edge Registration for all Paper Trays
Side Edge Registration for Paper Trays 1 - 6
Adjustment
1.
Side 2 Registration for Duplex Tray
Enter the PWS Diag. Screen for dC919 (IIT machines only).
All procedures must be checked.
2.
Place the Color Test Pattern on the Platen Glass.
3.
Select Start. (The output copy is in Photo/Halftone mode at Normal L/D.)
4.
Visually check the 20% densities on the output copy against the 20% densities on the pattern.
5.
a.
If necessary, adjust the Y,M,C,K density levels so that the densities on the copy
match the densities on the test pattern or the customer preference, using the + buttons. (Increasing the value increases the density.)
b.
Select Save.
Repeat steps 3 and 4 as necessary.
Lead Edge Registration (all Paper Trays)

Purpose
NOTE: There is only one lead edge setting for the paper supply. The Duplex Tray has a separate setting for second-side lead edge.
To correctly set the lead edge of the image in relation to the edge of the paper.
Check
NOTE: For 20% gray balance, match the Y, M, and C patch densities and let the gray be an
outcome. The gray patch on the dC 919 copy should not exactly match the gray patch on the
test pattern. Compare the gray patch on the dC 919 copy with the drawer/shipping sample, if
available. Adjustments to dC 919 affect all modes. The grays will look different in different
modes. If dC 919 is adjusted based on the Photo/Halftone output, check the output from the
other modes (Text, Photo, etc) to be sure that the gray is acceptable.
1.
Launch the DC12 / DCCS 50 Diagnostic Tool. Select dC129 from the DC Quick menu
2.
Select Start Data Read to read the NVM values for this adjustment.
NOTE: Do not use Tray 5 (MSI) to set Lead Edge Registration.

3.
When the Data Read is done, select a paper tray from the Tray/Size menu. If possible,
use a tray that contains the largest paper used by the customer.
4.
Enter 3 into the Print Count: box, and click on Start.
5.
Skew Check:
Compare the second print to Figure 1. If the skew is out of spec, go to the IQ3 RAP.
Resolve the cause of the skew before proceeding with this adjustment.
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ADJ 9.1.8, ADJ 9.1.10
Lead
Edge of
Paper
Check distance from intersection of lines to edge of

paper at points A and B
Check distance from intersection of lines to edge of paper at

points A and B, and at points C and D
A
A, B
LE
C, D
Dimension A, B
11x17 or 8.5x11 LEF: 10.0 mm +/- 0.5 mm
A3 or A4 LEF: 7.6 mm +/- 0.5 mm
12x18inch w/Tag P39: 22.5 mm +/- 0.5 mm
12x18inch w/out Tag P39: 10.0 mm +/- 0.5 mm
2
Skew is within spec. if difference
between A and B, or C and D, is
less than 2.5 mm.
Figure 1 Checking Skew

6.
A, B
Figure 2 Checking Lead Edge Registration
Lead Edge Check:
Adjustment
Check the Lead Edge Registration (Figure 2). If the measured values are not within specification, perform the Adjustment.
1.
Use the Right and Left Arrow buttons to move the image toward or away from the lead
edge of the paper. Each click on the button moves the image 0.11mm. The cumulative
amount of shift is indicated in the Lead Reg. box.
2.
After adjusting the registration, click Set Adjust Value.
3.
Select Start.
NOTE: If the Lead Edge Registration cannot be brought within specification, the NVM value for
the starting point may be out of range. Reset NVM location 761-043 to the default value of
3954 and perform the adjustment again.
4.
Repeat the check/adjustment until the specifications are met.
5.
Select Save [LR] to save the new NVM settings.
6.
Proceed to Side Edge Registration for Paper Trays 1 - 6.
Side Edge Registration for Paper Trays 1 - 6

Purpose
NOTE: Each Paper Tray has a separate setting for side edge registration.
To correctly position the side edge of the image in relation to the outboard edge of the paper.
ADJ 9.1.10
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Check
NOTE: If the Side Edge Registration cannot be brought within specification, the NVM value for
the starting point may be out of range. Reset the NVM location (Table 1) for the affected tray to
the default value and perform the adjustment again.
1.
Check that paper is loaded in all trays, and that the paper guides are adjusted correctly.
For Tray 1 and Tray 6 (if present), load 8.5 x 11 in. or A4 paper. For Tray 2 through Tray 5,
use 11 x 17 in. or A3 paper if available.
5.
2.
Enter 1 into the Print Count: box, and click on Print All.
6.
Select Save [SR] to save the new NVM settings.
NOTE: Print All prints from each tray in numerical sequence from Tray 1 through Tray 6
(HCF - if installed). Make sure to keep the sheets in the correct sequence.
7.
Repeat steps 1 through 6 for each tray that requires adjustment.
8.
Proceed to Lead Edge/Side Edge Registration for Duplex Tray.
3.
Check the Side Edge Registration (Figure 3) for each page. If the measured values are
not within specification, perform the Adjustment for that tray.
Table 1 Side Edge Reg. Defaults
NOTE: When the lead edge is to the right, the side to be checked is at the bottom of the
sheet.
1
Check distance from intersection of lines to edge of paper at points C and D
Tray
Location
Default
720-003
7406
720-004
7406
720-005
7406
720-006
7406
720-007
7406
720-003
7406
Side 2 Registration for Duplex Tray

Purpose
The purpose of this procedure is to correctly position the lead edge and side edge of the image
in relation to the edge of the paper.
LE
Check
C, D
C
Dimension C, D
11x17, 12x18, or 8.5x11 LEF: 10.0 mm +/- 0.5 mm
A3, SR-A3, or A4 LEF: 7.6 mm +/- 0.5 mm
8.5x11 or 8.5x14 SEF: 7.6 mm +/- 0.5 mm
1.
Select Duplex from the Tray/Size menu. Ensure that Paper Tray 2 contains paper and
that the paper guides are adjusted correctly. If available, load the tray with 11 x 17 in. or
A3 paper.
2.
Enter 1 into the Print Count: box, and click on Start.
NOTE: Side 2 will be face up in the output tray.

3.
Side Edge
of Paper
Check Skew:
Compare Side 2 of the print to Figure 1. If the skew is out of spec, go to the IQ3 RAP.
Resolve the cause of the skew before proceeding with this adjustment.
4.
Figure 3 Checking Side Edge Registration
Check Lead Edge:

Check the Side 2 Lead Edge Registration (Figure 2). If the measured values are not within
specification, perform the Adjustment.
Adjustment
5.
Check Side Edge:
1.
Select the paper tray to be adjusted from the Tray/Size menu.
2.
Use the Up and Down Arrow buttons to move the image toward or away from the outboard edge of the paper. Each click on the button moves the image 0.0423 mm. The
cumulative amount of shift is indicated in the Side Reg. box.
Adjustment
3.
4.
Select Start.
1.
Use the Right and Left Arrow buttons to move the image toward or away from the lead
edge of the paper. Each click on the button moves the image 0.1mm. The cumulative
amount of shift is indicated in the Lead Reg. box.
2.
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Check the Side Edge Registration (Figure 3). If the measured values are not within specification, perform the Adjustment.
Duplex Lead Edge:
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ADJ 9.1.10
3.
Select Start.
NOTE: If the Lead Edge Registration cannot be brought within specification, the NVM value for
4.
5.
Select Save [LR] to save the new NVM settings.
Duplex Side Edge:

1.
Use the Up and Down Arrow buttons to move the image toward or away from the outboard
edge of the paper. Each click on the button moves the image 0.0423 mm. The cumulative
amount of shift is indicated in the Side Reg. box.
2.
3.
Select Start.
NOTE: If the Side Edge Registration cannot be brought within specification, the NVM value for
4.
5.
Select Save [SR] to save the new NVM settings.
ADJ 9.1.10
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ADJ 9.1.14 IIT Lead Edge Registration
Adjustment
Purpose
1.
Enter dC131 NVM Read/Write.
2.
Change the value in location [715-132]:
To adjust the copy position.
a.
1 step: 0.0635mm
CAUTION
b.
Increase the value to move the image away from the lead edge.
Do not adjust the lead registration unless absolutely necessary, when the registration is not
correct in the IIT, since the IIT lead registration influences the precision of the document size
detection.
c.
Decrease the value to move the image toward the lead edge.
NOTE: Before running this function, check/adjust Side/Lead Edge Registration (ADJ 9.1.10).
Check
1.
Load 11 x 17 (A3) paper in Tray 2, if available.
2.
Place the B&W test pattern (82E8220) on the platen and copy it as follows:
3.
a.
Copy mode: Black
b.
Paper tray: Tray 2
c.
Magnification: 100
d.
Number of copies: 2
Check on the 2nd copy that the distance from the side edge to the top of Step 3 on the
LE1 and LE3 scales is 10.0mm +/- 2.1mm (Figure 1).
10.0mm +/2.1mm
Figure 1 Checking the IIT Lead Registration

4.
If the value is not within the allowable range, perform the Adjustment:
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1/05
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ADJ 9.1.14
ADJ 9.1.15 IIT Side Edge Registration
Adjustment
Purpose
1.
Enter dC131 NVM Read/Write [715-029] (REGI ADJ revise VAL)
2.
Change the value.
To adjust the IIT scan timing in the main scanning direction and to correct the copy position.
a.
1 step: 0.0635mm
CAUTION
b.
Increase the value to move the image toward the edge.
Do not adjust the side registration unless absolutely necessary, when the registration is not
correct in the IIT, since the IIT side registration influences the precision of the document size
detection.
c.
Decrease the value to move the image away from the edge.
NOTE: Before running this function, check/adjust Side/Lead Edge Registration (ADJ 9.1.10).
Check
1.
Load 11 x 17 (A3) paper in Tray 2, if available.
2.
Place the test pattern (82E8220) on the platen and copy it in the following copy mode:
3.
a.
Copy mode: Black
b.
Paper tray: Tray 2
c.
Magnification: 100
d.
Number of copies: 2
Check on the 2nd copy that the distance from the side edge to the top of Step 3 on the
SE2 and SE3 scales is 10.0mm 2.1mm (Figure 1).
PAPER
FEED
DIRECTION
Edge of
Copy
10.0mm
2.1mm
Figure 1 Checking the IIT Side Registration

4.
If the value is not within the allowable range, adjust the timing as follows:
ADJ 9.1.15
1/05
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ADJ 9.1.16 IIT Horizontal Magnification/Vertical

Magnification (IIT Machine)
PAPER FEED
DIRECTION
Purpose
To correct the horizontal (main) and vertical (sub) magnification for a 100% copy.
200mm+/1mm
CAUTION
Do not change these magnifications unless absolutely necessary, when the magnifications in
the IIT are not correctly set. These magnifications influence the AE/ACS/TI separation.
NOTE: Before running this function, make sure that the IOT horizontal magnification/vertical
magnification are correct.
Check
1.
2.
Place the test pattern (82E8220) on the platen and copy it in the following copy mode:
a.
Copy mode: Black
b.
Document type: Text/Photo
c.
Paper size: 11 x 17 or A3
d.
Magnification: 100%
e.
Number of copies: 2
Check the following on the 2nd copy:

a.
Horizontal magnification (Figure 1):

Measure the 200mm line running from near LE1 to near LE3. If the dimension is not
200mm 1mm, adjust the magnification as described below.
Figure 1 Checking the IIT Horizontal Magnification

b.
Vertical Magnification (Figure 2):
Measure the 300mm line running from near LE1 to the trail edge of the 1.8lp ladder. If the
dimension is not 300mm 1.5mm, adjust the magnification as described below.
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ADJ 9.1.16
PAPER FEED
DIRECTION
1.
Enter dC131 NVM Read/Write.
2.
Change the value in location [715-133] (MAG Revise VAL).

a.
1 step = 0.1%
b.
Increase the value to enlarge.
c.
Decrease the value to reduce.
300mm +/1.5mm
Figure 2 Checking the IIT Vertical Magnification
Adjustment
Horizontal magnification
NOTE: If you change the magnification, the following problems may occur:
a.
Degraded resolution because of the ASIC digital correction
b.
Degraded AE/ACS/TI separation
1.
Enter dC131 NVM Read/Write [715-023] (FS Mag Adjustment).
2.
Change the value.

a.
1 step = 0.1%
b.
Increase the value to enlarge.
c.
Decrease the value to reduce.
Vertical magnification
NOTE: If you change the magnification, the following problems may occur:
a.
Improper RGB overlapping/color shift
b.
Degraded AE/ACS/TI separation
ADJ 9.1.16
1/05
4-210
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DocuColor 12/DCCS50
ADJ 9.1.17 Tray 5 Guide (dC740)
Table 1 Paper Size Groups
Purpose
To check if the width direction size of the Tray 5 guide is being correctly detected.
Displayed paper
group
A/D range Paper
Width (mm)
A4SEF
222`177
A4S
210
1.
To set the sensor output values for the minimum/maximum position of the guide.
A4SEF
222`177
8.5"~11"S
215.9
2.
To display the result of the width direction size detection.
A4SEF
222`177
8.5"~12.4"S
215.9
Adjustment
A4SEF
222`177
8.5"~13"S
215.9
1.
Enter dC740 Tray 5 Guide Adjustment.
A4SEF
222`177
8.5"~14"S
215.9
2.
Move the Tray 5 guide to the minimum position.
B4SEF
176`8D
8"~10L
254
3.
Select Set at the minimum position on the PWS screen. Click Start.
B4SEF
176`8D
B5L
257
4.
If OK, go to Step 5.
B4SEF
176`8D
B4S
257
If NG:
B4SEF
176`8D
TFX Special Paper 267

L
a.
Enter dC131 NVM Read/Write and record the value in location [760-001] (Tray 5
Size Sensor Analog Value).
B4SEF
176`8D
b.
Enter the recorded value into loc. [760-002] Tray 5 Size Sensor analog smallest
Value. Exit dC131.
TFX Special Paper 267

S
B4SEF
176`8D
8.5"~11"L
279.4
5.
Move the Tray 5 guide to the maximum position.
B4SEF
176`8D
11"~17"S
279.4
6.
Enter dC740 Tray 5 Guide Adjustment. Select Set at the maximum position on the PWS
screen. Click Start.
A3SEF
8C`00
A4L
297
A3SEF
8C`00
A3S
297
If OK, go to Step 8.
A3SEF
8C`00
12"~18S"
304.8
If NG:
A3SEF
8C`00
12.6"~18S"
320
7.
a.
Enter the dC131 NVM Read/Write and record the NVM (760-001 Tray 5 Size Sensor
Analog Value) data.
b.
Enter the 760-001 data in the 760-002 Tray 5 Size Sensor analog smallest Value.
Exit dC131.
8.
If the Minimum and Maximum are being set, all sizes are automatically adjusted. If a particular size sheet causes a problem, check the following.
9.
Set the particular paper sheet in Tray 5 and adjust the guide accordingly.
10. Enter the dC740 Tray 5 Guide Adjustment. Select Guide Test in the PWS screen. Click
Start.
The paper size group is displayed in the result window in the PWS screen.
11. Consult the table below and check if the correct group is displayed for the particular paper
type. If an incorrect group is displayed, repeat Steps 2 - 7.
Table 1 Paper Size Groups
Displayed paper
group
A/D range Paper
Width (mm)
Postcard
3FF`385
Postcard S
100
Postcard
3FF`385
A6S
105
A5SEF
385`2AC
B6S
128
A5SEF
385`2AC
5.5"~8.5"S
139.7
A5SEF
385`2AC
A5S
148
B5SEF
2AB`223
B5S
182
A4SEF
222`177
A5L
210
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ADJ 9.1.17
ADJ 9.1.18 Touch Panel Starting Point Correction
5.
Purpose
Press the starting point connection switch again in order to display the adjustment
screen (Figure 2).
To align the starting points of the UI display and the touch panel switches.
A pattern of intersecting grid lines (P1 thru P9) will be displayed.
Check
This adjustment is required when replacing the Control Panel or the UI PWB.
Adjustment
NOTE: Each copier is equipped with an adjusting pen for this adjustment, which is stored
under the right side panel of the control panel.
1.
2.
Access the UI touch panel and adjusting pen.

a.
Remove the right side panel from the control panel.
b.
Remove the adjusting pen.
Figure 2 Adjustment Screen #1
3.
Switch on the copier.
4.
Push the starting point correction switch on the lower right corner of the UI PWB (Figure
1).
6.
Apply the point of the adjusting pen in sequence to each line intersection(P1 thru P9) on
the adjustment screen.
7.
Press the starting point correction switch again to display the next screen.
8.
Apply the adjusting pen to each of the four line intersections (Figure 3).
A blank screen will be displayed.
ADJUSTING
PEN
One or more LEDs may light on the UI PWB.

A new pattern of intersecting grid lines will be displayed.
If four audible beeps are heard, adjustment is OK.
If you dont hear four beeps, perform the adjustment again from the third step.
DISPLAY
Figure 3 Adjustment Screen #2

9.
LED(S)
Reinstall the adjusting pen and all removed parts.
STARTING POINT
CORRECTION
SWITCH
Figure 1 UI PWB and Touch Panel Display
ADJ 9.1.18
1/05
4-212
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ADJ 9.1.19 Tray 2, 3, and 4 for 12 x 18 Paper

Purpose
To set Paper Trays 2, 3, and 4 to use 12 x 18 paper.
Adjustment
1.
Remove the Paper Tray from the machine.
2.
Remove the Rear Stop (PL 2.1) item 17.
3.
Remove the Side Guide Plate (PL 2.3) item 1.
4.
Remove the Bottom Plate (PL 2.3) item 2.
5.
Remove the (3) screws securing the Regi. Side Guide (PL 2.3) item 8. Position the guide
flush with the front wall and secure it with the (3) screws.
6.
Remove the End Guide (PL 3.2) item 10 by removing the E-rings and washers on the
underside of the tray.
7.
Slide the guide to align the slot (Figure 1).
8.
Install the Bottom Plate and the Side Guide Plate.
9.
Install the tray into the machine.
1. Align the slot in the guide with the hole in the tray, and secure with a screw.
10. Store the Regi. End Guide, E-rings, washers and the Rear Stop Bracket in the tray 1 storage compartment.
NOTE: The UI will sense and display the 12 x 18 size for the modified tray.
NOTE: Paper specifications for Trays 2, 3, and 4; Standard Weight 16 to 24 #, Heavy
Weight 32 #.
Figure 1 Align the Slot
NOTE: If heavy weight paper is to be fed from the modified tray a set up change is
required. Go to Tools Management, disable Auto Tray and set up the modified tray for
Heavy Weight paper.
Reissue
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1/05
4-213
ADJ 9.1.19
ADJ 9.1.19
1/05
4-214
Reissue
DocuColor 12/DCCS50
ADJ 12.1.1 DADF Side Registration
5.

Purpose
Check that the value A is 10.0mm 0.6mm. If the value is not within the range, perform
Side/Lead Edge Registration(ADJ 9.1.10), then return to this procedure.
6.
Place the two document pages in the DADF. (The number "1" page is on top, and the bottom edge is fed in first.)
7.
Set the following copy mode and make a copy.
To ensure that the document is set into the correct position on the Platen (front-to-rear drum
axis direction).
Check
NOTE: Before running this function, the side registration in the Platen mode must be properly
adjusted (ADJ 9.1.15).
1.
Place the test pattern (82E8220) on the Platen so that there is no gap between the test
pattern and the Registration Guide at the rear.
2.
Copy the test pattern in the following copy mode:

a.
Copy mode: Black
b.
Paper tray: 11 x 17 or A3
c.
Magnification: 100
d.
Number of copies: 2
8.
a.
Copy mode: Black
b.
c.
Magnification: 100
d.
Number of copies: 1
Using the number 2 copy, measure the distance between the paper side edge and the
target line. Assume this distance is B (Figure 2).
PAPER
FEED
DIRECTION
3.
Number the ejected document pages as "1" and "2" in the order that they are ejected.
4.
Measure the distance between the paper side edge of the second document (2) and the
target line. Assume this distance is A (Figure 1).
PAPER
FEED
DIRECTION
B
Edge of
Copy
Figure 2 Checking the Side Registration B

9.
Check if B - A is 0 1mm.
Adjustment
A
Edge of
Copy
NOTE: You can adjust the side registration of the DADF simplex or duplex.
1.
Enter the dC131 NVM Read/Write[715-028] (DADF IPS Offset)
2.
If B in step 8 of the check is,

a.
b.
Figure 1 Checking the Side Registration A
Reissue
DocuColor 12/DCCS50
10.6mm or more: Increase the NVM value;

9.4mm or less: Decrease the NVM value.
(each NVM step=1mm)
1/05
4-215
ADJ 12.1.1
3.
Repeat check steps 1 - 5 and adjustment steps 1- 2 until the value is within the allowed
range (B=10mm 0.6mm).
ADJ 12.3.1 Left/Right Counter Balance

Purpose
To correct the spring pressure on the Left/Right Counter Balance.
Check
1.
Operate the DADF so that it closes from the Open state. Check whether the DADF
remains in the open position when fully raised and closes under its own weight from a
height of 100 50mm (Figure 1).
Figure 1 Checking the Counter Balance
Adjustment
WARNING
1.
Remove the rear cover PL 12.1.
2.
Adjust the Left/Right Counter Balance (Figure 2).

NOTE: If item b in the check steps is adjusted, adjust only the Left Counter Balance (as a
rule). (This is because floating may occur at the right side due to DADF rigidity.)
ADJ 12.1.1, ADJ 12.3.1
1/05
4-216
a.
Rotate in the A direction for stronger spring pressure.
b.
Rotate in the B direction for weaker spring pressure.
Reissue
DocuColor 12/DCCS50
1. Loosen the nut.

2. Turn the set screw to adjust the spring pressure.
3. Tighten the nut.
ADJ 12.3.2 DADF Parallelism

Purpose
To correct the ADF front/back position by adjusting the Right Counter Balance and to correct
any skew problems.
Check
WARNING
1.
Remove the Front Cover, PL 12.1.
2.
Remove the Entrance Tray, PL 12.1.
3.
Remove the Document Transport (REP 12.10.1. Steps 1 and 2).
4.
Measure the distance between the DADF rear frame and the front surface of the Paper
Side Guide. Check that the distance is 20mm (Figure 1).
NOTE: (Figure 1) The measurement point must be the center of the Right Counter Balance.
Press the scale onto the DADF rear frame.
Figure 2 Adjusting the Left/Right Counter Balance
Figure 1 Checking the Frame-to-Guide Dimension
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ADJ 12.3.1, ADJ 12.3.2
ADJ 12.3.3 DADF Height
Adjustment
CAUTION
The front/back position adjustment must be within 1mm. Do not adjust more than that.
1.
Rotate the adjustment screw and adjust the DADF front/back position (Figure 2).
a.
Rotate in the A direction: The DADF moves to the rear.
b.
Rotate in the B direction: The DADF moves to the front.

Purpose
To correct the DADF operation by adjusting the Counter Balance height.
a.
If the DADF mounting height is too low (23.5mm or less), too much load will be applied to
the DADF Transport Motor, causing problems such as paper jams and malfunctions.
b.
If the DADF mounting height is too high (24.5mm or more), small-size paper may cause
problems such as skewing and jams.

3. Rotate the adjusting screw.
Check
WARNING

1.
2.

a.
Front Cover, PL 12.1 Item 11
b.
Rear Cover, PL 12.1 Item 1
c.
Entrance Tray, PL 12.1 Item 6
Check the height of the Left/Right Counter Balance. At the two measurement positions
shown in the figure, make sure that the gap between the Platen Glass Side Guide and the
Transport Assembly Frame is 24 0.3mm (Figure 1).
Figure 2 Adjusting the DADF Front/Back Position

2.
Adjust the left side according to the right side adjustment.
3.
Repeat the check steps to make sure that the adjustment has been done properly.
4.
Set various size paper sheets in the DADF and make sure there is no skew.
ADJ 12.3.2, ADJ 12.3.3
1/05
4-218
Reissue
DocuColor 12/DCCS50
Figure 2 Preparing to Adjust

Figure 1 Checking the Gap
2.
Close the DADF and, by turning the Adjusting Screw, adjust the gap between the Platen
Glass Side Guide and the Transport Assembly Frame (Figure 3).
Adjustment
NOTE: The steps are the same for the left and right sides.
1.
Open the DADF and loosen the screws (Figure 2).

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ADJ 12.3.3
Figure 3 Adjusting the Gap

NOTE:
3.
a.
Rotate once in the A direction, approximately 0.75mm lower.
b.
Rotate once in the B direction, approximately 0.75mm higher.
Figure 4 Tightening the Screws

4.
Repeat the check steps and make sure that the height is correct.
Open the DADF and tighten the screws (Figure 4).

ADJ 12.3.3
1/05
4-220
Reissue
DocuColor 12/DCCS50
ADJ 12.4.1 DADF Lead Edge Registration
3.

Purpose
Check that the distance between the paper top and the target line in the second copy is
10mm 0.6mm. If the distance is not within this range, do the following to adjust the registration (Figure 1).
To ensure that the document is set into the correct position on the Platen (document feed direction).
NOTE: Before running this function, the lead edge registration in platen mode must be
adjusted (ADJ 9.1.14).
10.0 +/- 0.6

mm
Check
Check (Simplex mode)
1.
Place the test pattern (82E8220) on the Platen so that there is no gap between the test
pattern and the Top Registration Gate.
2.
Copy the test pattern in the following copy mode:

a.
Copy mode: Black
b.
c.
Magnification: 100
d.
Number of copies: 2
PAPER
FEED
DIRECTION
3.
Measure the distance between the paper top edge and the target line of the second document and check if the distance is 10mm 0.6mm. If the distance is not within this range,
perform IIT Lead Edge Registration (ADJ 9.1.14), then return to this procedure.
4.
Place the copies made in Step 2 into the DADF. Place the second page at the bottom.
Make sure the bottom edge (trail edge) is fed first.
5.
Measure the distance from the top of the paper to the target line of the copies made in
Step 2 and Step 4. the difference between the two dimensions must be 1.5mm or less.
Figure 1 Checking the Top Registration
Adjustment
Adjustment steps (Simplex mode)
Adjustment
Adjustment steps (Duplex mode)
1.
Enter dC131 NVM Read/Write [710-004] (DADF Lead Registration Time Simplex).
2.
If the value obtained in the check steps is:
NOTE: Depending on the paper size, the NVM adjustment differs.
a.
10.6mm or more, decrease the NVM value;
a.
b.
9.4mm or less, increase the NVM value.
DC131 [10-007] (Lead Registration Time Duplex 8.5x11LEF): Default 59): B5LEF, A5LEF,
8.5 x 11LEF
b.
DC131 [710-008] (Lead Registration Time Duplex A4SEF): Default 60): B5SEF, A5SEF,
8.5 x 11SEF
c.
DC131 [710-009] (Lead Registration Time Duplex 8.5x13LEF): Default 61): 8.5 x 14SEF,
B4, A3
1.
Check the paper size, enter dC131 NVM Read/Write and select the DC131 Chain Code
from above 9each NVM step=0.3mm).
2.
Copy mode: Black
Change the NVM value as shown below and adjust the registration to be within the
allowed range (10mm 0.6mm).
Paper tray: 8.5 x 11 or A4S
If the distance between the paper top and the target line measured in the check steps is:
Magnification: 100
a.
10.6mm or more, decrease the NVM value;
Number of copies: 1
b.
9.4mm or less, increase the NVM value.
(each NVM step=0.3mm)

c.
Repeat Step 2 until the value is within the range (10mm 0.6mm).
Check
Check (Duplex mode)
1.
Place the test pattern (82E8220) on the platen and make an A4S duplex copy.
2.
Place the copy made in Step 1 in the DADF and make a copy in the following mode:
(1 Step=0.3mm)
Mode: duplex-single
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1/05
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ADJ 12.4.1
3.
Repeat the adjustment steps until the registration is within the allowed range (10mm
0.6mm).
ADJ 12.4.1
1/05
4-222
Reissue
DocuColor 12/DCCS50
5 Parts List
Overview
Introduction .....................................................................................................................
Subsystem Information ...................................................................................................
Symbology ......................................................................................................................
PL 3.4 Full/Half Rate Carriage ........................................................................................

PL 3.5 IPS .......................................................................................................................
5-3
5-4
5-5
ROS
PL 4.1 ROS .....................................................................................................................
Parts Lists
PL 5.1 ESV Sensor, Erase Lamp ....................................................................................

PL 5.2 CC/PCC Connector, Waste Toner Bottle (IOT Rear)...........................................
PL 5.3 Drum Component.................................................................................................
PL 5.4 Charge/Pre Clean Corotron .................................................................................
PL 5.5 Waste Toner Auger..............................................................................................
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
5-17
5-18
5-19
5-20
5-21
5-22
5-23
5-24
5-25
5-26
5-27
5-28
5-29
5-30
5-31
5-32
5-33
5-34
5-35
5-36
5-37
5-38
5-39
Reissue
DocuColor 12/DCCS50
5-51
5-52
5-53
5-54
5-55
5-56
5-57
IBT
PL 7.1 IBT System Component.......................................................................................
PL 7.2 Rail Front Plate ....................................................................................................
PL 7.3 Left/Right Rail ......................................................................................................
PL 7.5 IBT-Belt, Sensor, Steering Roll ............................................................................
PL 7.6 IBT Component (Part 1 of 2)................................................................................
PL 7.7 IBT Component (Part 2 of 2)................................................................................
PL 7.8 IBT Cleaner..........................................................................................................
PL 7.9 2nd BTR...............................................................................................................
PL 7.10 2nd BTR Component .........................................................................................
5-58
5-59
5-60
5-61
5-62
5-63
5-64
5-65
5-66
Fusing
PL 8.1 Fuser Unit, Front Cover .......................................................................................
PL 8.2 Fuser Sub Assembly............................................................................................
PL 8.3 Heat/Pressure Roll...............................................................................................
PL 8.4 Heat Roll Sensor, External Heat Roll Retract/Web Motor....................................
PL 8.5 Web Shutter, Cleaning Roll (Heat Roll) ...............................................................
PL 8.6 Pressure Roll Sensor, Pressure Roll Nip .............................................................
PL 8.7 Oil Pump/Tank .....................................................................................................
PL 8.8 External Heat Roll ................................................................................................
PL 8.9 Pick Up/Donor Roll...............................................................................................
PL 8.10 Exit Chute ..........................................................................................................
IIT
PL 3.1 Platen Glass: ITT .................................................................................................
PL 3.2 CCD PWB, Sensor ..............................................................................................
PL 3.3 Carriage Cable/Motor ..........................................................................................
5-46
5-47
5-48
5-49
5-50
Development
PL 6.1 Development Components ..................................................................................
PL 6.2 Toner Cartridge Unit ............................................................................................
PL 6.3 Toner Cartridge Component (Part 1 of 2) ............................................................
PL 6.4 Toner Cartridge Component (Part 2 of 2) ............................................................
PL 6.5 Rotary Dispenser .................................................................................................
PL 6.6 Deve. Housing .....................................................................................................
PL 6.7 Rotary Frame/Auger ............................................................................................
Paper Transport
PL 2.1 Tray 1/2/3/4, Tray Sensor, Label .........................................................................
PL 2.2 Tray 1 Component ...............................................................................................
PL 2.3 Tray 2/3/4 Component .........................................................................................
PL 2.4 Tray 1-4 Feeder ...................................................................................................
PL 2.5 Feeder Component (Part 1 of 2)..........................................................................
PL 2.6 Feeder Component (Part 2 of 2)..........................................................................
PL 2.7A Tray 2-4 Take Away Drive (Part 1 of 2).............................................................
PL 2.7B Tray 2-4 Take Away Drive (Part 2 of 2).............................................................
PL 2.8 Left Lower Cover .................................................................................................
PL 2.9 Tray 5 Unit, Tray 5 Feed Clutch/Roll ...................................................................
PL 2.10 Tray 5 Upper (Part 1 of 2)..................................................................................
PL 2.11 Tray 5 Upper (Part 2 of 2)..................................................................................
PL 2.12 Tray 5 Base .......................................................................................................
PL 2.13 Tray 5 Tray ........................................................................................................
PL 2.14 Regi. Unit, DTS HVPS .......................................................................................
PL 2.15 Regi.-Regi..........................................................................................................
PL 2.16 Regi.-Pre Regi. ..................................................................................................
PL 2.17 Vacuum Transport .............................................................................................
PL 2.18 Drawer Accessory, Duplex Baffle ......................................................................
PL 2.19 Drawer Frame, Duplex Out Motor/Roll, Duplex Chute.......................................
PL 2.20 Duplex In/Aligner Baffle Component..................................................................
PL 2.21 Duplex In/Aligner Chute Component .................................................................
PL 2.22 Drawer Frame Component ................................................................................
PL 2.23 Inverter Unit .......................................................................................................
PL 2.24 Inverter 1 Component ........................................................................................
PL 2.25 Inverter 2 Component (Part 1 of 2) ....................................................................
PL 2.26 Inverter 2 Component (Part 2 of 2) ....................................................................
5-45
Xerographics
Drive
PL 1.1 Drum/IBT Drive ....................................................................................................
PL 1.2 Main Motor, Drum Brush Drive ............................................................................
PL 1.3 Deve./BPD Drive, IBT Cleaner Retract ................................................................
PL 1.4 2nd BTR/Oil Roll/Auger Drive ..............................................................................
PL 1.5 Main Motor 2, Tray 5/Regi./Tray 1 Take Away Drive ...........................................
PL 1.6 Fuser/Exit Drive ...................................................................................................
5-43
5-44
5-67
5-68
5-69
5-70
5-71
5-72
5-73
5-74
5-75
5-76
Electrical
5-40
5-41
5-42
PL 9.1 Front, Right ..........................................................................................................

PL 9.2 IOT Top/Rear .......................................................................................................
PL 9.3 Tray Module, Rear ...............................................................................................
1/05
5-1
5-77
5-78
5-79
Parts Lists
PL 9.4 Drawer Connectors..............................................................................................

PL 9.5 Control Panel .......................................................................................................
PL 9.6 EMI/Safety for Fuser Heat Lamp (50 Hz) ............................................................
5-80
5-81
5-82
Part Number Index ..........................................................................................................
5-119
Air System
PL 10.1 Air System-Front Door .......................................................................................
PL 10.2 Air System-Rear, Right ......................................................................................
5-83
5-84
Cover
PL 11.1 Platen/Top Cover...............................................................................................
PL 11.2 Front/Right Cover ..............................................................................................
PL 11.3 Rear/Left Cover .................................................................................................
5-85
5-86
5-87
DADF
PL 12.1 Front/Rear Cover, Entrance Tray ......................................................................
PL 12.2 Top Cover, Registration Gate Solenoid .............................................................
PL 12.3 Counter Balance, DADF Control PWB ..............................................................
PL 12.4 Document Feed Chute (Upper), Feed Motor .....................................................
PL 12.5 Document Feed Chute (Lower) .........................................................................
PL 12.6 DADF Belt Motor, Duplex Roll ...........................................................................
PL 12.7 Duplex Chute .....................................................................................................
PL 12.8 Registration Roll ................................................................................................
PL 12.9 Exit Motor/Chute ................................................................................................
PL 12.10 Document Transport, Platen Belt.....................................................................
PL 12.11 Platen Glass, Registration Gate, Exit Tray: DADF ..........................................
5-88
5-89
5-90
5-91
5-92
5-93
5-94
5-95
5-96
5-97
5-98
Mail Box
PL 13.1 Mail Box Accessory ...........................................................................................
PL 13.2 Docking Rail.......................................................................................................
PL 13.3 Mail Box Sub Assembly .....................................................................................
PL 13.4 Mail Box Cover ..................................................................................................
PL 13.5 ACT Cover, Bin Tray 1.......................................................................................
PL 13.6 Bin Tray 2/4/6/8 .................................................................................................
PL 13.7 Bin Tray 3/5/7/9 .................................................................................................
PL 13.8 Bin Tray 10 ........................................................................................................
PL 13.9 Mail Box Roll, Chute ..........................................................................................
PL 13.10 Mail Box Motor, PWB.......................................................................................
PL 13.11 Decurler Cover.................................................................................................
PL 13.12 Decurler Chute, PWB ......................................................................................
PL 13.13 Decurler Roll ....................................................................................................
PL 13.14 Decurler Transport Roll....................................................................................
PL 13.15 Cabinet ............................................................................................................
5-99
5-100
5-101
5-102
5-103
5-104
5-105
5-106
5-107
5-108
5-109
5-110
5-111
5-112
5-113
Offset Catch Tray

PL 14.1 Offset Catch Tray...............................................................................................
5-114
IDFE Components
PL 19.1 IDFE Assembly and Components......................................................................
5-115
Electrical Connectors
PL 25.1 Electrical Connectors .........................................................................................
5-116
Common Hardware
Common Hardware .........................................................................................................
Parts Lists
5-117
1/05
5-2
Reissue
DocuColor 12/DCCS50
Introduction
Table 1
Overview
Abbreviation
The Parts List section identifies all part numbers and the corresponding location of all spared
subsystem components.
R/E
Reduction/Enlargement
REF:
Refer to
SCSI
Small Computer Systems Interface
W/
With
W/O
Without
Organization
Parts Lists
Each item number in the part number listing corresponds to an item number in the related illustration. All the parts in a given subsystem of the machine will be located in the same illustration
or in a series of associated illustrations.
Meaning
Table 2
Operating Companies
Electrical Connectors and Fasteners
Abbreviation
This section contains the illustrations and descriptions of the plugs, jacks, and fasteners used
in the machine. A part number listing of the connectors is included.
AO
Americas Operations
NASG - US
North American Solutions Group - US
Common Hardware
NASG Canada
North American Solutions Group Canada
XE
Xerox Europe
The common hardware is listed in alphabetical order by the letter or letters used to identify
each item in the part number listing and in the illustrations. Dimensions are in millimeters
unless otherwise identified.
Meaning
Symbology
Part Number Index

This index lists all the spared parts in the machine in numerical order. Each number is followed
by a reference to the parts list on which the part may be found.
Symbology used in the Parts List section is identified in the Symbology section.
Service Procedure Referencing

If a part or assembly has an associated repair or adjustment procedure, the procedure number
will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3)
Other Information
Abbreviations
Abbreviations are used in the parts lists and the exploded view illustrations to provide information in a limited amount of space. The following abbreviations are used in this manual:
Table 1
Abbreviation
Meaning
A3
297 x 594 Millimeters
A4
A5
AD
Auto Duplex
AWG
American Wire Gauge
EMI
Electro Magnetic Induction
GB
Giga Byte
KB
Kilo Byte
MB
Mega Byte
MM
Millimeters
MOD
Magneto Optical Drive
NOHAD
Noise Ozone Heat Air Dirt
PL
Parts List
P/O
Part of
Reissue
DocuColor 12/DCCS50
1/05
5-223
Parts Lists
Introduction
Subsystem Information
Use of the Term Assembly
The term assembly will be used for items in the part number listing that include other itemized
parts in the part number listing. When the word assembly is found in the part number listing,
there will be a corresponding item number on the illustrations followed by a bracket and a listing of the contents of the assembly.
Brackets
A bracket is used when an assembly or kit is spared, but is not shown in the illustration. The
item number of the assembly or kit precedes the bracket; the item numbers of the piece parts
follow the bracket.
Tag
The notation W/Tag in the parts description indicates that the part configuration has been
updated. Check the change Tag index in the General Information section of the Service Data
for the name and purpose of the modification.
In some cases, a part or assembly may be spared in two versions: with the Tag and without the
Tag. In those cases, use whichever part is appropriate for the configuration of the machine on
which the part is to be installed. If the machine does not have a particular Tag and the only
replacement part available is listed as W/Tag, install the Tag kit or all of the piece parts. The
Change Tag Index tells you which kit or piece parts you need.
Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate
number on the Tag matrix.
Parts Lists
Subsystem Information
1/05
5-224
Reissue
DocuColor 12/DCCS50
Symbology
A Tag number within a circle pointing to an item number shows that the part has been changed
by the tag number within the circle (Figure 1). Information on the modification is in the Change
Tag Index.
A Tag number within a circle having a shaded bar and pointing to an item number shows that
the configuration of the part shown is the configuration before the part was changed by the Tag
number within the circle (Figure 2).
Figure 2 Without Tag Symbol

Figure 1 With Tag Symbol
Reissue
DocuColor 12/DCCS50
1/05
5-225
Parts Lists
Symbology
A tag number within a circle with no apex shows that the entire drawing has been changed by
the tag number within the circle (Figure 3). Information on the modification is in the Change Tag
Index.
A tag number within a circle with no apex and having a shaded bar shows that the entire drawing was the configuration before being changed by the tag number within the circle (Figure 4).
Figure 4 Entire Drawing Without Tag Symbol

Figure 3 Entire Drawing With Tag Symbol
Parts Lists
Symbology
1/05
5-226
Reissue
DocuColor 12/DCCS50
PL 1.1 Drum/IBT Drive

Item
Part
Description
1
2
3
4
5
6
7
8
007K84662
007K84671
007E55221
007E55230
9
10
11
12
13
14
15
16
17
18
19
20
21
22
007E52280
009E32160
127K21671
600K86080
007K84871
007K84680
IBT Drive Assembly

Gear (22/64)
Bracket (Motor) (P/O PL 1.1 Item 1)
Bearing (P/O PL 1.1 Item 1)
Gear
Gear (IBT Drive)
Bracket (IBT Drive) (P/O PL 1.1
Item 1)
Shaft (P/O PL 1.1 Item 1)
Fly Wheel (Not Spared)
Stopper Ring (Not Spared)
Spacer Ring (Not Spared)
Flange (Not Spared)
Gear
Spring
Drum Motor
Drum Motor Kit (W/TAG P34)
Pin (Not Spared)
Bearing (Not Spared)
Drum Idler Gear Assembly
Gear (23/64)
Stud (P/O PL 1.1 Item 19)
Bracket (P/O PL 1.1 Item 19)
Reissue
DocuColor 12/DCCS50
1/05
5-227
Parts Lists
PL 1.1
PL 1.2 Main Motor, Drum Brush Drive

Item
Part
Description
1
2
007K84820
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
007K84170
007K84634
007E50120
007E49980
007K84701
007E50112
007K84641
007K84650
127K21321
Main Motor Bracket Assembly

Bracket (Main Motor) (P/O PL 1.2
Item 1)
Gear (56/20)
Drum Brush Drive Assembly
Gear (Drum Brush)
Gear
Gear
Gear
Screw (P/O PL 1.2 Item 4)
Gear Pulley (42/27)
Gear Pulley (56/27)
Main Motor
Parts Lists
PL 1.2
1/05
5-228
Reissue
DocuColor 12/DCCS50
PL 1.3 Deve./BPD Drive, IBT Cleaner

Retract
Item
Part
Description
007K84468
2
3
4
5
6
7
8
9
10
007K84282
007K84291
006K84003
007E51790
007E50052
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
809E08690
007E50030
007E51800
007E51810
121K14881
007K84332
007E52290
26
27
28
29
30
31
32
33
34
35
36
37
121K17941
007E50042
423W55355
Developer/BPO Drive and IBT

Cleaner Retract Assembly
BPO Roll Drive Assembly
Developer Drive
Developer Housing Drive Shaft
Gear
Gear
Pulley (P/O PL 1.3 Item 2)
Coupling (BPO Drive) (P/O PL 1.3
Item 2)
Spring
Gear (18/44 )
Gear (16/26 )
Gear (22)
Gear (P/O PL 1.3 Item 3) (40/44 )
Developer Clutch
Gear (Developer Housing Drive)
Gear
Coupling (IBT Cleaner Retract)
(P/O PL 1.3 Item 1)
Cleaner Retract Clutch
Connector (P/O PL 1.3 Item 1)
Bracket (Not Spared)
Gear Pulley
Spring (Not Spared)
Belt (Developer Drive) (REP 1.3.1 )
Reissue
DocuColor 12/DCCS50
1/05
5-229
Parts Lists
PL 1.3
PL 1.4 2nd BTR/Oil Roll/Auger Drive

Item
Part
Description
600K85872
2
3
4
5
6
7
8
9
10
11
007E57660
007K84160
12
13
14
15
16
007K84265
007K84231
17
18
19
20
21
22
23
007K84240
423W57554
007E49950
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
130E82190
007E49940
007K84251
604K14830
2nd BTR Drive Assembly (W/TAG

P33)
Gear (16 ) (2nd BTR Roll )
Gear
Truque Limiter (P/O PL 1.4 Item 1)
2nd BTR Retract Clutch Assembly
(P/O PL 1.4 Item 42)
Gear (28) (2nd BTR Retract)
Oil Roll/Auger Drive Assembly
Auger Drive (23T) (Includes gear
and bracket)
Tension Roll
Spring (P/O PL 1.4 Item 15)
Belt (2nd BTR, Auger) (REP 1.4.1 )
Gear
Oil Roll Clutch (P/O PL 1.4 Item
15)
Sensor Bracket (P/O PL 1.4 Item
15)
Cam (P/O PL 1.4 Item 15)
Pin (P/O PL 1.4 Item 15)
Wheel (P/O PL 1.4 Item 15)
Oil Roll Home Position Sensor
Gear (Waste Toner Bottle Auger)
Connector (P/O PL 1.4 Item 15)
Gear Pulley
E-Ring (P/O PL 1.4 Item 42)
E-Ring (P/O PL 1.4 Item 42)
2BTR Clutch Kit
Parts Lists
PL 1.4
1/05
5-230
Reissue
DocuColor 12/DCCS50
PL 1.5 Main Motor 2, Tray 5/Regi./Tray

1 Take Away Drive
Item
Part
Description
007K84313
2
3
4
5
6
7
8
9
10
11
12
13
14
127K21311
007E46890
007E46880
407W08223
407W08273
407W08222
407W08328
15
16
17
18
19
20
21
22
009P62975
121K30050
007E52250
Tray 5/Regi./Tray 1 Take Away

Drive Assembly (REP 1.5.1 )
Main Motor 2
Gear
Gear
Dumper (P/O PL 1.5 Item 1)
Gear
Gear
Gear
Gear (28)
Coupling (Slide) (P/O PL 1.5 Item
1)
Coupling (Transmitter) (P/O PL 1.5
Item 1)
Spring
T/A Feed Clutch
Gear (Tray 1 T/A Roll)
Reissue
DocuColor 12/DCCS50
1/05
5-231
Parts Lists
PL 1.5
PL 1.6 Fuser/Exit Drive

Item
Part
Description
007K84577
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
121K21612
007E50270
007E50280
007K84553
007K84800
007E51490
007K84690
007K84360
007K84922
22
007K84110
23
24
25
26
27
28
29
30
31
007E51680
127K21301
Exit/Fuser Nip Drive Assembly

(W/TAG P9) (REP 1.6.3)
Fuser Nip Clutch
Gear (26)
Gear (16) (Exit Roll)
Gear (25/19) (P/O PL 1.6 Item 1)
Exit Drive Assembly (REP 1.6.1 )
Gear (41)
Gear (23)
Gear (27)
Gear (37/28) (Fuser Nip)
Fuser Drive Assembly (Includes
PWB) (REP 1.6.2 )
Gear (Fuser/V-Tra. Drive)
(Fuser/V-tra. Drive )
Fuser Motor (P/O PL 1.6 Item 21)
Gear (22)
Exit Motor
Motor Cover (Not Spared)
Fuser Rear Bracket (Not Spared)
Screw (Not Spared)
Parts Lists
PL 1.6
1/05
5-232
Reissue
DocuColor 12/DCCS50
PL 2.1 Tray 1/2/3/4, Tray Sensor, Label

Item
Part
Description
1
2
130E82190
110K10460
3
4
5
6
7
8
003E38110
050K33129
891E76090
891E78030
891E82980
050K40941
10
11
12
13
14
15
16
17
891E49510
891E49520
891E49060
891E80410
891E80481
891E80400
891E78020
891E80420
Tray 1 Set Sensor (REP 2.1.1 )

Tray 2 Size Sensor, Tray 3 Size
Sensor, Tray 4 Size Sensor (REP
2.1.2 )
Stopper
Tray 1 Assembly
Label (Tray 1)
Label (Max)
Label (Installation)
Tray 2 Assembly, Tray 3 Assembly,
Tray 4 Assembly
Label (Tray 3)
Label (Tray 4)
Label (Tray 2)
Label (Max) (Not Spared)
Label (Size E End 1)
Label (Size E Side)
Label (Max)
Label (Size E End 2)
Stopper (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
5-233
Parts Lists
PL 2.1
PL 2.2 Tray 1 Component

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
Description
015K34310
038E88641
038E88650
050E87465
019E39131
019K94390
015K41381
015K41370
015K31460
007E50410
007E30970
013E83730
007E50430
007E50420
Bottom Plate Assembly

Bottom Plate (P/O PL 2.2 Item 1)
Pad (P/O PL 2.2 Item 1)
Side Guide
End Guide
Cassette
Pad
Pad
Right Rail Plate
Left Rail Plate
Rear Plate
Gear (18/30)
Gear (13)
Bearing
Gear (60)
Gear (20/53)
Cover (P/O PL 2.1 Item 4)
Parts Lists
PL 2.2
1/05
5-234
Reissue
DocuColor 12/DCCS50
PL 2.3 Tray 2/3/4 Component

Item
Part
Description
1
2
3
4
5
038K84621
019K94400
6
7
015K41503
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
038E88922
019E39131
038K83973
050E88159
007E50410
007E30970
007E50420
007E50430
Side Guide Plate

Plate (P/O PL 2.1 Item 8)
Pad
Actuator End Guide (P/O PL 2.1
Item 8)
Plate
Actuator Side Guide (P/O PL 2.1
Item 8)
Regi. Side Guide
Pad
End Guide
Cassette
Link (P/O PL 2.1 Item 8)
Roll (P/O PL 2.1 Item 8)
Spacer (P/O PL 2.1 Item 8)
Gear (18/30)
Gear (13)
Gear (20/53)
Gear (60)
Reissue
DocuColor 12/DCCS50
1/05
5-235
Parts Lists
PL 2.3
PL 2.4 Tray 1-4 Feeder

Item
Part
Description
059K09948
2
3
4
5
054E88230
054E88220
003E40140
Tray 1 Feeder Assembly, Tray 2

Feeder Assembly, Tray 3 Feeder
Assembly, Tray 4 Feeder Assembly
(REP 2.4.1 )
Chute
Chute
Hinge
Stud (Not Spared)
Parts Lists
PL 2.4
1/05
5-236
Reissue
DocuColor 12/DCCS50
PL 2.5 Feeder Component (Part 1 of 2)

Item
Part
Description
059K09561
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
007E52210
007E52220
007E52230
007E52240
032E10250
011E08060
011E08050
809E19530
013E15290
011E08071
012E98281
809E19540
121K17561
130E82190
25
26
130E82650
27
Feed/Nudger Roll Assembly (REP

2.5.1 )
Gear (14)
Gear (15)
Gear (13/16)
Gear (17)
Support (P/O PL 2.5 Item 1)
Paper Guide
Nudger Roll (P/O PL 2.5 Item 1)
Feed Roll (P/O PL 2.5 Item 1)
Paper Guide (P/O PL 2.5 Item 1)
Lever
Lever
Spring
Bearing
Lever
Link
Spring
Nudger Solenoid
No Paper Sensor, Tray Stack
Height Sensor
Pre Feed Sensor
Front Up Chute (P/O PL 2.4 Item
1)
Actuator (P/O PL 2.4 Item 1)
Reissue
DocuColor 12/DCCS50
1/05
5-237
Parts Lists
PL 2.5
PL 2.6 Feeder Component (Part 2 of 2)

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Part
Description
830E09140
127K23230
009E61300
413W75959
007K83610
006K83280
007E31090
007E52150
005K81750
007E52130
007E52140
005K81760
007E52171
007E52161
809E19560
007E56210
005K81600
059K09591
809E09100
Motor Bracket
Feed/Lift Motor (REP 2.6.1 )
Spring
Gear (31) (P/O PL 2.4 Item 1)
Bearing
Gear (24)
Shaft
Gear (13)
Gear (16)
One Way Clutch
Gear (26)
Gear (13)
One Way Clutch
Gear (20)
Gear (17)
Spring
Retard Lever (P/O PL 2.4 Item 1)
Gear (15)
Collar (P/O PL 2.4 Item 1)
Friction Clutch
Retard Roll Assembly (REP 2.6.2 )
Retard Roll (P/O PL 2.6 Item 30)
Spring
Parts Lists
PL 2.6
1/05
5-238
Reissue
DocuColor 12/DCCS50
PL 2.7A Tray 2-4 Take Away Drive

(Part 1 of 2)
Item
Part
Description
007K84415
2
3
4
121K30050
5
6
7
8
9
10
11
12
13
007K84422
007E51580
007K84731
007E56020
007E56030
007E56010
127K23051
Tray 2-4 Take Away Drive (REP

2.7.1 )
Bearing (P/O PL 2.7A Item 1)
Shaft (P/O PL 2.7A Item 1)
Tray 2 T/A Feed Clutch, Tray 3 T/A
Feed Clutch, Tray 4 T/A Feed
Clutch (REP 2.7.2 )
Gear (43)
Motor Plate (P/O PL 2.7A Item 1)
Gear (22)
Gear (23/45)
Gear (56)
Gear (45)
Gear (100)
Bracket (P/O PL 2.7A Item 1)
T/A Motor (REP 2.7.3 )
Reissue
DocuColor 12/DCCS50
1/05
5-239
Parts Lists
PL 2.7A
PL 2.7B Tray 2-4 Take Away Drive

(Part 2 of 2)
Item
Part
Description
2
3
4
5
6
7
005K82730
059K06831
059K09930
600K74790
Gear (Teeth on both gears, pitch in

different directions) (Not Spared)
One Way Clutch
T/A Roll 1
T/A Roll 2, T/A Roll 3, T/A Roll 4
Bearing (P/O PL 2.7A Item 1)
Noise Impulse Kit
T/A Roll 3, T/A Roll 4 (P/O PL 2.7B
Item 6)
One Way Clutch (P/O PL 2.7B Item
6)
Bracket (P/O PL 2.7B Item 6)
Parts Lists
PL 2.7B
1/05
5-240
Reissue
DocuColor 12/DCCS50
PL 2.8 Left Lower Cover

Item
Part
Description
048K65250
2
3
054K10350
4
5
6
7
809E07780
809E07770
054E10780
130E82650
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
013E83380
162K37160
059E92920
009E63110
003E38120
048E61482
011E07950
003E38130
003K84500
054K10341
130K60770
25
26
27
068K14170
Left Lower Cover (Upper) and

Chute 1 Assembly
Chute 1 Assembly
Left Lower Cover (Upper) (P/O PL
2.8 Item 1)
Spring
Spring
Baffle
T/A Sensor, Tray 1 Feed Out Sensor (REP 2.8.1 )
Bearing
Wire Harness
Pinch Roll
Spring
Hinge
Left Lower Cover (Lower)
Handle
Latch
Spring (Not Spared)
Hinge
Spring (Not Spared)
Spring (Not Spared)
Chute 2/3/4 Assembly
Baffle (P/O PL 2.8 Item 21)
Tray 2 Feed Out Sensor, Tray 3
Feed Out Sensor, Tray 4 Feed Out
Sensor (REP 2.8.2 )
L/H Cover Interlock Switch
Reissue
DocuColor 12/DCCS50
1/05
5-241
Parts Lists
PL 2.8
PL 2.9 Tray 5 Unit, Tray 5 Feed

Clutch/Roll
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
Description
059K08821
121K17550
113E22970
114E11400
121E89780
830E09840
830E17961
059K31171
891E51581
891E73914
891E73982
891E73971
Tray 5 Feed Roll

Collar (Not Spared)
Tray 5 Feed Clutch
Holder
Gear (Not Spared)
Core (Not Spared)
Connector (P703)
Magnet
Bracket
Stopper Plate
Pad (Not Spared)
Chute (Not Spared)
Tray 5 Assembly (REP 2.9.1 )
Label (Max)
Label (Size)
Label (5)
Parts Lists
PL 2.9
1/05
5-242
Reissue
DocuColor 12/DCCS50
PL 2.10 Tray 5 Upper (Part 1 of 2)

Item
Part
Description
1
2
3
4
130E82190
059K08831
059E90770
5
6
7
8
9
10
11
12
13
14
15
130K58070
009E56020
009E56030
120E13100
809E09470
809E09410
Tray 5 Paper Sensor

Pinch Roll
Take Away Pinch Roll (P/O PL 2.9
Item 14)
Tray 5 Feed Sensor
Spring
Spring
Actuator
Spring
Latch Lever (P/O PL 2.9 Item 14)
Spring
Upper Cover (P/O PL 2.9 Item 14)
Latch Bracket (P/O PL 2.9 Item 14)
Inner Cover (P/O PL 2.9 Item 14)
Reissue
DocuColor 12/DCCS50
1/05
5-243
Parts Lists
PL 2.10
PL 2.11 Tray 5 Upper (Part 2 of 2)

Item
Part
Description
1
2
3
4
5
6
032E10010
059K08850
7
8
9
10
11
12
13
14
15
007E31180
130E82190
121K17561
007E31160
009E76430
16
17
18
19
20
21
22
23
24
809E09410
Chute (P/O PL 2.9 Item 14)

Paper Guide
Tray 5 Nudger Roll, Tray 5 Feed
Roll (REP 2.11.1 REP 2.11.2 )
Gear
Tray 5 Stack Up Sensor
Gear (P/O PL 2.9 Item 14)
Tray 5 Nudger Solenoid
Gear
Spring
Lever Plate (P/O PL 2.9 Item 14)
Chute (Upper Front) (P/O PL 2.9
Item 14)
Spring
Lever (P/O PL 2.9 Item 14)
Parts Lists
PL 2.11
1/05
5-244
Reissue
DocuColor 12/DCCS50
PL 2.12 Tray 5 Base

Item
Part
Description
5
6
7
110E93440
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
007E23260
007E50250
007E51430
007E22430
127K23470
059K08840
007E54910
005K82490
130E82190
34
35
36
37
113E24030
Bracket (Rear) (P/O PL 2.9 Item

14)
Bracket (Front) (P/O PL 2.9 Item
14)
Damper (Front) (P/O PL 2.9 Item
14)
Damper (Rear) (P/O PL 2.9 Item
14)
Tray 5 Interlock Switch
Switch Bracket (P/O PL 2.9 Item
14)
Frame (Front) (P/O PL 2.9 Item 14)
Frame (Rear) (P/O PL 2.9 Item 14)
Gear (12/28)
Gear (10/20)
Gear
Frame (P/O PL 2.9 Item 14)
Gear (12/28)
Tray 5 Lift Motor (REP 2.12.1 )
Tray 5 Retard Roll (REP 2.12.2 )
Gear
Fiction Clutch
Tray 5 Stack Down Sensor
Tray 5 Feeder Harness (P/O PL
2.9 Item 14)
Bracket Cover (Front) (P/O PL 2.9
Item 14)
Bracket Cover (Rear) (P/O PL 2.9
Item 14)
Gear Cover (P/O PL 2.9 Item 14)
Connector (J703)
Reissue
DocuColor 12/DCCS50
1/05
5-245
Parts Lists
PL 2.12
PL 2.13 Tray 5 Tray

Item
Part
Description
1
2
3
4
5
6
7
8
009E53370
130K58001
9
10
11
12
13
14
15
16
17
18
19
20
21
22
038K14700
038E89060
019K93320
007E66030
600K82960
604K07960
600K85970

Spring
Tray 5 Size Sensor
Tray (Lower) (P/O PL 2.9 Item 14)
Rail Bracket (P/O PL 2.9 Item 14)
Tray (Extension) (P/O PL 2.13 Item
21)
Pad (P/O PL 2.9 Item 14)
Regi. Guide
Side Guide
Pad (Bottom)
Tray 5 Tray (P/O PL 2.9 Item 14)
Lift Shaft (P/O PL 2.9 Item 14)
Gear
Tie Plate (P/O PL 2.9 Item 14)
Lower Cover (P/O PL 2.9 Item 14)
Size Sensor Kit
Tray 5 Extension Kit
Lift Shaft and Gear Kit
Parts Lists
PL 2.13
1/05
5-246
Reissue
DocuColor 12/DCCS50
PL 2.14 Regi. Unit, DTS HVPS

Item
1
2
3
4
5
6
7
Part
Description
059K10025
105K14923
Regi. Unit Assembly (REP 2.14.1 )

Chute (Not Spared)
Cover (Not Spared)
Guide (Not Spared)
Cover (Not Spared)
DTS HVPS
Reissue
DocuColor 12/DCCS50
1/05
5-247
Parts Lists
PL 2.14
PL 2.15 Regi.-Regi.
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Part
Description
048K65921
160K46290
130K60600
127K21871
054K11072
809E09430
013E88020
059K08760
013E88030
013E82490
809E08090
059K08790
007E51370
Regi. Cover Assembly

Regi. Cover (P/O PL 2.15 Item 1)
OHP Sensor 1, OHP Sensor 2
Regi. Sensor (REP 2.15.1 )
Regi. Motor (REP 2.15.3 )
Upper Chute
Spring
Bearing
Pinch Roll
Bearing
Bearing
Label (P/O PL 2.15 Item 6)
Spring
Regi. Roll (REP 2.15.2 )
Gear
Parts Lists
PL 2.15
1/05
5-248
Reissue
DocuColor 12/DCCS50
PL 2.16 Regi.-Pre Regi.

Item
Part
Description
1
2
3
4
5
6
005E85810
130K58030
059K08780
054K11090
7
8
9
10
11
12
13
14
013E88030
059K08770
013E88020
013E82490
009P61135
Coupling
Pre Regi. Sensor (REP 2.16.1 )
Pre Regi. Roll (REP 2.16.2 )
Pre Regi. Chute Assembly
Pre Regi. Chute (P/O PL 2.16 Item
5)
Bearing
Pinch Roll
Bearing
Bearing
Spring
Reissue
DocuColor 12/DCCS50
1/05
5-249
Parts Lists
PL 2.16
PL 2.17 Vacuum Transport

Item
Part
Description
059K10122
023E15480
3
4
5
6
7
8
9
10
11
059E92950
413W77359
007E46610
006K84210
007E49781
Vacuum Transport Assembly (REP

2.17.1 )
Vacuum Transport Belt (REP
2.17.2 )
Idler Roll
Snap Bearing (P/O PL 2.17 Item 1)
Seal (P/O PL 2.17 Item 1)
Bearing
Gear
Shaft
Gear
Parts Lists
PL 2.17
1/05
5-250
Reissue
DocuColor 12/DCCS50
PL 2.18 Drawer Accessory, Duplex

Baffle
Item
Part
Description
1
2
054K11395
054K11416
3
4
5
6
7
8
9
10
11
12
13
003K84760
003K84750
032K93621
891E51561
891E51571
891E74062
015K33973
Duplex In Baffle Assembly

Aligner Baffle Assembly (W/TAG
P3)
Hinge
Hinge
Guide
Drawer Cover (Not Spared)
Label
Label
Label
Screw (Not Spared)
Drawer Interlock Switch
Guide (Not Spared)
Guide (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
5-251
Parts Lists
PL 2.18
PL 2.19 Drawer Frame, Duplex Out

Motor/Roll, Duplex Chute
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part
Description
054K11363
054K11373
059K08600
007E51840
423W82555
011K90420
127K23191
050K34065
038E89072
Duplex In Chute Assembly

Aligner Chute Assembly
Duplex Out Roll
Gear
Pulley (Not Spared)
Pulley (Not Spared)
Belt
Joint
Shaft (Not Spared)
Duplex Out Motor
Drawer Frame Assembly
Paper Guide
Link (Not Spared)
Parts Lists
PL 2.19
1/05
5-252
Reissue
DocuColor 12/DCCS50
PL 2.20 Duplex In/Aligner Baffle

Component
Item
Part
Description
3
4
5
6
7
8
9
10
11
011E08041
003E40151
003E36290
809E16590
809E16580
809E14710
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
059K05750
059E92980
809E20210
011E08031
809E09040
Pinch Roll (Duplex In) (Roll:F) (P/O

PL 2.18 Item 1)
Duplex In Baffle (P/O PL 2.18 Item
1)
Lever
Latch
Knob
Spring
Spring (16MM)
Spring (12.4MM)
Pinch Roll (Duplex Path) (Roll: F)
Stopper (P/O PL 2.18 Item 1)
Guide (P/O PL 2.18 Item 1)
Pinch Roll (Duplex Out)
Aligner Baffle (P/O PL 2.18 Item 2)
Pinch Roll
Spring
Lever
Spring
Reissue
DocuColor 12/DCCS50
1/05
5-253
Parts Lists
PL 2.20
PL 2.21 Duplex In/Aligner Chute

Component
Item
Part
Description
1
2
3
4
5
059K08610
059K08621
423W11055
7
8
9
809E09150
10
11
12
13
14
15
16
059K09331
059K09341
059K09350
17
130K93210
18
19
20
21
423W10055
Duplex In Roll
Duplex Path Roll
Duplex In Chute (P/O PL 2.19 Item
1)
Duplex Belt 1, Duplex Belt 2 (REP
2.21.3)
Spring
Coupling (Trans) (P/O PL 2.19 Item
1)
Coupling (Slide) (P/O PL 2.19 Item
1)
Pipe (P/O PL 2.19 Item 1)
Aligner Chute (P/O PL 2.19 Item 2)
Aligner Roll 1
Aligner Roll 2
Aligner Roll 3
2)
Duplex Path Sensor, Duplex Out
Sensor (REP 2.21.1 REP 2.21.2 )
Frange (P/O PL 2.19 Item 2)
Belt
2)
Parts Lists
PL 2.21
1/05
5-254
Reissue
DocuColor 12/DCCS50
PL 2.22 Drawer Frame Component

Item
Part
Description
1
2
3
4
5
001E50590
001E46411
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
003K85871
003K85851
003E37791
006E56620
008E93261
011E08111
809E09210
809E09171
809E09180
114E11390
113E24020
Rail (Left)
Rail (Right)
Wire Harness (P/O PL 2.19 Item
14)
Latch Assembly
Knob
Latch
Shaft
Cam
Joint
Handle (P/O PL 2.22 Item 8)
Spring
Block (P/O PL 2.22 Item 8)
Spring
Spring
Finger Guide (P/O PL 2.22 Item 8)
Frame Connector
Drawer Connector (P701)
Reissue
DocuColor 12/DCCS50
1/05
5-255
Parts Lists
PL 2.22
PL 2.23 Inverter Unit

Item
Part
Description
1
2
3
4
5
6
7
059K08686
059K33080
054K11512
015E58040
012E98271
009E84220
9
10
11
003K84472
003K84792
050K36514
Inverter 1 Assembly (REP 2.23.1 )

Inverter 2 Assembly (REP 2.23.2)
Inverter 3 Upper Chute Assembly
Stopper
Link
Spring
Inverter 3 Upper Chute (P/O PL
2.23 Item 3)
Inverter 3 Lower Chute (Not
Spared)
Hinge
Hinge
Exit Tray
Parts Lists
PL 2.23
1/05
5-256
Reissue
DocuColor 12/DCCS50
PL 2.24 Inverter 1 Component

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Part
Description
054K10303
127K21661
121K16372
110E93440
001K56820
009E84220
059K09022
130K93220
007E50130
059K09030
007E51630
007E51641
059K09040
007K84601
007E91170
130K57810
007E50140
059E92850
011K94050
Inverter 1 Upper Chute

Inverter Motor (REP 2.24.1 )
Release Solenoid (REP 2.24.2 )
Inverter Cover Switch
Rear Frame
Spring
Inverter Roll (Upper)
Inverter Path Sensor
Gear (14)
Inverter Roll (Duplex)
Gear (25/30)
Gear
Inverter Roll (Lower)
Gear
Gear (27)
Duplex In Sensor
Gear (15/20)
Roll
Lever
Solenoid Cover (P/O PL 2.23 Item
1)
Reissue
DocuColor 12/DCCS50
1/05
5-257
Parts Lists
PL 2.24
PL 2.25 Inverter 2 Component (Part 1

of 2)
Item
Part
Description
1
2
3
054K10317
105E98690
4
5
6
7
8
9
10
11
12
13
14
15
16
121K16383
130K59660
802E30660
054K14675
130K57820
050K36851
891E82991
Inverter 2 Upper Chute

Eliminator
Inverter 2 Transport (P/O PL 2.23
Item 2)
Inverter Gate Solenoid
Exit Path Sensor
Gate 1 Link (P/O PL 2.23 Item 2)
Inverter 2 Cover
Exit Chute
M/C Exit Sensor
Gate 1
Label
Parts Lists
PL 2.25
1/05
5-258
Reissue
DocuColor 12/DCCS50
PL 2.26 Inverter 2 Component (Part 2

of 2)
Item
Part
Description
1
2
054K10323
3
4
5
6
7
009E62420
001K57333
059K14872
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
054K10333
059E92841
038E88772
054K11161
809E09530
011K94391
413W66250
005K82470
600K79560
600K83590
Inverter 2 Lower Baffle

Inverter 2 Lower Chute (P/O PL
2.26 Item 1)
Pinch Roll (P/O PL 2.26 Item 1)
Spring
Frame
Exit Roll Assembly (W/TAG P23)
(REP 2.26.1)
Inverter 2 Mid.1 Baffle
Pinch Roll
Guide
Inverter 2 Mid. 2 Baffle
Link Shaft (P/O PL 2.25 Item 3)
Spring
Lever
Bearing
Roller Shaft (P/O PL 2.26 Item 7)
Clutch (One-way)
Offset Roller Kit (W/O TAG P23)
Offset Corrugation Mark Roller Kit
(W/O TAG P23)
Reissue
DocuColor 12/DCCS50
1/05
5-259
Parts Lists
PL 2.26
PL 3.1 Platen Glass: ITT

Item
Part
Description
1
2
3
4
5
6
7
8
9
090K92572
10
11
12
015K37641
Stopper (Not Spared) (REP 3.1.2 )

Bracket (Rear) (Not Spared)
Stopper (Rear) (Not Spared)
Bracket (Front) (Not Spared)
Stopper (Front) (Not Spared)
Brace (Not Spared)
Stud (Not Spared)
Right Side Plate (Not Spared)
Platen Glass (With ADF) (REP
3.1.1)
Left Side Plate
Screw (Not Spared)
Screw (Not Spared)
Parts Lists
PL 3.1
1/05
5-260
Reissue
DocuColor 12/DCCS50
PL 3.2 CCD PWB, Sensor

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part
Description
048K71860
127K23590
107E06650
110K08471
130K57990
160K48230
160K51931
130K87150
Cable Stopper (Not Spared)

Cable Stopper
IPS Fan
IIT Regi. Sensor
Platen Open Switch
Platen Angle Sensor
IIT Driver PWB
Lens Assembly (Not Spared)
CCD PWB Assembly (REP 3.2.1 )
Lens Cover (Not Spared)
APS Sensor
Screw (Not Spared)
Shield (Not Spared)
Ribbon Cable (P/O PL 3.2 Item 10)
CCD PWB (P/O PL 3.2 Item 10)
Reissue
DocuColor 12/DCCS50
1/05
5-261
Parts Lists
PL 3.2
PL 3.3 Carriage Cable/Motor

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part
Description
063E94040
020K94970
012K93440
012K93450
063E94050
020E25100
023E15550
020E25090
009E62830
017E92140
127K21513
Tape
Frame (Not Spared)
Pulley
Front Carriage Cable (REP 3.3.1 )
Rear Carriage Cable (REP 3.3.1 )
Tape
Timing Pulley
Belt
Capstan Shaft (Not Spared)
Capstan Pulley
Spring
Foot
Stud (Not Spared)
Pin (Not Spared)
Carriage Motor (REP 3.3.2 )
Parts Lists
PL 3.3
1/05
5-262
Reissue
DocuColor 12/DCCS50
PL 3.4 Full/Half Rate Carriage

Item
Part
Description
1
2
3
041K94210
4
5
6
7
8
9
10
11
117E15970
062E98370
019E50400
118E12090
122E92000
105E08900
041K93792
12
13
14
15
16
062E98380
809E09110
809E15210
Harness Guide (Not Spared)

Full Rate Carriage Assembly
Full Rate Carriage (P/O PL 3.4
Item 2)
Lamp Wire Harness (REP 3.4.2 )
No.1 Mirror
Clip (Single)
Insulator
Exposure Lamp (REP 3.4.1 )
Lamp Ballast PWB
Half Rate Carriage Assembly (REP
3.4.1 )
Half Rate Carriage (P/O PL 3.4
Item 11)
No.2, No.3 Mirror
Dumper (P/O PL 3.4 Item 11)
Clamp (Not Spared)
Clip (Double)
Clip (Single)
Reissue
DocuColor 12/DCCS50
1/05
5-263
Parts Lists
PL 3.4
PL 3.5 IPS
Item
Part
Description
3
4
5
6
7
8
9
10
11
12
13
14
105E07351
105E07322
160K57369
160K42710
160K60380
160K84771
160K57375
160K46113
048E62151
117E15951
160K53462
IPS Chassis (Not Spared) (REP

3.5.1 )
IIT/IPS LVPS (50 Hz)
IIT/IPS LVPS (60 Hz)
Pre. IPS PWB
BR PWB
XCD PWB
Post. IPS PWB
Mem. Sys PWB
Option Memory PWB (Duplex)
Wire Harness (DC) (Not Spared)
Wire Harness (AC) (Not Spared)
Cover
Cover (Not Spared)
Cable
IPS Edit PWB
Spacer Screw (Not Spared)
Parts Lists
PL 3.5
1/05
5-264
Reissue
DocuColor 12/DCCS50
PL 4.1 ROS
Item
Part
Description
062K10670
2
3
4
5
6
7
8
9
10
160K42851
048K76921
600K86001
ROS Assembly (W/TAG P5, TAG

P32) (REP 4.1.1)
ROS (P/O PL 4.1 Item 1)
Ldd PWB
Wire Harness (Not Spared)
Screw (Not Spared)
Screw (Not Spared)
ROS Top Cover
ROS and Halftone PWB Repair Kit
(W/TAG P32)
Reissue
DocuColor 12/DCCS50
1/05
5-265
Parts Lists
PL 4.1
PL 5.1 ESV Sensor, Erase Lamp

Item
Part
Description
1
2
3
4
5
6
114K81062
054K10151
122K92892
7
8
130K57720
9
10
11
12
006K84192
Connector (EP ROM PWB)

Duct and Erase Lamp Assembly
Erase Lamp (REP 5.1.1 )
Duct (P/O PL 5.1 Item 2)
Duct (Not Spared)
ESV Sensor and Cover Assembly
(Not Spared)
ESV Sensor
ESV Sensor Cover (P/O PL 5.1
Item 6)
Drum Shaft
Screw (Not Spared)
Parts Lists
PL 5.1
1/05
5-266
Reissue
DocuColor 12/DCCS50
PL 5.2 CC/PCC Connector, Waste

Toner Bottle (IOT Rear)
Item
1
2
3
4
5
6
7
8
9
Part
Description
114K81082
114K81362
115K91160
007K84593
130E91010
130K82921
CC Connector
PCC Connector
Earth Plate
Gear (Bottle Auger)
Waste Toner Full Sensor
Waste Toner Bottle Sensor
Waste Toner Bottle (REF: PL 5.2)
(Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
5-267
Parts Lists
PL 5.2
PL 5.3 Drum Component

Item
Part
Description
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
802K04428
059K09532
042K91811
033K92970
035E40690
Front Plate (Not Spared) (REP

5.3.1 )
Front Cover
Drum (REP 5.3.1)
Seal (Top Cover) (Not Spared)
Top Cover (Not Spared)
Seal (Blade Side) (Not Spared)
Shutter Spring (Not Spared)
Shutter Pipe (Not Spared)
Auger (Not Spared)
EP ROM PWB (Not Spared)
Rear Cover (Not Spared)
Cleaning Brush (REP 5.3.3 )
Cleaning Blade (REP 5.3.4 )
Gear (Not Spared)
Side Seal
Gear (Not Spared)
Gear (Not Spared)
Screw (Not Spared)
Screw (Not Spared)
Parts Lists
PL 5.3
1/05
5-268
Reissue
DocuColor 12/DCCS50
PL 5.4 Charge/Pre Clean Corotron

Item
Part
Description
1
2
3
4
125K03650
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
125K93062
118E12251
118K91900
009P62935
117K92100
604K22290
BPO Roll and Duct (Not Spared)

Charge Corotron Assembly
CC Wire (P/O PL 5.4 Item 2) (REP
5.4.1 )
Arc Shield (Front) (P/O PL 5.4 Item
2)
Arc Shield (Rear) (P/O PL 5.4 Item
2)
CC Shield (P/O PL 5.4 Item 2)
Insulator (Front) (P/O PL 5.4 Item
2)
Insulator (Rear) (P/O PL 5.4 Item 2)
Grid Spring (P/O PL 5.4 Item 2)
CC Grid (P/O PL 5.4 Item 2)
Pre Clean Corotron Assembly
PCC Shield (P/O PL 5.4 Item 12)
Insulator (Front)
Insulator (Rear)
Arc Shield (Rear) (Not Spared)
Arc Shield (Front) (Not Spared)
Spring
PCC Wire (REP 5.4.2 )
Screw (Not Spared)
Earth Wire (Not Spared)
Wire Repair Kit
Reissue
DocuColor 12/DCCS50
1/05
5-269
Parts Lists
PL 5.4
PL 5.5 Waste Toner Auger

Item
Part
Description
119K90765
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
059K09510
059K09500
059K09490
011K94141
011K93990
011K94160
011E08021
011K94150
011E08010
052E93470
005E85760
052E93460
013K81260
007E52030
413W08350
413W88650
423W82054
007E51830
052E93640
413W77559
009E84150
052E93480
013K81270
068K14541
007E52040
007E52050
068K14550
020E26710
035E45550
020E26990
Waste Toner Junction Assembly

(REP 5.5.1 )
Auger (Waste Toner Bottle)
Auger (Drum)
Auger
Wing Plate (P/O PL 5.5 Item 1)
Joint (Drum)
Joint (IBT)
Joint (Rear)
Joint (Front)
Joint (Rear)
Joint (Front)
Pipe
Ring
Pipe
Bearing
Gear
Bearing
Bearing
Auger Belt (REP 5.5.2 )
Gear Pulley
Shutter
Bearing
Spring
Pipe (Waste Toner Bottle)
Bearing
Bracket
Gear
Gear
Auger Sensor
Pulley
Seal
Pulley
Parts Lists
PL 5.5
1/05
5-270
Reissue
DocuColor 12/DCCS50
PL 6.1 Development Components

Item
Part
Description
011K94091
2
3
4
5
6
7
8
9
10
11
121K16401
809E15180
130E82190
600K82900
12
13
14
15
16
17
068K86934
115K91133
127K28490
130K87380
18
19
20
21
22
099P03019
Rotary Latch Lever Assembly

(REP 6.1.3 )
Rotary Latch Solenoid Assembly
Solenoid (P/O PL 6.1 Item 2)
Lever (P/O PL 6.1 Item 2)
Spring
Rotary Latch Sensor
Rotary PWB (P/O PL 6.1 Item 22)
High Frequence Noise Rotary PWB
Kit (W/TAG P18) (REP 6.1.1)
Film Seal (Not Spared)
Gear Assembly
Bias Brush (REP 6.1.4 )
Rotary Motor
Rotary Home Position Sensor
(REP 6.1.2 )
Support Tray (Not Spared)
High Frequence Noise Rotary PWB
Fuses
Rotary PWB Assembly (Not
Spared) (W/TAG P2)
Reissue
DocuColor 12/DCCS50
1/05
5-271
Parts Lists
PL 6.1
PL 6.2 Toner Cartridge Unit

Item
Part
Description
094K91307
6
7
055E30790
8
9
10
11
891E74014
891E74023
891E74033
891E74003
Toner Cartridge (Y) (Not Spared)

(REF: PL 6.2)
Toner Cartridge (M) (Not Spared)
(REF: PL 6.2))
Toner Cartridge (C) (Not Spared)
(REF: PL 6.2)
Toner Cartridge (K) (Not Spared)
(REF: PL 6.2))
Toner Cartridge Unit Assembly
(REP 6.2.1 )
Shutter
Toner Cartridge Cover (Not
Spared)
Label (Y)
Label (M)
Label (C)
Label (K)
Parts Lists
PL 6.2
1/05
5-272
Reissue
DocuColor 12/DCCS50
PL 6.3 Toner Cartridge Component

(Part 1 of 2)
Item
Part
Description
802K08652
130E82720
802K08662
4
5
802K08672
127K32940
802K08682
8
9
10
11
12
127K21270
413W11660
005E85181
007E46710
809E06790
Toner Cartridge Housing (C) (REP

6.3.1 )
Low Toner Sensor (C), Low Toner
Sensor (M), Low Toner Sensor (Y),
Low Toner Sensor (K)
Toner Cartridge Housing (M) (REP
6.3.1 )
Toner Cartridge Housing (Y) (REP
6.3.1 )
Cartridge Motor (C), Cartridge
Motor (M), Cartridge Motor (Y),
Cartridge Motor (K) (REP 6.3.2 )
Toner Cartridge Housing (REP
6.3.1 )
Dispense Motor (REP 6.3.2 )
Bearing
Coupling
Gear
Spring
Reissue
DocuColor 12/DCCS50
1/05
5-273
Parts Lists
PL 6.3
PL 6.4 Toner Cartridge Component

(Part 2 of 2)
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
Description
007E46680
007E46780
007E46760
007E49650
007E46700
007E46720
413W11660
007E46740
009E34940
015E54911
015K29910
048K61830
048K61840
160K45930

Shaft (K) (P/O PL 6.2 Item 5)
Shaft (C, M) (P/O PL 6.2 Item 5)
Gear (43)
Gear (23)
Gear (23)
Gear
Gear (25)
Gear (21)
Bearing
Gear
Spring
Shutter
Plate
Auger (M, K)
Auger (C)
Pipe (Y) (P/O PL 6.2 Item 5)
Dispense PWB (REP 6.4.1 )
Parts Lists
PL 6.4
1/05
5-274
Reissue
DocuColor 12/DCCS50
PL 6.5 Rotary Dispenser

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
019K94332
026E58330
026K80730
026K80740
026K80750
12
048K61963
13
14
15
16
17
18
19
20
21
22
23
049E85681
068K87041
130K57930
048K76720
802K08850
809E08810
011E08640
24
600K83451

Block
Screw
Screw
Screw Assembly (With Spring )
Screw
Outer Dispense Housing (P/O PL
6.5 Item 24) (W/TAG P26)
Inner Dispense Housing (W/TAG
P26)
Outer Dispense Cover
Inner Dispense Cover
Trickle Toner Full Sensor
Screw (Not Spared)
Cover Assembly
Cover
Spring
Lever
Trickle Toner Bottle (REF: PL 6.5)
(Not Spared)
DCD Kit (Tag P26) (W/TAG P26)
Reissue
DocuColor 12/DCCS50
1/05
5-275
Parts Lists
PL 6.5
PL 6.6 Deve. Housing

Item
Part
Description
1
2
007E46820
048K61638
3
4
5
096E75880
096E75850
048K77228
6
7
8
9
007K84881
096E75860
096E75870
10
11
019E39442
12
007E46650
Auger Gear (19) (M/C)

Deve. Housing Assembly (Y/M/C)
(REP 6.6.1 REP 6.6.2 )
Label (C)
Label (K)
Deve. Housing Assembly (REP
6.6.1 REP 6.6.2 )
Auger Gear (19) (Y/K)
Label (Y)
Label (M)
Deve. Housing (Y/M/C) (P/O PL 6.6
Item 2)
Holder
Deve. Housing (K) (P/O PL 6.6 Item
5)
Developer Housing Shaft Gear
Parts Lists
PL 6.6
1/05
5-276
Reissue
DocuColor 12/DCCS50
PL 6.7 Rotary Frame/Auger

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Part
Description
019K94230
019E33780
809E06550
019K94221
106K90660
052K91470
106K90650
106K90640
106K90670
Rotary Frame (Not Spared)

Holder Assembly (Rear)
Holder (P/O PL 6.7 Item 2)
Clamp
Spring
Holder Assembly (Front)
Rotary Auger (Y) (REP 6.7.1)
Brush (Not Spared)
Trickle Auger (REP 6.7.2 )
Rotary Auger (M) (REP 6.7.1 )
Rotary Auger (C) (REP 6.7.1)
Rotary Auger (K) (REP 6.7.1)
Reissue
DocuColor 12/DCCS50
1/05
5-277
Parts Lists
PL 6.7
PL 7.1 IBT System Component

Item
Part
Description
1
2
3
600K86096
042K91906
4
5
6
7
8
9
10
11
12
130K57690
015K36962
015K36972
015K29634
048K77264
011E07092
IBT Assembly (REP 7.1.1 )

Screw (M3 X 4) (Not Spared)
IBT Cleaner Assembly (W/TAG P1)
(REP 7.1.2 )
Temp Humidity Sensor
Right Rail Assembly
Left Rail Assembly
Rail Front Plate Assembly
IBT Inner Cover
Lever (Yellow Color)
Screw (M3 X 12) (Not Spared)
Parts Lists
PL 7.1
1/05
5-278
Reissue
DocuColor 12/DCCS50
PL 7.2 Rail Front Plate

Item
1
2
3
4
5
6
7
8
9
10
Part
Description
014E87701
006E56632
009E43970
008E93400
Front Plate (P/O PL 7.1 Item 9)

Block
Shaft
Spring
Retract Cam
Reissue
DocuColor 12/DCCS50
1/05
5-279
Parts Lists
PL 7.2
PL 7.3 Left/Right Rail

Item
Part
Description
1
2
3
4
5
6
7
162K37360
130E82190
8
9
10
11
12
13
14
15
16
17
18
001K59370
Left Tie Plate (P/O PL 7.1 Item 8)

Left Rail (P/O PL 7.1 Item 8)
Harness Cover
Wire Harness
IBT Cleaner Blade Home Position
Sensor
Wheel (P/O PL 7.1 Item 7)
Coupling (P/O PL 7.1 Item 7)
Plate Spring (P/O PL 7.1 Item 7)
Right Rail
Right Tie Plate (P/O PL 7.1 Item 7)
Parts Lists
PL 7.3
1/05
5-280
Reissue
DocuColor 12/DCCS50
PL 7.5 IBT-Belt, Sensor, Steering Roll

Item
1
2
3
4
5
6
7
8
9
10
11
12
Part
Description
064K91243
130K57973
048E64920
130E84270
600K82710
015K35842
IBT Assembly (P/O PL 7.1 Item 1)

IBT Belt (REP 7.5.1 )
ADC Sensor
Harness Cover
TRO Sensor
Drive Roll Kit (W/TAG P20)
Inlet Plate
IBT Rear Cover (P/O PL 7.1 Item
1)
Reissue
DocuColor 12/DCCS50
1/05
5-281
Parts Lists
PL 7.5
PL 7.6 IBT Component (Part 1 of 2)

Item
Part
Description
1
2
3
4
5
059K07800
013K81510
013E88310
059K07843
6
7
8
9
10
11
12
13
14
15
16
17
18
007E46502
048K61601
059K07812
059K08160
013E85430
809E06330
042K91650
830E81410
105K14062
Bias Roll (REP 7.6.1 )

Bearing and Spring Assembly
Bearing
Drive Roll (Pre-Tag 20) (REP 7.6.2
)
Gear
Gear Cover
Back Up Roll (REP 7.6.3)
Contact Roll (REP 7.6.4)
Bearing
Spring
Drive Roll Cleaning Blade
Plate
1st BTR HVPS
Parts Lists
PL 7.6
1/05
5-282
Reissue
DocuColor 12/DCCS50
PL 7.7 IBT Component (Part 2 of 2)

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Part
Description
059E92720
012E98080
029E26770
012E98070
059K07882
031E94101
809E06360
003E39980
008E93250
008E93090
008E93270
011E08081
006E56290
031E93022
Idler Roll
Link (Rear)
Arm Pivot
Link (Front)
Tension Roll
Arm
Spring
Stopper
Rear Cam
Front Cam
Earth Plate (Not Spared)
Foot Cam
Front Lever
Shaft
Earth Plate (Not Spared)
Inboard Tension Roll Arm
Reissue
DocuColor 12/DCCS50
1/05
5-283
Parts Lists
PL 7.7
PL 7.8 IBT Cleaner

Item
1
2
3
4
5
6
7
8
9
10
Part
Description
035K81498
033K93272
809E17001
809E17010
035E48290
035E48300
809E06401
Seal (W/TAG P17)

Cleaning Blade
Spring
Spring
Housing (P/O PL 7.1 Item 3)
Seal
Seal
Spring
Parts Lists
PL 7.8
1/05
5-284
Reissue
DocuColor 12/DCCS50
PL 7.9 2nd BTR

Item
1
2
3
4
5
6
Part
Description
059K14186
029E26180
130E82190
2nd BTR (REP 7.9.1 )

Screw
Indicator (Not Spared)
Label (Not Spared)
Plate (Not Spared)
2nd BTR Retract Home Position
Sensor
Reissue
DocuColor 12/DCCS50
1/05
5-285
Parts Lists
PL 7.9
PL 7.10 2nd BTR Component

Item
Part
Description
1
2
3
130K60600
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
809E06380
059K13021
031K92420
809E06370
006K84114
413W75959
007E46530
048K69086
048E64910
015K39880
015K35800
031K92410
007E46541
007E46551
054K19721
054E88182
130E91120
29
30
Inlet Plate (Not Spared)

Pre IBT Sensor
Cleaning Blade Assembly (P/O PL
7.9 Item 1)
Cleaning Blade (P/O PL 7.10 Item
3)
Spring
2nd BTR Roll (REP 7.10.1 )
Front Arm
Spring
Cam Shaft Assembly
Bearing
Gear
2nd BTR Housing
Cover
Earth Plate
Earth Plate
Rear Arm
Gear
Gear
Exit Chute Assembly
Guide
Pre Fuser Sensor
24)
Screw
BTR Brush (Not Spared)
Parts Lists
PL 7.10
1/05
5-286
Reissue
DocuColor 12/DCCS50
PL 8.1 Fuser Unit, Front Cover

Item
Part
Description
604K00846
604K00836
2
3
4
5
048E52741
068K87161
Fuser Unit (50 Hz) (W/TAG P12)

(REP 8.1.1,ADJ 8.1.1)
Fuser Unit (60 Hz) (W/TAG P12)
(REP 8.1.1,ADJ 8.1.1)
Front Cover
Pin Bracket
Cartridge Guide (Not Spared)
Oil Cartridge (Not Spared) (REF:
PL 8.1)
Label (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
5-287
Parts Lists
PL 8.1
PL 8.2 Fuser Sub Assembly

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
891E76040
891E76001
013E87700
891E75990
809E09190
007E49730
007K84120
007E49831
20
604K08100
Top Cover (P/O PL 8.1 Item 1)

Label
Label
Bearing
Label
Spring
Web CRU (P/O PL 8.1 Item 1)
Gear (19)
Gear (28/49)
Gear
Donor Roll Assembly (P/O PL 8.2
Item 20) (REP 8.2.1)
Fuser Reliability Improvement Kit
(For Streaks and Offsetting)
Parts Lists
PL 8.2
1/05
5-288
Reissue
DocuColor 12/DCCS50
PL 8.3 Heat/Pressure Roll

Item
Part
Description
1
2
059K39500
126K07960
126K08510
4
5
049E86600
7
8
9
10
019K94651
009E59690
019E42010
11
12
13
026P63503
059K39670
126K07970
126K08520
14
15
16
809E06730
049E86370
049E86360
Heat Roll (REP 8.3.1 )

Heat Roll Heater Rod (60 Hz) (REP
8.3.2 )
Heat Roll Heater Rod (50 Hz)
(REP 8.3.2 )
Heat Roll Stopper (Front) (P/O PL
8.1 Item 1)
Heater Rod Bracket (Front)
Heater Rod Bracket (Rear) (P/O PL
8.1 Item 1)
Heat Roll Stopper (Rear) (P/O PL
8.1 Item 1)
Heat Roll Finger Assembly
Spring
Heat Roll Striper Finger (REP 8.3.5
)
Stud
Pressure Roll (REP 8.3.3 )
Pressure Roll Heater Rod (60 Hz)
(REP 8.3.4 )
Pressure Roll Heater Rod (50 Hz)
(REP 8.3.4 )
Spring
Heater Rod Bracket (Rear)
Reissue
DocuColor 12/DCCS50
1/05
5-289
Parts Lists
PL 8.3
PL 8.4 Heat Roll Sensor, External Heat

Roll Retract/Web Motor
Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
130K57471
130K57430
130K57390
130K57400
127K27910
007E82390
121K16800
160K46120
127K21351
18
19
007E51980
130K57490
Heat Roll Sensor Assembly

H/R Thermostat
H/R Control Thermistor
H/R Overheat Thermistor
Upper Frame (P/O PL 8.1 Item 1)
Web Motor (REP 8.4.1 )
Gear
Magnet
Web Drive PWB
PWB Support (P/O PL 8.1 Item 1)
External Heat Roll Retract Motor
(REP 8.4.1 )
Gear
External Heat Roll Retract Sensor
Parts Lists
PL 8.4
1/05
5-290
Reissue
DocuColor 12/DCCS50
PL 8.5 Web Shutter, Cleaning Roll

(Heat Roll)
Item
Part
Description
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
003K85453
003K85483
913W02310
162K37050
162K36960
600K84050
059K24360
013E87551
014K81273
003K85731
Web Guide Block Assembly (P/O

PL 8.1 Item 1)
Rear Guide Block (P/O PL 8.5 Item
1)
Front Guide Block (P/O PL 8.5
Item 1)
Contact Plate (P/O PL 8.1 Item 1)
Wire Harness (P/O PL 8.1 Item 1)
Front Latch Assembly
Rear Latch Assembly
Upper Frame (P/O PL 8.1 Item 1)
Connector (Blue) (PJ700)
Fuser Side Harness
Frame Side Harness
Web Shutter Repair Kit
Shutter (P/O PL 8.5 Item 13)
Cleaning Roll
Bearing
Tie Plate (P/O PL 8.1 Item 1)
CRU Block Guide Assembly
Front Latch (P/O PL 8.5 Item 6)
Web Release Button
Rear Latch (P/O PL 8.5 Item 7)
Reissue
DocuColor 12/DCCS50
1/05
5-291
Parts Lists
PL 8.5
PL 8.6 Pressure Roll Sensor, Pressure

Roll Nip
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Part
Description
130K57380
130K57370
130K87470
068K87410
007E49760
007E51500
007E49740
007K84130
007K84140
011K94040
026K80720
011K94030
013E87730
413W10650
008E93160
120E12630
015K33670
P/R Overheat Thermistor

P/R Control Thermistor
P/R Thermostat
Bracket
Harness Cover (P/O PL 8.1 Item 1)
Gear (28)
Gear (20)
Gear (20)
Gear (32)
Gear (34)
Rear Lever Assembly
Rear Lever (P/O PL 8.6 Item 13)
Adjust Screw
Front Lever Assembly
Front Lever (P/O PL 8.6 Item 16)
Bearing
Bearing
Cam
Actuator
Nip Sensor
Stand Plate (P/O PL 8.1 Item 1)
Harness Guard (P/O PL 8.1 Item 1)
Parts Lists
PL 8.6
1/05
5-292
Reissue
DocuColor 12/DCCS50
PL 8.7 Oil Pump/Tank

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part
Description
127K21410
052E92750
019E39570
052E93181
809E06530
039K90592
068K21850
050E17450
054K11220
093E91961
130K57940
052E93920
052E96630
809E19010
053E92650
019E49780
604K01911
Oil Pump (REP 8.7.1 )

Tube
Clamp
Oil Pipe
Spring Plate
Oil Wick (W/TAG P12) (REP 8.7.2 )
Bracket
Oil Pan
Inlet Chute
Oil Tank
Oil Empty Sensor
Tube
Tube (Alternate)
Support Plate Spring
Oil Filter
Hose Clamp
Oil System Upgrade Kit (W/TAG
P37)
Reissue
DocuColor 12/DCCS50
1/05
5-293
Parts Lists
PL 8.7
PL 8.8 External Heat Roll

Item
Part
Description
001K62603
001K62613
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
130K87520
130K87500
130K57350
013E87600
013E87700
049E86030
049E86040
007K85270
013E87620
809E06770
059E92780
21
126K07980
126K08530
External Heat Roll Assembly (60

Hz)
External Heat Roll Assembly (50
Hz)
External H/R Overheat Thermistor
External H/R Control Thermistor
External H/R Thermostat
Bearing
Ring (P/O PL 8.8 Item 1)
Bearing
Heater Rod Bracket (Rear)
Gear (18) (18 )
Shaft Cam (P/O PL 8.8 Item 1)
Bearing
Lever (Rear) (P/O PL 8.8 Item 1)
Spring
Lever (Front) (P/O PL 8.8 Item 1)
External Heater Roll (REP
8.8.2,ADJ 8.8.1)
External H/R Heater Rod (60 Hz)
(REP 8.8.1 )
External H/R Heater Rod (50 Hz)
(REP 8.8.1 )
Parts Lists
PL 8.8
1/05
5-294
Reissue
DocuColor 12/DCCS50
PL 8.9 Pick Up/Donor Roll

Item
1
2
3
4
5
6
7
8
Part
Description
013E94380
600K83631
033K92892
013E94320
022K62370

Bearing
Pick Up Roll Kit (W/TAG P21)
Blade
Bearing
Donor Roll
Reissue
DocuColor 12/DCCS50
1/05
5-295
Parts Lists
PL 8.9
PL 8.10 Exit Chute

Item
Part
Description
2
3
4
5
6
7
8
9
10
11
12
13
14
15
054K10114
054K10115
130K92950
022K48260
413W77559
007E84880
022K48250
019E33860
16
17
18
009E59690
019K94202
Exit Chute Assembly (50 Hz)

Exit Chute Assembly (60 Hz)
Chute Frame (P/O PL 8.10 Item 1)
Fuser Exit Sensor
Pinch Roll
Wire Cover (P/O PL 8.10 Item 1)
Bearing
Gear (17)
Handle (P/O PL 8.10 Item 1)
Lower Chute (P/O PL 8.10 Item 1)
Exit Roll
Pressure Roll Stripper Finger (REP
8.10.1 )
Spring
Pressure Roll Finger Assembly
Parts Lists
PL 8.10
1/05
5-296
Reissue
DocuColor 12/DCCS50
PL 9.1 Front, Right

Item
Part
Description
1
2
3
4
5
6
7
910W00211
910W00122
015K38560
8
9
10
11
015K33986
12
13
14
105E99122
048E65041
117E22350
117K31400
117E10550
152S05105
152S05121
152S05106
152S05122
152S05107
152S05123
152S05104
152S05120
15
16
117K23770
117K22350
117E25300
962K01820
962K01830
962K01810
962K01840
130K60561
606K91040
Main Switch
Front Door Interlock Switch
Deve. Bias and CC/PCC HVPS
Assembly
Deve. Bias HVPS Assembly
Deve. Bias HVPS (P/O PL 9.1 Item
7)
CC/PCC HVPS
Interlock Cover
Power Cord (120V) (60 Hz)
Power Cord (110V)
Power Cord (220V) (60 Hz)
Power Cord (United Kingdom
250V/10A Gray)
Power Cord (United Kingdom
240V/10A Black)
Power Cord (Denmark 250V/10A
Gray)
Power Cord (Denmark 250V/10A
Black)
Power Cord (Switzerland 250V/10A
Gray)
Power Cord (Switzerland 250V/10A
Black)
Power Cord (Europe 250V/10A
Gray)
Power Cord (Europe 250V/10A
Black)
Power Cord (19A)
Power Cord (20A)
1670 Epson Scanner Power Cord
Power Cord (United Kingdom)
Power Cord (Denmark)
Power Cord (Europe)
Power Cord (CH)
Atc Sensor Bracket (W/TAG P14)
ATC Sensor Kit (W/TAG P14)
Reissue
DocuColor 12/DCCS50
1/05
5-297
Parts Lists
PL 9.1
PL 9.2 IOT Top/Rear

Item
Part
Description
1
2
162K41511
162K41521
160K74412
4
5
6
7
8
9
160K61620
10
11
160K61611
160K47911
12
13
14
15
16
17
18
105K14914
127K21750
048K76941
19
20
21
160K48688
160K48704
22
23
24
25
162K42260
026E56431
Flat Cable (FPC-IOT)

Flat Cable (FPC-ROS) (W/TAG
P42)
Half Tone PWB (W/TAG P32)
(REP 9.2.3 )
PWB Bracket (Not Spared)
Screw (Not Spared)
Washer (Not Spared)
IOT Control PWB Chassis Assembly (Not Spared) (REP 9.2.1)
PWB Chassis (P/O PL 9.2 Item 7)
IOT Drive PWB (W/TAG P14)
(REP 9.2.2)
IOT CPU PWB (W/TAG P6)
IOT NVM PWB (REF: PL 9.2) (Rep
9.2.2 )
PWB Support (P/O PL 9.2 Item 7)
2nd BTR HVPS
Rotary Fan
Half Tone PWB Cover
IOT Control PWB Cover (Not
Spared)
Extension Plate (Not Spared)
VSEL Base TTL PWB
VSEL Extension PWB (W/TAG
P13)
Flat Cable (J388/J389)
Cover (Not Spared)
Blind Cover (Not Spared)
VSEL Screw
Parts Lists
PL 9.2
1/05
5-298
Reissue
DocuColor 12/DCCS50
PL 9.3 Tray Module, Rear

Item
Part
Description
160K45940
160K60770
2
3
4
5
108E94360
101K33185
101K31295
6
7
8
9
10
11
12
908W00914
908W00909
13
101K31312
101K31322
14
15
16
17
18
19
20
21
22
23
24
25
908W00134
908W00131
109E93220
109E93230
101K31342
101K31352
105E07314
105E07344
160K48351
105E98090
105E98110
26
27
28
29
30
109E93260
Distribution PWB Assembly

Distribution PWB Assembly (Alternate)
PWB (P/O PL 9.3 Item 1)
Fuse (5A/125V)
LVPS Bracket (Not Spared)
Power Chassis Assembly (50 Hz)
(W/TAG P28) (REP 9.3.1)
Power Chassis Assembly (60 Hz)
(W/TAG P28) (REP 9.3.1 )
Power Chassis (P/O PL 9.3 Item 5)
Inlet (P/O PL 9.3 Item 5)
Circuit Breaker (60 Hz)
Circuit Breaker (50 Hz)
Noise Filter (P/O PL 9.3 Item 5)
Outlet (P/O PL 9.3 Item 5)
Inlet Plate (P/O PL 9.3 Item 5)
Outlet Plate (FX/TFX) (P/O PL 9.3
Item 5)
AC Driver PWB Assembly (60 Hz)
(REP 9.3.1 )
AC Driver PWB Assembly (50 Hz)
(REP 9.3.1 )
PWB Chassis (P/O PL 9.3 Item 13)
AC Driver PWB (P/O PL 9.3 Item
13)
Fuse (6.3A/125V)
Fuse (3.15A/125V)
SSR (60 Hz)
SSR (50 Hz)
Transformer Assembly (60 Hz)
Transformer (50 Hz)
IOT LVPS (60 Hz) (REP 9.3.2 )
IOT LVPS (50 Hz) (REP 9.3.2 )
Tray PWB Assembly
Tray PWB (P/O PL 9.3 Item 21)
Fuse (P/O PL 9.3 Item 21)
Cap (Not Spared)
Printer B3 LVPS (60 Hz) (REP
9.3.3 )
Printer B3H LVPS (50 Hz) (REP
9.3.3 )
LVPS Bracket (Not Spared)
Connector Bracket (Not Spared)
Transformer (P/O PL 9.3 Item 19)
ESS SSR
Reissue
DocuColor 12/DCCS50
1/05
5-299
Parts Lists
PL 9.3
PL 9.4 Drawer Connectors

Item
Part
Description
1
2
3
4
5
6
009E73310
7
8
9
10
009E81210
11
12
13
14
15
101K24030
16
17
18
19
160K29150
160K80150
537K49510
537K43720
Screw (Not Spared)

C/R Connector (Not Spared)
Spring
Screw (Not Spared)
Connector Housing (P702 ) (Not
Spared)
Collar (Not Spared)
Spring
Connector Housing (J700 ) (Not
Spared)
Screw (Not Spared)
Connector Housing (P701 ) (Not
Spared)
Foreign Interface Bracket (Not
Spared)
Foreign Interface Chassis Assembly
Foreign Interface Chassis (P/O PL
9.4 Item 15)
A I/F PWB (Foreign Interface PWB)
I/F PWB (Foreign Interface PWB)
ROM (Coin Vend/Debit Card)
ROM (External Auditron)
Chassis Cover (P/O PL 9.4 Item
15)
Parts Lists
PL 9.4
1/05
5-300
Reissue
DocuColor 12/DCCS50
PL 9.5 Control Panel

Item
Part
Description
048K77776
2
3
4
5
6
7
802K31691
8
9
10
11
12
13
14
15
16
17
18
19
600K83650
Control Panel Assembly (W/TAG

P24) (REP 9.5.1 )
Control Panel Housing Assembly
Panel Housing (P/O PL 9.5 Item 2)
Set Key (P/O PL 9.5 Item 2)
Display (P/O PL 9.5 Item 2)
Lamp (P/O PL 9.5 Item 2)
Touch Panel (P/O PL 9.5 Item 2)
(ADJ 9.1.18 )
Power Supply (P/O PL 9.5 Item 2)
VR PWB (P/O PL 9.5 Item 2)
UI PWB Kit (W/TAG P24)
Panel (Right) (P/O PL 9.5 Item 1)
Panel (Center) (P/O PL 9.5 Item 1)
Panel (Left) (P/O PL 9.5 Item 1)
Adjust Pen (Not Spared)
Wire Harness (Edit Pad) (Not
Spared)
Reissue
DocuColor 12/DCCS50
1/05
5-301
Parts Lists
PL 9.5
PL 9.6 EMI/Safety for Fuser Heat

Lamp (50 Hz)
Item
1
2
3
Part
Description
103E24040
109E93260
160K61560
Surge Resistor
Surge SSR
Varistor PWB
Parts Lists
PL 9.6
1/05
5-302
Reissue
DocuColor 12/DCCS50
PL 10.1 Air System-Front Door

Item
Part
Description
127K21761
2
3
4
5
127K21801
054K99181
054K99191
Fuser Intake Fan and Duct Assembly

Fuser Intake Fan
Duct (Fuser Intake)
Duct (CC Intake)
Duct (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
5-303
Parts Lists
PL 10.1
PL 10.2 Air System-Rear, Right

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
127K21770
127K21780
053K91410
053K91420
053K91430
127K21822
Duct (Not Spared)

Duct (Not Spared)
Filter Case (Not Spared)
Duct (Rotary Deve.) (Not Spared)
Vacuum Transport Duct (Not
Spared)
Fuser Fan and Duct Assembly
Duct Fuser (P/O PL 10.2 Item 6)
Fan Cover (P/O PL 10.2 Item 6)
Fuser Fan (REP 10.2.1 )
Duct (Not Spared)
Duct (Not Spared)
Duct (Xero. Module) (Not Spared)
Filter Assembly (Not Spared)
Filter (Suction)
Filter (Ozone)
Filter (Ozone)
Suction Blower Motor (REP 10.2.2
)
Parts Lists
PL 10.2
1/05
5-304
Reissue
DocuColor 12/DCCS50
PL 11.1 Platen/Top Cover

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part
Description
048E61921
004E08250
048E66331
048E66221
048K71213
048E62452
048E62462
003E40250
003K85090
121E90620
050E88440
003E43840
830E20010
Top Cover
Screw (Not Spared)
Label (Not Spared)
Label (Not Spared)
Platen Cushion (REP 11.1.1 )
Blind Cover
Blind Cover
Platen Cover Assembly
Platen Cover
Pocket Cover
Hinge
Stopper
Magnet
Wing Tray
Thumb Screw (Not Spared)
Bracket
Reissue
DocuColor 12/DCCS50
1/05
5-305
Parts Lists
PL 11.1
PL 11.2 Front/Right Cover

Item
Part
Description
1
2
3
802K06232
048E60750
048K77462
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
048E60741
048E60762
048E60670
048E60690
891E75721
892E02000
891E75951
048K69818
017E93753
017E93743
802E61690
600K82870
Right Upper Cover

Right Lower Front Cover
Filter Unit Cover and Seal Assembly
Filter Unit Cover
Power Chassis Cover
Hinge (Not Spared)
Blind Cover (PSW)
Blind Cover (AC Out)
Name Plate (DC12)
Name Plate (DCCS50)
Label (Not Spared)
Logo Plate
Front Door Assembly
Front Door (P/O PL 11.2 Item 13)
Block (P/O PL 11.2 Item 13)
Blind Cover (Not Spared)
Caster (Front) (Locking)
Caster (Rear) (Unlocking)
Front Lower Cover
Cover Seal Kit (W/TAG P15)
Parts Lists
PL 11.2
1/05
5-306
Reissue
DocuColor 12/DCCS50
PL 11.3 Rear/Left Cover

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
048E60772
048E60781
048E60790
802K04681
802K31420
048E65171
048E65391
048K76341
048E65330
048E65341
048E61933
048E61941
048E61950
21
22
23
802E61670
600K84700
Left Upper Front Cover

Left Upper Rear Cover
Left Inner Cover
Bracket (Front) (Not Spared)
Bracket (Rear) (Not Spared)
Left Middle Cover
IOT Rear Cover (W/TAG P38)
Blind Cover (EPSV)
ESS Cover
Data Plate (Not Spared)
Tray Module Rear Cover
Connector Cover (Not Spared)
ESS Left Cover
ESS Rear Cover
IIT Rear Cover
IIT Left Cover
Blind Cover
Blind Cover (P/O PL 11.3 Item 23)
Blind Cover (P/O PL 11.3 Item 23)
Left Lower Rear Cover (Not
Spared)
Left Lower Front Cover
Extension Bracket (Not Spared)
Cover Kit
Reissue
DocuColor 12/DCCS50
1/05
5-307
Parts Lists
PL 11.3
PL 12.1 Front/Rear Cover, Entrance

Tray
Item
Part
Description
048K76181
2
3
4
5
6
7
140K60480
891E65180
050K36410
8
9
10
11
12
13
14
032K93800
048E64201
891E77561
891E65210
059K23063
Rear Cover Assembly (REP 12.1.1

)
Rear Cover (P/O PL 12.1 Item 1)
Led PWB
Label (Display)
Entrance Tray Assembly
Entrance Tray (P/O PL 12.1 Item
6)
Document Guide
Front Cover
Label
Label (Size)
DADF Feeder Assembly
Parts Lists
PL 12.1
1/05
5-308
Reissue
DocuColor 12/DCCS50
PL 12.2 Top Cover, Registration Gate

Solenoid
Item
Part
Description
1
2
3
4
5
6
7
054K13622
015E48890
809E11130
059K11880
015E48900
110K91972
8
9
10
11
12
13
121K93870
121K87790
14
15
121K86550
16
17
031E92550
Top Cover Assembly

Top Cover (P/O PL 12.2 Item 1)
Plate (Front Magnet)
Spring
Pinch Roll
Plate (Rear Magnet)
Top Cover Interlock Switch (Front),
Top Cover Interlock Switch (Rear)
Screw (Not Spared)
Magnet
Label (Not Spared)
Registration Gate Solenoid Assembly
Registration Gate Solenoid (REP
12.2.2 )
Regi. Arm
Push Rivet (P/O PL 12.2 Item 13)
Reissue
DocuColor 12/DCCS50
1/05
5-309
Parts Lists
PL 12.2
PL 12.3 Counter Balance, DADF

Control PWB
Item
Part
Description
1
2
003K91881
036K91431
5
6
7
8
036K91420
9
10
11
12
13
14
160K51502
15
16
17
18
537K51016
19
162K43311
Knob Screw
Right Counter Balance Assembly
(ADJ 12.3.1 ADJ 12.3.3 )
Counter Balance (P/O PL 12.3
Item 2)
DADF Interlock Switch (P/O PL
12.3 Item 2)
Screw (Not Spared)
Left Counter Balance (ADJ 12.3.1
ADJ 12.3.3 )
PWB Support (Not Spared)
Screw (Not Spared)
Safety Bracket (Not Spared)
DADF Control PWB Assembly
(ADJ 12.3.2 )
Fuse (F2 ) (P/O PL 12.3 Item 14)
Fuse (F1 ) (P/O PL 12.3 Item 14)
ROM
DADF Control PWB (P/O PL 12.3
Item 14)
Wire Harness
Parts Lists
PL 12.3
1/05
5-310
Reissue
DocuColor 12/DCCS50
PL 12.4 Document Feed Chute

(Upper), Feed Motor
Item
Part
Description
054K13600
2
3
4
5
6
7
8
059K11840
007E39420
013E92760
007E39430
600K90370
9
10
11
12
13
14
15
16
17
18
19
20
21
22
413W77559
007E39410
007E39390
007E39400
802K08320
020E22160
023E12610
127K27590
Document Feed Upper Chute

Assembly
Feed Roll Assembly
Upper Baffle (P/O PL 12.4 Item 1)
Shaft (Drive) (P/O PL 12.4 Item 1)
Gear
Bearing
Gear
Nudger Roll Kit, Feed Roll Kit
(2/Kit) (REP 12.4.2 )
Link (Not Spared)
Bearing
Gear
Gear
Shaft (Feed) (P/O PL 12.4 Item 1)
Gear
Housing (P/O PL 12.4 Item 1)
Inner Cover
Pulley
Belt
Feed Motor (REP 12.4.1 )
Screw (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
5-311
Parts Lists
PL 12.4
PL 12.5 Document Feed Chute

(Lower)
Item
Part
Description
054K13591
2
3
4
5
6
7
8
9
10
11
009E71890
809E11120
055K19260
022K46560
12
121K87800
13
14
15
16
17
121K87810
130E80890
18
130E91220
19
20
21
050K27660
Document Feed Lower Chute

Assembly (REP 12.5.1 )
Spring
Plate Spring
Arm (P/O PL 12.5 Item 1)
Guard
Shaft (Arm) (P/O PL 12.5 Item 1)
Shaft (Retard) (P/O PL 12.5 Item 1)
Retard Roll (REP 12.5.2 )
Screw (M3 X 12) (P/O PL 12.5 Item
1)
Set Gate Solenoid Assembly (REP
12.5.3 )
Set Gate Solenoid
Size Sensor 1 (Rear), Size Sensor
2 (Front) (REP 12.5.5 )
Registration Sensor, Document
Sensor (REP 12.5.4 )
Damper (Not Spared)
Set Gate
Parts Lists
PL 12.5
1/05
5-312
Reissue
DocuColor 12/DCCS50
PL 12.6 DADF Belt Motor, Duplex Roll

Item
Part
Description
127K83520
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
013P60566
007K91871
023E92341
020K91230
022E93660
023E94140
020E21050
007E83260
022K37080
022K37070
023E12230
DADF Belt Motor Assembly (REP

12.6.1 )
DADF Belt Motor (P/O PL 12.6
Item 1)
Damper (P/O PL 12.6 Item 1)
Tension Roll
Screw (Not Spared)
Gear Pulley
Belt
Spacer (Not Spared)
Pulley
Spacer (Not Spared)
Tension Roll
Belt
Pulley
Gear Pulley
Duplex Roll (Upper)
Duplex Roll (Lower)
Belt
Reissue
DocuColor 12/DCCS50
1/05
5-313
Parts Lists
PL 12.6
PL 12.7 Duplex Chute

Item
1
2
3
4
5
6
7
8
9
10
11
Part
Description
054K06692
130E91220
050K27670
054K18790
059K11850
121E90640
Duplex Chute
Duplex Sensor (REP 12.7.1 )
Gate
Screw (Not Spared)
Tapping Screw (Not Spared)
Lower Chute Assembly
Pinch Roll
Magnet (Open Switch)
Guide (Not Spared)
Parts Lists
PL 12.7
1/05
5-314
Reissue
DocuColor 12/DCCS50
PL 12.8 Registration Roll

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
007K81120
059K11830
007K91860
009E28580
013E94561
022K38040
12
13
14
15
16
009E39080
009E28570
050K43870
009E28560
Spacer (Not Spared)

Gear Pulley
Registration Roll
Gear
Spring (Rear)
C-Clip (Not Spared)
Bearing
Cam (Rear) (Not Spared)
Link (Not Spared)
Registration Pinch Roll (REP
12.8.1 )
Cam (Front) (Not Spared)
Spring (Front)
Spring
Gate
Spring
Reissue
DocuColor 12/DCCS50
1/05
5-315
Parts Lists
PL 12.8
PL 12.9 Exit Motor/Chute

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
127K24060
127K24070
020E93240
423W07753
020E93230
059K11860
130E80890
054K18770
105E06910
16
17
054K13082
18
19
20
019E92320
059K11821
Exit Motor Assembly (REP 12.9.1 )

Exit Motor
Pulley
Spacer (Not Spared)
Belt
Pulley
Exit Roll
DADF Exit Sensor
Exit Upper Chute Assembly
Eliminator
Exit Upper Chute (P/O PL 12.9
Item 13)
Exit Lower Chute Assembly
Exit Lower Chute (P/O PL 12.9
Item 16)
Sensor Pad
Pinch Roll
Parts Lists
PL 12.9
1/05
5-316
Reissue
DocuColor 12/DCCS50
PL 12.10 Document Transport, Platen

Belt
Item
Part
Description
1
2
059K11870
3
4
5
6
7
8
9
10
11
12
007E83141
013E80970
049E91070
022K39710
023E15690
022K39700
13
14
15
16
17
18
059K13440
Document Transport Assembly

Self Lock Screw (P/O PL 12.10
Item 1)
Gear
Bearing
Tension Plate
Idler Roll
Platen Belt (REP 12.10.1 )
Drive Roll
Belt Guide (P/O PL 12.10 Item 1)
Belt Guide (P/O PL 12.10 Item 1)
Transport Frame (P/O PL 12.10
Item 1)
Deflector (P/O PL 12.10 Item 1)
Pinch Roll
Eliminator (P/O PL 12.10 Item 1)
Reissue
DocuColor 12/DCCS50
1/05
5-317
Parts Lists
PL 12.10
PL 12.11 Platen Glass, Registration

Gate, Exit Tray: DADF
Item
1
2
3
4
5
6
Part
Description
090K92572
050K36421
015K83700
673K51383
003E43840
Platen Glass (REP 3.1.1 )

Registration Gate
Plate
Exit Roll Kit
Knob Screw
Parts Lists
PL 12.11
1/05
5-318
Reissue
DocuColor 12/DCCS50
PL 13.1 Mail Box Accessory

Item
1
2
3
4
5
6
Part
Description
001K57693
003K91881
830E19412
029E21610
Mail Box Assembly (Not Spared)

Docking Rail Assembly
Knob Screw
Docking Plate
Docking Pin
Reissue
DocuColor 12/DCCS50
1/05
5-319
Parts Lists
PL 13.1
PL 13.2 Docking Rail

Item
1
2
3
4
5
6
7
8
9
Part
Description
015K31853
015K35862
068K14921
015K31871
830E17801
032E10210
015K31860
Rail Assembly
Rail
Bracket (Mail Box Left)
Plate (Tray Module Left)
Bracket (Mail Box Right)
Guide (Tray Module Right)
Bracket
Gasket (P/O PL 13.1 Item 2)
Parts Lists
PL 13.2
1/05
5-320
Reissue
DocuColor 12/DCCS50
PL 13.3 Mail Box Sub Assembly

Item
1
2
3
4
5
6
Part
Description
059K17861
022K65790
802K07903
048K77410
121E90490
Mail Box Assembly

Decurler Assembly (REP 13.3.1)
Cabinet Assembly
Decurler Front Cover
Catch Magnet
Screw (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
5-321
Parts Lists
PL 13.3
PL 13.4 Mail Box Cover

Item
Part
Description
1
2
3
4
049E77290
009E94910
110K08600
5
6
003K85101
7
8
9
10
11
12
13
14
15
16
17
048K77952
048E66520
048K77971
048E66540
802K08530
048E66560
891E73451
048E66571
048E66581
891E73441
Docking Plate
Spring
Mail Box Front Cover Interlock
Switch
Hinge
Exit OCT Cover (Rear) (P/O PL
13.3 Item 1)
Front Cover
Left Cover
Top Cover
Exit OCT Cover (Rear)
Exit Cover
Panel
Label
Rear Lower Cover
Rear Cover
Label
Parts Lists
PL 13.4
1/05
5-322
Reissue
DocuColor 12/DCCS50
PL 13.5 ACT Cover, Bin Tray 1

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
160K53431
802K09190
038E88980
038E86180
105E98450
022K43710
120E13130
120E17020
050K36832
005E83570
013E89540
020E21490
022E83451
16
17
18
830E32600
050E88781
413W77559
Vertical Led (REP 13.5.1 )

ACT Cover Assembly
ACT Cover (P/O PL 13.5 Item 2)
Paper Guide
Paper Guide
Eliminator
Pinch Roll
Actuator
Actuator
Bin Tray 1 Assembly (REP 13.5.2 )
Collar
Bearing
Pulley
Roll
Tapping Screw (M3 X 10) (P/O PL
13.5 Item 10)
Support
Bin Tray
Bearing
Reissue
DocuColor 12/DCCS50
1/05
5-323
Parts Lists
PL 13.5
PL 13.6 Bin Tray 2/4/6/8

Item
Part
Description
050K36822
2
3
4
5
6
009E64140
013E89540
020E21490
022E83451
7
8
9
10
11
12
13
14
15
038E88980
050E88781
050K33220
105E98450
120E13130
120E17020
121E83120
413W77559
830E32600
Bin Tray 2/4/6/8 Assembly (REP

13.6.1 )
Spring
Bearing
Pulley
Roll
13.6 Item 1)
Paper Guide
Bin Tray
Gate
Eliminator
Actuator
Actuator
Gate Solenoid
Bearing
Support
Parts Lists
PL 13.6
1/05
5-324
Reissue
DocuColor 12/DCCS50
PL 13.7 Bin Tray 3/5/7/9

Item
Part
Description
050K36812
2
3
4
5
6
009E64140
013E89540
020E21490
022E83451
7
8
9
10
11
12
13
14
15
16
038E88980
050E88781
050K33220
059K13261
105E98450
120E13130
120E17020
121E83120
413W77559
830E32600

13.6.1 )
Spring
Bearing
Pulley
Roll
13.7 Item 1)
Paper Guide
Bin Tray
Gate
Idler Roll
Eliminator
Actuator
Actuator
Gate Solenoid
Bearing
Support
Reissue
DocuColor 12/DCCS50
1/05
5-325
Parts Lists
PL 13.7
PL 13.8 Bin Tray 10

Item
Part
Description
050K36801
2
3
4
5
6
7
005E83570
009E64140
013E89540
020E21490
022E83451
8
9
10
11
12
050E88781
050K33220
121E83120
413W77559
830E32600
Bin Tray 10 Assembly (REP 13.6.1

)
Collar
Spring
Bearing
Pulley
Roll
13.8 Item 1)
Bin Tray
Gate
Gate Solenoid
Bearing
Support
Parts Lists
PL 13.8
1/05
5-326
Reissue
DocuColor 12/DCCS50
PL 13.9 Mail Box Roll, Chute

Item
Part
Description
1
2
3
4
5
6
7
8
9
121K19230
059K12460
059K12471
050K30120
121K14541
054K14091
10
11
12
13
003E36290
059K08590
891E73331
14
15
16
054K14102
17
18
19
20
21
105E98690
130E80100
130K94740
22
160K53431
23
24
25
068K15350
054K14131
26
27
28
29
30
31
022K43720
022K48240
891E73431
005K82400
413W75959
Magnet
Entrance Roll
Exit Roll
OCT Gate
OCT Gate Solenoid
Pulley (Not Spared)
Entrance Lower Baffle Assembly
Entrance Lower Baffle (P/O PL
13.9 Item 8)
Knob
Pinch Roll
Label (7)
Exit Lower Chute (P/O PL 13.3
Item 1)
Entrance Upper Chute (P/O PL
13.3 Item 1)
Exit Upper Chute Assembly
Exit Upper Chute (P/O PL 13.9
Item 15)
Eliminator
OCT Exit Sensor
V-Tra. In Sensor
Lower Tray Chute (P/O PL 13.3
Item 1)
Mail Box Vertical Sensor (REP
13.5.1 )
Magnet
Transport Baffle Assembly
Transport Baffle (P/O PL 13.9 Item
24)
Pinch Roll
Pinch Roll
Label (8)
Torque Limiter Gear
Bearing
Reissue
DocuColor 12/DCCS50
1/05
5-327
Parts Lists
PL 13.9
PL 13.10 Mail Box Motor, PWB

Item
Part
Description
1
2
3
4
5
6
7
8
015K48190
007E55351
007E56970
022E83460
023E13160
127K24943
9
10
11
12
13
14
15
16
17
127K24952
162K47062
162K47500
162K47510
007E55361
162K47050
18
160K56450
19
539K90924

Tension Roll
Gear Pulley
Gear Pulley (Not Spared)
Roller
Belt
Mail Box Drive Motor Assembly
Motor Bracket (P/O PL 13.10 Item
7)
Wire Harness (PWB-IOT)
Wire Harness (PWB-Motor)
Wire Harness (PWB-Sensor)
Gear Pulley
Core (P/O PL 13.3 Item 1)
Wire Harness (PWB-Decurler)
Wire Harness (PWB-OCT) (P/O PL
13.3 Item 1)
Mail Box Control PWB (Sorter Configuration Only)
ROM
Parts Lists
PL 13.10
1/05
5-328
Reissue
DocuColor 12/DCCS50
PL 13.11 Decurler Cover

Item
Part
Description
1
2
3
4
5
6
7
003K85570
003E46501
003K85101
048K77420
048E65721
110E97990
8
9
10
11
12
13
048E65730
048E65740
809E02991
003K83211
121E90490
Knob Assembly
Handle
Hinge
Decurler Inner Cover Assembly
Decurler Inner Cover
Decurler Front Cover Interlock
Switch
Decurler Top Cover
Decurler Rear Cover
Spring
Knob
Catch Magnet
Screw (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
5-329
Parts Lists
PL 13.11
PL 13.12 Decurler Chute, PWB

Item
Part
Description
1
2
054K15550
3
4
5
059K08590
110K91391
6
7
054K13920
8
9
10
11
12
13
14
003E36290
121E89780
160K52902
15
130E82970
Entrance Lower Chute Assembly

Entrance Lower Chute (P/O PL
13.12 Item 1)
Pinch Roll
Mail Box Docking Interlock Switch
Mail Box Docking Interlock Switch
(P/O PL 13.12 Item 1)
Exit Lower Baffle Assembly
Exit Lower Baffle (P/O PL 13.12
Item 6)
Knob
Chute (Not Spared)
Upper Chute (P/O PL 13.3 Item 2)
Magnet Catch
Decurler Control PWB
Wire Harness (PWB-Mail Box) (P/O
PL 13.3 Item 2)
Decurler Exit Sensor
Parts Lists
PL 13.12
1/05
5-330
Reissue
DocuColor 12/DCCS50
PL 13.13 Decurler Roll

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
006E61320
007E54990
007E55010
007E55030
007E55040
015K28141
007E45091
008E93390
011K94401
011K94411
022K57120
15
022K57130
16
17
18
062E98711
121K83981
19
20
21
22
130E82530
809E14570
413W08350
413W75959
Cam Drive Shaft

Gear (32)
Gear (28/33)
Gear (52/56)
Gear (20) (REP 13.13.2 )
Idler Gear Assembly
Gear
Cam (REP 13.13.2 )
Lever (Front)
Lever (Rear)
Decurler Roll 1 (Upper) (REP
13.13.1 )
Decurler Roll 2 (Lower) (REP
13.13.1 )
Reflector
Decurler Clutch
2)
Decurler Cam Sensor
Spring
Bearing
Bearing
Reissue
DocuColor 12/DCCS50
1/05
5-331
Parts Lists
PL 13.13
PL 13.14 Decurler Transport Roll

Item
Part
Description
1
2
007E54960
3
4
5
6
7
8
9
10
11
12
13
14
007E54980
007E54990
007E55000
407W08220
007E54970
022E19660
022E19670
022K51610
022K51621
127K24901
15
16
17
413W08350
413W75959
Gear (38)
Torque Limiter Gear (P/O PL 13.3
Item 2)
Gear (16)
Gear (32)
Gear (16)
Gear (20)
Gear (34)
Decurler Drive Roll
Decurler Drive Roll
Entrance Roll
Exit Roll
Motor Shaft (P/O PL 13.3 Item 2)
Decurler Stepping Motor (REP
13.14.1 )
Bearing
Bering
Parts Lists
PL 13.14
1/05
5-332
Reissue
DocuColor 12/DCCS50
PL 13.15 Cabinet
Item
1
2
3
4
5
6
7
8
Part
Description
021E96430
003K91881
Cabinet (P/O PL 13.3 Item 3)

Caster (P/O PL 13.3 Item 3)
Nut (P/O PL 13.3 Item 3)
Cap
Front Cover (P/O PL 13.3 Item 3)
Hinge (P/O PL 13.3 Item 3)
OCT Guide (P/O PL 13.3 Item 3)
Knob Screw
Reissue
DocuColor 12/DCCS50
1/05
5-333
Parts Lists
PL 13.15
PL 14.1 Offset Catch Tray

Item
Part
Description
1
2
3
4
5
6
7
8
9
050K36782
120E11991
007E40060
049E58660
127K18372
006E50190
013E85922
130E82190
10
11
12
13
14
15
16
015K30880
050E88161
130K60600
048E30000
17
18
19
20
21
22
23
049E86811
830E33491
809E08900
029E96861
026E68120
004K92210
Offset Catch Tray Assembly

Tray (Lower) (P/O PL 14.1 Item 1)
Actuator
Rack
Support
Offset Motor (REP 14.1.1 )
Shaft
Bearing
Offset Home Sensor, Offset Position Sensor
Plate
Tray
Full Stack Sensor
Cover
Topping Screw (M3 X 14) (P/O PL
14.1 Item 1)
Motor Cover
Baffle (P/O PL 14.1 Item 1)
Extention Plate
Spring
Rivet
Thumb Screw
Exit Poper Guide
Parts Lists
PL 14.1
1/05
5-334
Reissue
DocuColor 12/DCCS50
PL 19.1 IDFE Assembly and

Components
Item
Part
Description
1
2
3
600N01584
604K13420
600N01593
4
5
6
7
144N00070
152N01668
101N01175
IDFE Assembly (GL2) (REP 19.1 )

IDFE Assembly (MFY) (REP 19.1)
Cobra AUI to BNC Transceiver
(REP 19.2)
256MB Memory DIMM (REP 19.3 )
IDFE DC Wiring Harness
DDI Cable
IDFE Rear Cover (P/O PL 19.1
Item 1)
IDFE Housing (P/O PL 19.1 Item 1)
Reissue
DocuColor 12/DCCS50
1/05
5-335
Parts Lists
PL 19.1
PL 25.1 Electrical Connectors

Item
1
3
4
Part
Description
114E08970
913W01400
114E11400
113E24020
113E20900
913W01399
113E24030
114E18430
498K02510
Connector (P543)
Connector (P702)
Connector (P703)
Connector (P701)
Connector (J543)
Connector (J702)
Connector (J703)
Europe Converter
Adapter
Parts Lists
PL 25.1
1/05
5-336
Reissue
DocuColor 12/DCCS50
Common Hardware
Item
Part
Description
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
U
V
W
X
Y
Z
!!
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
AN
AP
AQ
AR
AS
AT
AU
AV
AW
AX
AY
112W27651
112W27851
112W27859
112W28051
112W28251
112W29151
112W29751
113W15551
113W20457
113W20657
113W20857
113W21057
113W21257
113W21651
113W21657
113W27451
113W27456
113W27551
113W27651
113W27851
113W28451
113W35657
113W35851
158W27663
158W35863
113W36051
113W36057
113W36251
113W36851
113W37457
113W38257
141W27351
141W27451
141W27851
141W35451
153W17655
153W17855
153W18055
153W18255
153W27650
153W27655
158W27655
158W27855
158W27863
158W28055
158W28255
158W28655
158W35655
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw (M2.5 X 14)
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Screw
(DB) Screw (M3 X 6)
(DR) Screw (M4 X 8)
Screw
Screw
Screw
Screw
Screw
Screw
Setscrew
Setscrew
Setscrew
Setscrew
Tapping Screw
Tapping Screw
Tapping Screw
Tapping Screw
Tapping Screw
Tapping Screw
Screw
Screw
Screw (M3 X 8)
Screw
Screw
Screw
Screw
Reissue
DocuColor 12/DCCS50
AZ
BA
BB
BC
BD
BE
BF
BG
BH
BJ
BK
BL
BM
BN
BP
BQ
BR
BS
BT
BU
BV
BW
BX
BY
BZ
CA
CB
CC
CD
CE
CF
CG
CH
CJ
CK
CL
CM
CN
CP
CQ
CR
CS
CT
CU
CW
CX
CY
CZ
DA
DB
DC
1/05
5-337
158W35855
158W36050
158W36255
158W36655
158W45055
201W21251
220W21250
251W19251
251W21251
251W24251
251W27251
252W26450
252W27350
252W27450
252W29350
252W29450
252W31350
271W21650
271W28050
271W28250
271W28650
271W28850
271W37150
285W16251
354W15251
354W19251
354W21251
354W20952
354W21254
354W24251
354W24254
354W26251
354W27251
354W27254
354W29251
354W29254
220W24350
285W15851
113W35857
252W27250
113W15851
113W28056
113W28251
141W27651
153W27850
158W27650
Screw (M4 X 16)

Screw
Screw
Screw
Screw
Screw
Nut (M3 )
Flange Nut (M3 )
Washer (2.5 )
Washer (3 )
Washer (4 )
Washer (6 )
Nylon Washer (5 )
Nylon Washer (6 )
Nylon Washer (6 )
Nylon Washer (8 )
Nylon Washer (8 )
Nylon Washer (10 )
Dowel (2.5 X 16 )
Dowel Pin (3 X 10 )
Dowel Pin (3 X 12 )
Dowel Pin (3 X 16 )
Dowel Pin (3 X 20 )
Dowel Pin (3 X 25 )
Dowel Pin (4 X 25 )
Dowel Pin (5 X 36 )
Spring Pin (2 X 12 )
E-clip (2 )
E-clip (2.5 )
E-clip (3 )
KL-Clip (3)
Kl-clip (3 )
E-clip (4 )
Kl-clip (4 )
E-clip (5 )
E-clip (6 )
Kl-clip (6 )
E-clip (8 )
Kl-clip (8 )
Flange Nut (M4 )
Spring Pin (2 X 8 )
Spring Pin (1.6 X 10 )
Screw
Nylon Washer (6 )
Screw
Screw
Screw
Setscrew
Tapping Screw
Screw (M3 X 6)
Screw
Parts Lists
Common Hardware
DD
DE
DF
DG
DH
DJ
DK
DL
DM
DN
DP
DQ
DR
DS
DT
DU
DV
DW
DX
DY
DZ
EA
EB
EC
ED
EE
EF
251W29251
153W16055
113W22557
113W35557
113W27656
113W35850
285W28651
285W29151
351W29250
113W28856
113W20557
102W27651
153W28050
112W25255
153W23452
354W00555
354W20852
354W20952
354W21052
153W23852
Setscrew (M4 X 5)
Washer (8 )
Tapping Screw
Tapping Screw (M3 X 10)
Screw
Screw
Screw (M4 X 16)
Spring Washer (12 )
Screw
Screw
Spring Pin (3-16 )
Screw (M4 X 8)
Retaining Clip (8 )
Screw
Dowel Pin Pin (3 X 22 )
Screw
Capscrew (M3 X 8)
Screw
Screw
Screw (M3 X 8)
Screw (M3 X 8)
Screw (2.9 X 9.5)
Retaining Ring (4MM)
Retaining Ring (5 - 7MM)
Retaining Ring (5 - 7mm)
Retaining Ring
Screw
Parts Lists
Common Hardware
1/05
5-338
Reissue
DocuColor 12/DCCS50
Part Number Index
Table 1 Part Number Index

Part Number
Part List
PL 13.1
Part Number
Part List
004E08250
PL 11.1
001E46411
PL 2.22
004K92210
PL 14.1
001E50590
PL 2.22
005K81600
PL 2.6
001K56820
PL 2.24
005K81750
PL 2.6
001K57333
PL 2.26
005K81760
PL 2.6
001K57693
PL 13.1
005K82400
PL 13.9
001K59370
PL 7.3
005K82470
PL 2.26
001K62603
PL 8.8
005K82490
PL 2.12
001K62613
PL 8.8
005K82730
PL 2.7B
003E36290
PL 13.12
005E83570
PL 13.5
PL 2.20
PL 13.8
PL 13.9
005E85181
PL 6.3
003E37791
PL 2.22
005E85760
PL 5.5
003E38110
PL 2.1
005E85810
PL 2.16
003E38120
PL 2.8
006E50190
PL 14.1
003E38130
PL 2.8
006E56290
PL 7.7
003E39980
PL 7.7
006E56620
PL 2.22
003E40140
PL 2.4
006E56632
PL 7.2
003E40151
PL 2.20
006E61320
PL 13.13
003E40250
PL 11.1
006K83280
PL 2.6
003E43840
PL 11.1
006K84003
PL 1.3
PL 12.11
006K84114
PL 7.10
003E46501
PL 13.11
006K84192
PL 5.1
003K83211
PL 13.11
006K84210
PL 2.17
003K84472
PL 2.23
007E22430
PL 2.12
003K84500
PL 2.8
007E23260
PL 2.12
003K84750
PL 2.18
007E30970
PL 2.2
003K84760
PL 2.18
003K84792
PL 2.23
007E31090
PL 2.6
003K85090
PL 11.1
007E31160
PL 2.11
003K85101
PL 13.11
007E31180
PL 2.11
PL 13.4
007E39390
PL 12.4
003K85453
PL 8.5
007E39400
PL 12.4
003K85483
PL 8.5
007E39410
PL 12.4
003K85570
PL 13.11
007E39420
PL 12.4
003K85731
PL 8.5
007E39430
PL 12.4
003K85851
PL 2.22
007E40060
PL 14.1
003K85871
PL 2.22
007E45091
PL 13.13
003K91881
PL 12.3
007E46502
PL 7.6
PL 13.15
007E46530
PL 7.10
Reissue
DocuColor 12/DCCS50
PL 2.3
1/05
5-339
Parts Lists
Part Number Index
Part Number
Part List
Part Number
Part List
007E46541
PL 7.10
007E51490
PL 1.6
007E46551
PL 7.10
007E51500
PL 8.6
007E46610
PL 2.17
007E51580
PL 2.7A
007E46650
PL 6.6
007E51630
PL 2.24
007E46680
PL 6.4
007E51641
PL 2.24
007E46700
PL 6.4
007E51680
PL 1.6
007E46710
PL 6.3
007E51790
PL 1.3
007E46720
PL 6.4
007E51800
PL 1.3
007E46740
PL 6.4
007E51810
PL 1.3
007E46760
PL 6.4
007E51830
PL 5.5
007E46780
PL 6.4
007E51840
PL 2.19
007E46820
PL 6.6
007E51980
PL 8.4
007E46880
PL 1.5
007E52030
PL 5.5
007E46890
PL 1.5
007E52040
PL 5.5
007E49650
PL 6.4
007E52050
PL 5.5
007E49730
PL 8.2
007E52130
PL 2.6
007E49740
PL 8.6
007E52140
PL 2.6
007E49760
PL 8.6
007E52150
PL 2.6
007E49781
PL 2.17
007E52161
PL 2.6
007E49831
PL 8.2
007E52171
PL 2.6
007E49940
PL 1.4
007E52210
PL 2.5
007E49950
PL 1.4
007E52220
PL 2.5
007E49980
PL 1.2
007E52230
PL 2.5
007E50030
PL 1.3
007E52240
PL 2.5
007E50042
PL 1.3
007E52250
PL 1.5
007E50052
PL 1.3
007E52280
PL 1.1
007E50112
PL 1.2
007E52290
PL 1.3
007E50120
PL 1.2
007E54910
PL 2.12
007E50130
PL 2.24
007E54960
PL 13.14
007E50140
PL 2.24
007E54970
PL 13.14
007E50250
PL 2.12
007E54980
PL 13.14
007E50270
PL 1.6
007E54990
PL 13.13
007E50280
PL 1.6
007E50410
PL 2.2
007E55000
PL 13.14
PL 2.3
007E55010
PL 13.13
PL 2.2
007E55030
PL 13.13
PL 2.3
007E55040
PL 13.13
PL 2.2
007E55221
PL 1.1
PL 2.3
007E55230
PL 1.1
007E51370
PL 2.15
007E55351
PL 13.10
007E51430
PL 2.12
007E55361
PL 13.10
007E50420
007E50430
Parts Lists
Part Number Index
PL 13.14
1/05
5-340
Reissue
DocuColor 12/DCCS50
Part Number
Part List
Part Number
Part List
007E56010
PL 2.7A
007K84701
PL 1.2
007E56020
PL 2.7A
007K84731
PL 2.7A
007E56030
PL 2.7A
007K84800
PL 1.6
007E56210
PL 2.6
007K84820
PL 1.2
007E56970
PL 13.10
007K84871
PL 1.1
007E57660
PL 1.4
007E84880
PL 8.10
007E66030
PL 2.13
007K84881
PL 6.6
007K81120
PL 12.8
007K84922
PL 1.6
007E82390
PL 8.4
007K85270
PL 8.8
007E83141
PL 12.10
007E91170
PL 2.24
007E83260
PL 12.6
007K91860
PL 12.8
007K83610
PL 2.6
007K91871
PL 12.6
007K84110
PL 1.6
008E93090
PL 7.7
007K84120
PL 8.2
008E93160
PL 8.6
007K84130
PL 8.6
008E93250
PL 7.7
007K84140
PL 8.6
008E93261
PL 2.22
007K84160
PL 1.4
008E93270
PL 7.7
007K84170
PL 1.2
008E93390
PL 13.13
007K84231
PL 1.4
008E93400
PL 7.2
007K84240
PL 1.4
009E28560
PL 12.8
007K84251
PL 1.4
009E28570
PL 12.8
007K84265
PL 1.4
009E28580
PL 12.8
007K84282
PL 1.3
009E32160
PL 1.1
007K84291
PL 1.3
009E34940
PL 6.4
007K84313
PL 1.5
009E39080
PL 12.8
007K84332
PL 1.3
009E43970
PL 7.2
007K84360
PL 1.6
009E53370
PL 2.13
007K84415
PL 2.7A
009E56020
PL 2.10
007K84422
PL 2.7A
009E56030
PL 2.10
007K84468
PL 1.3
009E59690
PL 8.10
007K84553
PL 1.6
007K84577
PL 1.6
009P61135
PL 2.16
007K84593
PL 5.2
009E61300
PL 2.6
007K84601
PL 2.24
009E62420
PL 2.26
007K84634
PL 1.2
009E62830
PL 3.3
007K84641
PL 1.2
009P62935
PL 5.4
007K84650
PL 1.2
009P62975
PL 1.5
007K84662
PL 1.1
009E63110
PL 2.8
007K84671
PL 1.1
009E64140
PL 13.6
007K84680
PL 1.1
PL 13.8
007K84690
PL 1.6
PL 13.7
Reissue
DocuColor 12/DCCS50
PL 8.3
1/05
5-341
Parts Lists
Part Number Index
Part Number
Part List
Part Number
Part List
009E71890
PL 12.5
013K81260
PL 5.5
009E73310
PL 9.4
013K81270
PL 5.5
009E76430
PL 2.11
013K81510
PL 7.6
009E81210
PL 9.4
013E82490
PL 2.15
009E84150
PL 5.5
009E84220
PL 2.23
013E83380
PL 2.8
PL 2.24
013E83730
PL 2.2
009E94910
PL 13.4
013E85430
PL 7.6
011E07092
PL 7.1
013E85922
PL 14.1
011E07950
PL 2.8
013E87551
PL 8.5
011E08010
PL 5.5
013E87600
PL 8.8
011E08021
PL 5.5
013E87620
PL 8.8
011E08031
PL 2.20
013E87700
PL 8.2
011E08041
PL 2.20
011E08050
PL 2.5
013E87730
PL 8.6
011E08060
PL 2.5
013E88020
PL 2.15
011E08071
PL 2.5
011E08081
PL 7.7
011E08111
PL 2.22
011E08640
PL 6.5
013E88310
PL 7.6
011K90420
PL 2.19
013E89540
PL 13.5
011K93990
PL 5.5
PL 13.6
011K94030
PL 8.6
PL 13.8
011K94040
PL 8.6
011K94050
PL 2.24
013E92760
PL 12.4
011K94091
PL 6.1
013E94320
PL 8.9
011K94141
PL 5.5
013E94380
PL 8.9
011K94150
PL 5.5
013E94561
PL 12.8
011K94160
PL 5.5
014K81273
PL 8.5
011K94391
PL 2.26
014E87701
PL 7.2
011K94401
PL 13.13
015K28141
PL 13.13
011K94411
PL 13.13
015K29634
PL 7.1
012K93440
PL 3.3
015K29910
PL 6.4
012K93450
PL 3.3
015K30880
PL 14.1
012E98070
PL 7.7
015K31460
PL 2.2
012E98080
PL 7.7
015K31853
PL 13.2
012E98271
PL 2.23
015K31860
PL 13.2
012E98281
PL 2.5
015K31871
PL 13.2
013E15290
PL 2.5
015K33670
PL 8.6
013P60566
PL 12.6
015K33973
PL 2.18
013E80970
PL 12.10
015K33986
PL 9.1
Parts Lists
Part Number Index
PL 2.16
PL 8.8
PL 2.16
013E88030
PL 2.15
PL 2.16
PL 13.7
1/05
5-342
Reissue
DocuColor 12/DCCS50
Part Number
Part List
015K34310
PL 2.2
PL 13.8
015K35800
PL 7.10
PL 13.6
015K35842
PL 7.5
015K35862
PL 13.2
020E22160
PL 12.4
015K36962
PL 7.1
020E25090
PL 3.3
015K36972
PL 7.1
020E25100
PL 3.3
015K37641
PL 3.1
020E26710
PL 5.5
015K38560
PL 9.1
020E26990
PL 5.5
015K39880
PL 7.10
020K91230
PL 12.6
015K41370
PL 2.2
020E93230
PL 12.9
015K41381
PL 2.2
020E93240
PL 12.9
015K41503
PL 2.3
020K94970
PL 3.3
015K48190
PL 13.10
021E96430
PL 13.15
015E48890
PL 12.2
022E19660
PL 13.14
015E48900
PL 12.2
022E19670
PL 13.14
015E54911
PL 6.4
022K37070
PL 12.6
015E58040
PL 2.23
022K37080
PL 12.6
015K83700
PL 12.11
022K38040
PL 12.8
017E92140
PL 3.3
022K39700
PL 12.10
017E93743
PL 11.2
022K39710
PL 12.10
017E93753
PL 11.2
022K43710
PL 13.5
019E33780
PL 6.7
022K43720
PL 13.9
019E33860
PL 8.10
022K46560
PL 12.5
019E39131
PL 2.2
022K48240
PL 13.9
PL 2.3
022K48250
PL 8.10
019E39442
PL 6.6
022K48260
PL 8.10
019E39570
PL 8.7
022K51610
PL 13.14
019E42010
PL 8.3
022K51621
PL 13.14
019E49780
PL 8.7
022K57120
PL 13.13
019E50400
PL 3.4
022K57130
PL 13.13
019E92320
PL 12.9
022K62370
PL 8.9
019K93320
PL 2.13
022K65790
PL 13.3
019K94202
PL 8.10
022E83451
PL 13.5
019K94221
PL 6.7
PL 13.7
019K94230
PL 6.7
PL 13.8
019K94332
PL 6.5
019K94390
PL 2.2
022E83460
PL 13.10
019K94400
PL 2.3
022E93660
PL 12.6
019K94651
PL 8.3
023E12230
PL 12.6
020E21050
PL 12.6
023E12610
PL 12.4
020E21490
PL 13.5
023E13160
PL 13.10
Reissue
DocuColor 12/DCCS50
Part Number
Part List
PL 13.7
PL 13.6
1/05
5-343
Parts Lists
Part Number Index
Part Number
Part List
Part Number
Part List
023E15480
PL 2.17
038K84621
PL 2.3
023E15550
PL 3.3
038E86180
PL 13.5
023E15690
PL 12.10
038E88641
PL 2.2
023E92341
PL 12.6
038E88650
PL 2.2
023E94140
PL 12.6
038E88772
PL 2.26
026E56431
PL 9.2
038E88922
PL 2.3
026E58330
PL 6.5
038E88980
PL 13.5
026P63503
PL 8.3
026E68120
PL 14.1
026K80720
PL 8.6
038E89060
PL 2.13
026K80730
PL 6.5
038E89071
PL 2.19
026K80740
PL 6.5
038E89072
PL 2.19
026K80750
PL 6.5
039K90592
PL 8.7
029E21610
PL 13.1
041K93792
PL 3.4
029E26180
PL 7.9
041K94210
PL 3.4
029E26770
PL 7.7
042K91650
PL 7.6
029E96861
PL 14.1
042K91811
PL 5.3
031K92410
PL 7.10
042K91906
PL 7.1
031K92420
PL 7.10
048E30000
PL 14.1
031E92550
PL 12.2
048E52741
PL 8.1
031E93022
PL 7.7
048E60670
PL 11.2
031E94101
PL 7.7
048E60690
PL 11.2
032E10010
PL 2.11
048E60741
PL 11.2
032E10210
PL 13.2
048E60750
PL 11.2
032E10250
PL 2.5
048E60762
PL 11.2
032E13130
PL 2.16
048E60772
PL 11.3
032K93621
PL 2.18
048E60781
PL 11.3
032K93800
PL 12.1
048E60790
PL 11.3
033K92892
PL 8.9
048E61482
PL 2.8
033K92970
PL 5.3
048K61601
PL 7.6
033K93272
PL 7.8
048K61638
PL 6.6
035E40661
PL 5.3
048K61830
PL 6.4
035E40690
PL 5.3
048K61840
PL 6.4
035E45550
PL 5.5
048E61921
PL 11.1
035E48290
PL 7.8
048E61933
PL 11.3
035E48300
PL 7.8
048E61941
PL 11.3
035K81498
PL 7.8
048E61950
PL 11.3
036K91420
PL 12.3
048K61963
PL 6.5
036K91431
PL 12.3
048E62151
PL 3.5
038K14700
PL 2.13
048E62452
PL 11.1
038K83973
PL 2.3
048E62462
PL 11.1
Parts Lists
Part Number Index
PL 13.7
PL 13.6
1/05
5-344
Reissue
DocuColor 12/DCCS50
Part Number
Part List
Part Number
Part List
048E64201
PL 12.1
049E86030
PL 8.8
048E64910
PL 7.10
049E86040
PL 8.8
048E64920
PL 7.5
049E86360
PL 8.3
048E65041
PL 9.1
049E86370
PL 8.3
048E65171
PL 11.3
049E86600
PL 8.3
048K65250
PL 2.8
049E86811
PL 14.1
048E65330
PL 11.3
049E91070
PL 12.10
048E65341
PL 11.3
050E17450
PL 8.7
048E65391
PL 11.3
050K27660
PL 12.5
048K65660
PL 5.1
050K27670
PL 12.7
048E65721
PL 13.11
050K30120
PL 13.9
048E65730
PL 13.11
050K33129
PL 2.1
048E65740
PL 13.11
050K33220
PL 13.6
048K65921
PL 2.15
048E66221
PL 11.1
048E66331
PL 11.1
050K34065
PL 2.19
048E66520
PL 13.4
050K36410
PL 12.1
048E66540
PL 13.4
050K36421
PL 12.11
048E66560
PL 13.4
050K36514
PL 2.23
048E66571
PL 13.4
050K36782
PL 14.1
048E66581
PL 13.4
050K36801
PL 13.8
048K69086
PL 7.10
050K36812
PL 13.7
048K69818
PL 11.2
050K36822
PL 13.6
048K71213
PL 11.1
050K36832
PL 13.5
048K71860
PL 3.2
050K36851
PL 2.25
048K76181
PL 12.1
050K40941
PL 2.1
048K76341
PL 11.3
050K43870
PL 12.8
048K76720
PL 6.5
050E87465
PL 2.2
048K76921
PL 4.1
050E88159
PL 2.3
048K76941
PL 9.2
050E88161
PL 14.1
048K77228
PL 6.6
050E88440
PL 11.1
048K77264
PL 7.1
050E88781
PL 13.5
048K77410
PL 13.3
PL 13.6
048K77420
PL 13.11
PL 13.8
048K77462
PL 11.2
048K77776
PL 9.5
052K91470
PL 6.7
048K77952
PL 13.4
052E92750
PL 8.7
048K77971
PL 13.4
052E93181
PL 8.7
049E58660
PL 14.1
052E93460
PL 5.5
049E77290
PL 13.4
052E93470
PL 5.5
049E85681
PL 6.5
052E93480
PL 5.5
Reissue
DocuColor 12/DCCS50
PL 13.8
PL 13.7
PL 13.7
1/05
5-345
Parts Lists
Part Number Index
Part Number
Part List
Part Number
Part List
052E93640
PL 5.5
054E88220
PL 2.4
052E93920
PL 8.7
054E88230
PL 2.4
052E96630
PL 8.7
054K99181
PL 10.1
053K91410
PL 10.2
054K99191
PL 10.1
053K91420
PL 10.2
055K19260
PL 12.5
053K91430
PL 10.2
055E30790
PL 6.2
053E92650
PL 8.7
059K05750
PL 2.20
054K06692
PL 12.7
059K05780
PL 2.20
054K10114
PL 8.10
059K06831
PL 2.7B
054K10115
PL 8.10
059K07800
PL 7.6
054K10151
PL 5.1
059K07812
PL 7.6
054K10303
PL 2.24
059K07843
PL 7.6
054K10317
PL 2.25
059K07882
PL 7.7
054K10323
PL 2.26
059K08160
PL 7.6
054K10333
PL 2.26
059K08590
PL 13.12
054K10341
PL 2.8
054K10350
PL 2.8
059K08600
PL 2.19
054E10780
PL 2.8
059K08610
PL 2.21
054K11072
PL 2.15
059K08621
PL 2.21
054K11090
PL 2.16
059K08686
PL 2.23
054K11161
PL 2.26
059K08760
PL 2.15
054K11220
PL 8.7
059K08770
PL 2.16
054K11363
PL 2.19
059K08780
PL 2.16
054K11373
PL 2.19
059K08790
PL 2.15
054K11395
PL 2.18
059K08821
PL 2.9
054K11416
PL 2.18
059K08831
PL 2.10
054K11512
PL 2.23
059K08840
PL 2.12
054K13082
PL 12.9
059K08850
PL 2.11
054K13591
PL 12.5
059K09022
PL 2.24
054K13600
PL 12.4
059K09030
PL 2.24
054K13622
PL 12.2
059K09040
PL 2.24
054K13920
PL 13.12
059K09331
PL 2.21
054K14091
PL 13.9
059K09341
PL 2.21
054K14102
PL 13.9
059K09350
PL 2.21
054K14131
PL 13.9
059K09490
PL 5.5
054K14675
PL 2.25
059K09500
PL 5.5
054K15550
PL 13.12
059K09510
PL 5.5
054K18770
PL 12.9
059K09532
PL 5.3
054K18790
PL 12.7
059K09561
PL 2.5
054K19721
PL 7.10
059K09591
PL 2.6
054E88182
PL 7.10
059K09930
PL 2.7B
Parts Lists
Part Number Index
PL 13.9
1/05
5-346
Reissue
DocuColor 12/DCCS50
Part Number
Part List
Part Number
Part List
059K09948
PL 2.4
068K14541
PL 5.5
059K10025
PL 2.14
068K14550
PL 5.5
059K10122
PL 2.17
068K14921
PL 13.2
059K11821
PL 12.9
068K15350
PL 13.9
059K11830
PL 12.8
068K21850
PL 8.7
059K11840
PL 12.4
068K86934
PL 6.1
059K11850
PL 12.7
068K87041
PL 6.5
059K11860
PL 12.9
068K87161
PL 8.1
059K11870
PL 12.10
068K87410
PL 8.6
059K11880
PL 12.2
090K92572
PL 12.11
059K12140
PL 2.20
059K12460
PL 13.9
093E91961
PL 8.7
059K12471
PL 13.9
094K91307
PL 6.2
059K13021
PL 7.10
096E75850
PL 6.6
059K13261
PL 13.7
096E75860
PL 6.6
059K13440
PL 12.10
096E75870
PL 6.6
059K14186
PL 7.9
096E75880
PL 6.6
059K14872
PL 2.26
099P03019
PL 6.1
059K17861
PL 13.3
101N01175
PL 19.1
059K23063
PL 12.1
101K24030
PL 9.4
059K24360
PL 8.5
101K31295
PL 9.3
059K31171
PL 2.9
101K31312
PL 9.3
059K33080
PL 2.23
101K31322
PL 9.3
059K39500
PL 8.3
101K31342
PL 9.3
059K39670
PL 8.3
101K31352
PL 9.3
059E90770
PL 2.10
101K33185
PL 9.3
059E92720
PL 7.7
103E24040
PL 9.6
059E92780
PL 8.8
105E06910
PL 12.9
059E92841
PL 2.26
105E07314
PL 9.3
059E92850
PL 2.24
105E07322
PL 3.5
059E92920
PL 2.8
105E07344
PL 9.3
059E92950
PL 2.17
105E07351
PL 3.5
059E92980
PL 2.20
105E08900
PL 3.4
062K10670
PL 4.1
105K14062
PL 7.6
062E98370
PL 3.4
105K14914
PL 9.2
062E98380
PL 3.4
105K14923
PL 2.14
062E98711
PL 13.13
105E98090
PL 9.3
063E94040
PL 3.3
105E98110
PL 9.3
063E94050
PL 3.3
105E98450
PL 13.5
064K91243
PL 7.5
PL 13.7
068K14170
PL 2.8
PL 13.6
Reissue
DocuColor 12/DCCS50
PL 3.1
1/05
5-347
Parts Lists
Part Number Index
Part Number
Part List
Part Number
Part List
105E98690
PL 13.9
117K22350
PL 9.1
PL 2.25
117K23770
PL 9.1
105E99122
PL 9.1
117E25300
PL 9.1
106K90640
PL 6.7
117K31400
PL 9.1
106K90650
PL 6.7
117K92100
PL 5.4
106K90660
PL 6.7
118E12090
PL 3.4
106K90670
PL 6.7
118E12110
PL 9.3
107E06650
PL 3.2
118E12251
PL 5.4
108E94360
PL 9.3
118K91900
PL 5.4
109E93220
PL 9.3
119K90765
PL 5.5
109E93230
PL 9.3
120E11991
PL 14.1
109E93260
PL 9.3
120E12630
PL 8.6
PL 9.6
120E13100
PL 2.10
110K08471
PL 3.2
120E13130
PL 13.5
110K08600
PL 13.4
110K10460
PL 2.1
110K91391
PL 13.12
110K91972
PL 12.2
110E93440
PL 2.12
PL 13.6
PL 13.7
120E17020
PL 13.5
PL 13.7
PL 13.6
PL 2.24
121K14541
PL 13.9
110E97990
PL 13.11
121K14881
PL 1.3
113E20900
PL 25.1
121K16372
PL 2.24
113E22970
PL 2.9
121K16383
PL 2.25
113E24020
PL 2.22
121K16401
PL 6.1
PL 25.1
121K16800
PL 8.4
PL 2.12
121K17550
PL 2.9
PL 25.1
121K17561
PL 2.11
113E24030
114E08970
PL 25.1
114E11390
PL 2.22
121K17941
PL 1.3
114E11400
PL 2.9
121K19230
PL 13.9
PL 25.1
121K21612
PL 1.6
114E18430
PL 25.1
121K30050
PL 1.5
114K81062
PL 5.1
114K81082
PL 5.2
114K81362
PL 5.2
115K91133
PL 6.1
115K91160
PL 5.2
121K83981
PL 13.13
117E10550
PL 9.1
121K86550
PL 12.2
117E15951
PL 3.5
121K87790
PL 12.2
117E15970
PL 3.4
121K87800
PL 12.5
117E22350
PL 9.1
121K87810
PL 12.5
Parts Lists
Part Number Index
PL 2.5
PL 2.7A
121E83120
PL 13.6
PL 13.8
PL 13.7
1/05
5-348
Reissue
DocuColor 12/DCCS50
Part Number
Part List
Part Number
Part List
121E89780
PL 13.12
127K24901
PL 13.14
PL 2.9
127K24943
PL 13.10
PL 13.11
127K24952
PL 13.10
PL 13.3
127K27590
PL 12.4
121E90620
PL 11.1
127K27910
PL 8.4
121E90640
PL 12.7
127K28490
PL 6.1
121K93870
PL 12.2
127K32940
PL 6.3
122E92000
PL 3.4
127K83520
PL 12.6
122K92892
PL 5.1
130K57350
PL 8.8
125K03650
PL 5.4
130K57370
PL 8.6
125K93062
PL 5.4
130K57380
PL 8.6
126K07960
PL 8.3
130K57390
PL 8.4
126K07970
PL 8.3
130K57400
PL 8.4
126K07980
PL 8.8
130K57430
PL 8.4
126K08510
PL 8.3
130K57471
PL 8.4
126K08520
PL 8.3
130K57490
PL 8.4
126K08530
PL 8.8
130K57690
PL 7.1
127K18372
PL 14.1
130K57720
PL 5.1
127K21270
PL 6.3
130K57810
PL 2.24
127K21301
PL 1.6
130K57820
PL 2.25
127K21311
PL 1.5
130K57930
PL 6.5
127K21321
PL 1.2
130K57940
PL 8.7
127K21351
PL 8.4
130K57973
PL 7.5
127K21410
PL 8.7
130K57990
PL 3.2
127K21513
PL 3.3
130K58001
PL 2.13
127K21661
PL 2.24
130K58030
PL 2.16
127K21671
PL 1.1
130K58070
PL 2.10
127K21750
PL 9.2
130K59660
PL 2.25
127K21761
PL 10.1
130K60561
PL 9.1
127K21770
PL 10.2
130K60600
PL 14.1
127K21780
PL 10.2
127K21801
PL 10.1
127K21822
PL 10.2
130K60770
PL 2.8
127K21871
PL 2.15
130E80100
PL 13.9
127K23051
PL 2.7A
130E80890
PL 12.5
127K23191
PL 2.19
127K23230
PL 2.6
127K23470
PL 2.12
PL 7.9
127K23590
PL 3.2
PL 7.3
127K24060
PL 12.9
PL 6.1
127K24070
PL 12.9
PL 2.5
121E90490
Reissue
DocuColor 12/DCCS50
PL 2.15
PL 7.10
PL 12.9
130E82190
1/05
5-349
PL 1.4
Parts Lists
Part Number Index

Part Number
Part List
Part Number
Part List
PL 2.12
160K46113
PL 3.5
PL 2.11
160K46120
PL 8.4
PL 2.10
160K46290
PL 2.15
PL 2.1
160K47911
PL 9.2
PL 14.1
160K48230
PL 3.2
130E82530
PL 13.13
160K48351
PL 9.3
130E82650
PL 2.5
160K48688
PL 9.2
PL 2.8
160K48704
PL 9.2
130E82720
PL 6.3
160K51502
PL 12.3
130K82921
PL 5.2
160K51931
PL 3.2
130E82970
PL 13.12
160K52902
PL 13.12
130E84270
PL 7.5
160K53431
PL 13.5
130K87150
PL 3.2
130K87380
PL 6.1
160K53462
PL 3.5
130K87470
PL 8.6
160K56450
PL 13.10
130K87500
PL 8.8
160K57369
PL 3.5
130K87520
PL 8.8
160K57375
PL 3.5
130E91010
PL 5.2
160K60380
PL 3.5
130E91120
PL 7.10
160K60770
PL 9.3
130E91220
PL 12.5
160K61560
PL 9.6
PL 12.7
160K61611
PL 9.2
130K92950
PL 8.10
160K61620
PL 9.2
130K93210
PL 2.21
160K74412
PL 9.2
130K93220
PL 2.24
160K80150
PL 9.4
130K94740
PL 13.9
160K84771
PL 3.5
140K60480
PL 12.1
162K36860
PL 9.3
144N00070
PL 19.1
162K36960
PL 8.5
152N01668
PL 19.1
162K37050
PL 8.5
152S05104
PL 9.1
162K37160
PL 2.8
152S05105
PL 9.1
162K37360
PL 7.3
152S05106
PL 9.1
162K41511
PL 9.2
152S05107
PL 9.1
162K41521
PL 9.2
152S05120
PL 9.1
162K42260
PL 9.2
152S05121
PL 9.1
162K43311
PL 12.3
152S05122
PL 9.1
162K47050
PL 13.10
152S05123
PL 9.1
162K47062
PL 13.10
160K29150
PL 9.4
162K47500
PL 13.10
160K42710
PL 3.5
162K47510
PL 13.10
160K42851
PL 4.1
407W08220
PL 13.14
160K45930
PL 6.4
407W08222
PL 1.5
160K45940
PL 9.3
407W08223
PL 1.5
Parts Lists
Part Number Index
PL 13.9
1/05
5-350
Reissue
DocuColor 12/DCCS50
Part Number
Part List
Part Number
Part List
407W08273
PL 1.5
600K82900
PL 6.1
407W08328
PL 1.5
600K82960
PL 2.13
413W08350
PL 13.13
600K83451
PL 6.5
PL 13.14
600K83590
PL 2.26
PL 5.5
600K83631
PL 8.9
413W10650
PL 8.6
600K83650
PL 9.5
413W11660
PL 6.3
600K84050
PL 8.5
PL 6.4
600K84700
PL 11.3
413W66250
PL 2.26
600K85872
PL 1.4
413W75959
PL 13.13
600K85970
PL 2.13
PL 2.6
600K86001
PL 4.1
PL 13.9
600K86080
PL 1.1
PL 13.14
600K86096
PL 7.1
PL 7.10
600K90370
PL 12.4
413W77359
PL 2.17
604K00836
PL 8.1
413W77559
PL 12.4
604K00846
PL 8.1
PL 13.5
604K01911
PL 8.7
PL 13.6
604K07960
PL 2.13
PL 8.10
604K08100
PL 8.2
PL 5.5
604K13420
PL 19.1
PL 13.8
604K14830
PL 1.4
PL 13.7
604K22290
PL 5.4
413W88650
PL 5.5
606K91040
PL 9.1
423W07753
PL 12.9
673K51383
PL 12.11
423W10055
PL 2.21
802K04428
PL 5.3
423W11055
PL 2.21
802K04681
PL 11.3
423W55355
PL 1.3
802K06232
PL 11.2
423W57554
PL 1.4
802K07903
PL 13.3
423W82054
PL 5.5
802K08320
PL 12.4
423W82555
PL 2.19
802K08530
PL 13.4
498K02510
PL 25.1
802K08652
PL 6.3
537K43720
PL 9.4
802K08662
PL 6.3
537K49510
PL 9.4
802K08672
PL 6.3
537K51016
PL 12.3
802K08682
PL 6.3
539K90924
PL 13.10
802K08850
PL 6.5
600N01584
PL 19.1
802K09190
PL 13.5
600N01593
PL 19.1
802E30660
PL 2.25
600K74790
PL 2.7B
802K31420
PL 11.3
600K79560
PL 2.26
802K31691
PL 9.5
600K82710
PL 7.5
802E61670
PL 11.3
600K82870
PL 11.2
802E61690
PL 11.2
Reissue
DocuColor 12/DCCS50
1/05
5-351
Parts Lists
Part Number Index
Part Number
Part List
Part Number
Part List
809E02991
PL 13.11
809E19530
PL 2.5
809E06330
PL 7.6
809E19540
PL 2.5
809E06360
PL 7.7
809E19560
PL 2.6
809E06370
PL 7.10
809E20210
PL 2.20
809E06380
PL 7.10
830E09140
PL 2.6
809E06401
PL 7.8
830E09800
PL 9.3
809E06530
PL 8.7
830E09840
PL 2.9
809E06550
PL 6.7
830E17550
PL 9.3
809E06730
PL 8.3
830E17801
PL 13.2
809E06770
PL 8.8
830E17961
PL 2.9
809E06790
PL 6.3
830E19412
PL 13.1
809E07770
PL 2.8
830E20010
PL 11.1
809E07780
PL 2.8
830E32600
PL 13.5
809E08090
PL 2.15
PL 13.8
809E08690
PL 1.3
PL 13.7
809E08810
PL 6.5
809E08900
PL 14.1
830E33491
PL 14.1
809E09040
PL 2.20
830E81410
PL 7.6
809E09100
PL 2.6
891E48750
PL 2.1
809E09110
PL 3.4
891E49060
PL 2.1
809E09150
PL 2.21
891E49510
PL 2.1
809E09171
PL 2.22
891E49520
PL 2.1
809E09180
PL 2.22
891E50480
PL 8.2
809E09190
PL 8.2
891E51561
PL 2.18
809E09210
PL 2.22
891E51571
PL 2.18
809E09410
PL 2.10
891E51581
PL 2.9
PL 2.11
891E51590
PL 2.9
809E09430
PL 2.15
891E51600
PL 2.9
809E09470
PL 2.10
891E65180
PL 12.1
809E09530
PL 2.26
891E65210
PL 12.1
809E11120
PL 12.5
891E73331
PL 13.9
809E11130
PL 12.2
891E73431
PL 13.9
809E14570
PL 13.13
891E73441
PL 13.4
809E14710
PL 2.20
891E73451
PL 13.4
809E15180
PL 6.1
891E73880
PL 2.9
809E15210
PL 3.4
891E73900
PL 2.9
809E16580
PL 2.20
891E73914
PL 2.9
809E16590
PL 2.20
891E73971
PL 2.9
809E17001
PL 7.8
891E73982
PL 2.9
809E17010
PL 7.8
891E74003
PL 6.2
809E19010
PL 8.7
891E74014
PL 6.2
Parts Lists
Part Number Index
PL 13.6
1/05
5-352
Reissue
DocuColor 12/DCCS50

Part Number
Part List
891E74023
PL 6.2
891E74033
PL 6.2
891E74062
PL 2.18
891E75721
PL 11.2
891E75951
PL 11.2
891E75990
PL 8.2
891E76001
PL 8.2
891E76010
PL 8.2
891E76020
PL 8.2
891E76040
PL 8.2
891E76090
PL 2.1
891E77561
PL 12.1
891E78020
PL 2.1
891E78030
PL 2.1
891E80400
PL 2.1
891E80410
PL 2.1
891E80420
PL 2.1
891E80481
PL 2.1
891E82980
PL 2.1
891E82991
PL 2.25
892E02000
PL 11.2
908W00131
PL 9.3
908W00134
PL 9.3
908W00909
PL 9.3
908W00914
PL 9.3
910W00122
PL 9.1
910W00211
PL 9.1
913W01399
PL 25.1
913W01400
PL 25.1
913W02310
PL 8.5
962K01810
PL 9.1
962K01820
PL 9.1
962K01830
PL 9.1
962K01840
PL 9.1
Reissue
DocuColor 12/DCCS50
1/05
5-353
Parts Lists
Part Number Index
Parts Lists
Part Number Index
1/05
5-354
Reissue
DocuColor 12/DCCS50
6 General Procedures & Information

General Procedures
GP 1 Fuser Break-In Procedure......................................................................................
GP 2 Increased Imageable Area Setup .........................................................................
GP 4 Intermittent Problem RAP ......................................................................................
GP 5 Verifying the Administration Tools Password.........................................................
GP 6 Verifying the Auditron Password............................................................................
GP 7 Verifying Tools Mode Password ............................................................................
GP 8 IDFE Power OFF/Power ON (PO/PO) Procedure .................................................
GP 9 IDFE Software Installation (CD-ROM) Procedure..................................................
GP 10 Replacing Billing PWBs ......................................................................................
GP 11 PWS (Diagnostics) Software Installation Procedure............................................
GP 12 Printing Configuration Reports .............................................................................
GP 13 Printing a Complex Test Page .............................................................................
GP 15 Setting the Machine for a Time & Materials (T & M) Account ..............................
GP 16 Setting the Machine to recognize the Sorter as a Mailbox...................................
GP 17 IDFE Software Update (CD-ROM) .......................................................................
GP 18 IOT UI Language Change....................................................................................
GP 20 2nd BTR Service Procedure ...............................................................................
dC131 Developer NVM List (776) ...................................................................................

dC131 Fuser NVM List (777)...........................................................................................
dC131 Sorter/Finisher NVM List (780)(790)....................................................................
dC132 Serial Number/Billing Meter Synchronization ......................................................
dC135 HFSI Counters .....................................................................................................
dC135 HFSI Counter List ................................................................................................
dC140 Analog Monitor.....................................................................................................
dC188 How to Exit from Service Mode ...........................................................................
dC301 NVM Initialization .................................................................................................
dC305 UI Component Check ..........................................................................................
dC330 Component Control..............................................................................................
dC351 NVM Initialize, Save/Restore ...............................................................................
dC361 NVM Save/Restore ..............................................................................................
dC371 Configuration Page ..............................................................................................
dC391 Edit Pad ..............................................................................................................
dC612 Color Test Pattern Print .......................................................................................
dC701 Fuser Nip Measurement ......................................................................................
dC740 Tray 5 Guide Adjustment .....................................................................................
dC915 Machine Output ..................................................................................................
dC918 IOT Highlight Setup .............................................................................................
dC919 Color Balance Setup (IIT installed machine only)................................................
dC920 Developer Unit Check..........................................................................................
dC922 TRC Control/Toner Density Adjustment ..............................................................
dC923 PROCON PG.......................................................................................................
dC924 TRC Adjust / dC939 TRC Check PG ...................................................................
dC929 Max Setup............................................................................................................
dC933 VH/VM Setup .......................................................................................................
dC934 ADC/AGC Setup ..................................................................................................
dC945 IIT Calibration ......................................................................................................
6-3
6-4
6-4
6-5
6-8
6-11
6-11
6-12
6-13
6-13
6-14
6-14
6-15
6-15
6-16
6-17
6-17
PWS Diagnostics
Entering the Service Diagnostic Mode using the PWS ...................................................
DC Quick (CODE Number LIST).....................................................................................
dC100 Service Entry .......................................................................................................
dC110 Displaying the CRU-Related Data .......................................................................
dC118 Jam Counter ........................................................................................................
dC120 Fail Counter .........................................................................................................
dC122 Shutdown History ................................................................................................
dC129 System Registration Adjustment ........................................................................
dC131 NVM Read/Write..................................................................................................
dC131 UI/Tools (700)......................................................................................................
dC131 UI NVM List (702) ................................................................................................
dC131 UI NVM List (800) ................................................................................................
dC131 UI NVM List (850) ................................................................................................
dC131 DADF NVM List (710)..........................................................................................
dC131 IIT NVM List (715, 719) .......................................................................................
dC131 ROS NVM List (720)............................................................................................
dC131 IPS NVM List (730)..............................................................................................
dC131 PH NVM List (749)...............................................................................................
dC131 PH NVM List (760)...............................................................................................
dC131PH NVM List (761)................................................................................................
dC131SYS NVM List (752) .............................................................................................
dC131SYS NVM List (759) .............................................................................................
dC131 BILLING NVM List (990)......................................................................................
dC131 Procon1 NVM List (773) ......................................................................................
dC131 IBT NVM List (771), dC131 Drive NVM List (772) ...............................................
Reissue
DocuColor 12/DCCS50
6-19
6-20
6-22
6-23
6-23
6-24
6-25
6-26
6-26
6-27
6-30
6-33
6-33
6-39
6-40
6-41
6-43
6-44
6-44
6-47
6-81
6-82
6-83
6-84
6-86
6-87
6-88
6-90
6-92
6-93
6-93
6-94
6-94
6-95
6-96
6-96
6-99
6-99
6-115
6-117
6-118
6-119
6-119
6-122
6-123
6-123
6-125
6-126
6-126
6-127
6-127
6-128
6-128
6-129
6-129
6-130
UI (IOT) Diagnostics
How to Enter/Exit the UI (IOT) Diagnostics Mode ...........................................................
UI (IOT) Diagnostic Modes..............................................................................................
NVM Reset / NVM Initialization (dC301 UI Diagnostics) .................................................
NVM Read / Write (dC131 NVM UI Diagnostics) ............................................................
Component Control (dC330 UI Diagnostics) ...................................................................
Print (dC612 Test Pattern UI Diagnostics) ......................................................................
Fuser Nip Measurement (dC701 UI Diagnostics)............................................................
Developer Unit Check (dC920 UI Diagnostics) ...............................................................
Max Setup (UI Diagnostics).............................................................................................
IIT Calibration (dC945 UI Diagnostics) (IIT installed machine only)................................
ADC/AGC Setup (dC934 UI Diagnostics) .......................................................................
VH/VM Setup (dC933 UI Diagnostics) ............................................................................
IOT Highlight Setup (dC918 UI Diagnostics)...................................................................
TRC Setup/Toner Concentration Adjustment (dC922 UI Diagnostics)............................
TRC Adjustment (dC924 UI Diagnostics)........................................................................
Color Balance Setup (dC919 UI Diagnostics) (IIT installed machine only) .....................
1/05
6-1
6-131
6-131
6-132
6-132
6-133
6-133
6-137
6-138
6-138
6-139
6-139
6-140
6-140
6-141
6-141
6-142
General Procedures
Product Specifications
General Information ........................................................................................................
Installation Space Requirements ....................................................................................
Product Specifications.....................................................................................................
6-143
6-143
6-148
Tools and Supplies

Common Tools ................................................................................................................
Product Tools and Test Patterns.....................................................................................
Cleaning Materials ..........................................................................................................
Machine Consumables....................................................................................................
6-157
6-157
6-158
6-158
Change Tag Information

Change Tag Introduction.................................................................................................
Processor (P) Tags .........................................................................................................
Mail Box / Sorter Tags.....................................................................................................
High Capacity Feeder (HCF) Tags..................................................................................
Integrated Digital Front End (IDFE) Tags........................................................................
General Procedures
6-159
6-159
6-166
6-167
6-168
1/05
6-2
Reissue
DocuColor 12/DCCS50
GP 1 Fuser Break-In Procedure
5.
Without following proper Fuser Break-In Procedures after servicing the Fuser Assembly, damage to the Fuser may occur due to lack of oil in the system.
Visually observe that the clear oil tubes above and below the oil pump are full of oil and
have no air bubbles and show no sign of leaks. If leaks or air bubbles are found, reposition
clamps/fittings and repeat steps 3 and 4 above.
6.
Standard Break-In Procedure
Place a blank sheet of paper on the Platen Glass. Run 20 blank copies from Tray 1 in Full
Color mode.
7.
Place the Color Test Pattern on the Platen Glass. Run 20 copies from Tray 1 in Full Color
mode. (While running these copies, listen for unusual fuser or exit noises and observe
output for Image Quality.)
8.
When entire Fuser Assembly is replaced, also perform Fuser Nip Adjustment (ADJ 8.1.1).
CAUTION
1.
2.
Perform this procedure whenever any of the following components are either cleaned or
replaced:
Donor Roll Assembly or Oil System Kit
Heat Roll
External Heat Roll
Donor Roll
Pickup Roll
Pressure Roll
Wick
Heat Roll Stripper Fingers
Pressure Roll Stripper Fingers
Cleaning Roll
If the External Heat Roll is replaced, adjust the External Heat Roll nip (ADJ 8.8.1).
After performing service, allow the machine to come to the Ready Condition.
NOTE: During a full warm-up cycle, the Fuser Drives rotate for 2 minutes and Oil Pump
runs for 5 minutes.
3.
Place a blank sheet of paper on the Platen Glass. Run 20 blank copies from Tray 1 in Full
Color mode.
4.
Place the Color Test Pattern on the Platen Glass. Run 20 copies from Tray 1 in Full Color
mode.
5.
When Heat or Pressure Rolls are replaced, also perform Fuser Nip Adjustment (ADJ
8.1.1).
If the External Heat Roll is replaced, adjust the External Heat Roll nip (ADJ 8.8.1).
Full Break-In Procedure

1.
2.
Perform this procedure whenever any of the following components are replaced or the oil
supply system has been emptied:
Entire Fuser Assembly
Oil Pump
Oil Supply Tubes
Oil Drip Pipe
Oil Tank
After performing service, allow the machine to come to the Ready condition.
NOTE: During a full warm-up cycle, the Fuser Drives rotate for 2 minutes and Oil Pump
runs for 5 minutes.
3.
Enter Diagnostics. Select dC330 Component Control.
4.
Enter Code 10-033 (oil Pump ON) and press Start, repeat twice (pump will run for 90 seconds each time).
Reissue
DocuColor 12/DCCS50
1/05
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General Procedures
GP 1 Fuser Break-In Procedure
GP 2 Increased Imageable Area Setup
GP 4 Intermittent Problem RAP
CAUTION
The purpose of this RAP is to provide guidance for resolving an intermittent problem. This is
not an exact procedure, but a set of recommended actions that use the resources of the service manual to help locate the cause of an intermittent problem.
This procedure is for DC12 Copier/Printers only. Attempting to use this setup on DCCS50
machines may result in Image Quality problems.
The purpose of this procedure is to adjust the maximum imageable area to allow for full-bleed
printing of 11 x 17 in. images onto 12 x 18 in. paper, or A3 images onto SR-A3 paper. This will
allow oversize sheets to be trimmed to 11 x 17 or A3, with the image extending through the
trimmed area.
Procedure
Prerequisites
1.
Check the service log. Recent service actions may provide information about the problem.
For example, a component that was recently replaced to correct another problem may be
the cause of the new intermittent problem.
2.
Run the machine in a mode that vigorously exercises the function that is suspected. The
machine may fail more frequently or may fail completely under these conditions. Look for
signs of failure or abnormal operation.
The following hardware/software are required in order to implement this procedure:
Tag P39 (V5) or higher IOT software level
DC12 with one of the following DFEs:
EFI X12 with V1.5 software
Splash G620 with V2.5 software
Splash G630 with V3.0 software
An intermittent problem can usually be associated with a RAP, since when it does fail, it
results in a Fail Code, a Jam Code, or some other observable symptom.
3.
Specifications
The guaranteed imageable area is as follows:
Using the RAP that is associated with the symptom of the intermittent problem, examine
all of the components that are referenced in the RAP. Look for:
contamination, such as a feed roller that has a build up of dirt or toner
wear, such as gear teeth that are rounded or have excessive backlash
HFSI, even if they are not near or have not exceeded the SPEC LIFE or COPY
COUNT value
wires chafing against components of the machine, especially against moving components
Print mode
12 x 18 paper - 297mm (+2.0/-0.5mm) x 438 mm (+13.0/- 0.5mm)
SR A3 paper - 297mm (+6.0/-0.5mm) x 438 mm (+6.0/- 0.5mm)
Copy mode
misaligned, misadjusted, or incorrectly installed components
12 x 18 or SR A3 paper - 297mm x 432 mm (+/-0.5mm) @105% R/E
slow or slipping clutches; slow or binding solenoids
Procedure
NOTE: Registration adjustments are not affected by this procedure.
1.
Enter the Service Diagnostics Mode. Refer to Entering the Service Diagnostic Mode
using the PWS.
2.
Select Adjustments in the Service Entry Screen. dC131 NVM Read/Write is the default
screen.
3.
Select the ROS tab.
4.
Change the value in locations 720-360 and 720-361 to 1.
General Procedures
GP 2 Increased Imageable Area Setup, GP 4 Intermit-
1/05
6-4
damaged components
excessive heat, or symptoms of excessive heat, such as the discoloration of a component
loose cables or wires
4.
Using the RAP that is associated with the symptom of the intermittent problem, perform
all of the adjustments for the components or functions that are referenced in the RAP.
Check to ensure that the adjustment CAN BE MADE and that there is an adequate range
of adjustment, and that it can be set to or near the nominal value. Any abnormality that is
observed may be an indication of the cause of the problem. For example, a component
can be adjusted to the nominal value, but it is at the limit of the adjustment range. This is
not normal and may be an indication of the cause of the problem.
5.
Operate all of the components in the appropriate RAP that is associated with the symptom of the intermittent problem with DC330 Component Control (refer to dC330 Component Control). Observe the components for any symptoms of abnormal operation, such as
a hesitation, or an unusual sound.
CAUTION
Make sure to change both NVM locations. Changing only one location will result in Image
Quality problems.
6.
Check that the AC and DC power are within specification.
7.
Get technical advice or assistance when it is appropriate. This will depend upon the situation and the established local procedures.
8.
Examine the components that are not in the RAP, but are associated with the function that
is failing. Refer to the BSDs. Look for:
contamination, such as a feed roller that has a build up of dirt or toner
wear, such as gear teeth that are rounded or have excessive backlash
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DocuColor 12/DCCS50
9.
HFSI, even if they are not near or have not exceeded the SPEC LIFE or COPY
COUNT value
wires chafing against components of the machine, especially against moving components
misaligned, misadjusted, or incorrectly installed components
slow or slipping clutches; slow or binding solenoids
damaged components
excessive heat, or symptoms of excessive heat, such as the discoloration of a component
loose cables or wires
GP 5 Verifying the Administration Tools Password

This procedure will enable the CSE to read a machine Administration Tools password if the SA
has forgotten their password or if the SA is unavailable.
CAUTION
Use this procedure only to read the password resident on the machine. Then use the password to access the Administration Tools Screen and change the password using the normal
procedure.
Procedure
1.
Perform the adjustments for the components that are not in the RAP, but are associated
with the function that is failing. Refer to the BSDs. Check to ensure that the adjustment
CAN BE MADE and that there is an adequate range of adjustment, and that it can be set
to or near the nominal value. Any abnormality that is observed may be an indication of the
cause of the problem. For example, a component can be adjusted to the nominal value,
but it is at the limit of the adjustment range. This is not normal and may be an indication of
the cause of the problem
10. Operate all of the components that are not in the RAP, but are associated with the function
that is failing with DC330 Component Control (refer to dC330 Component Control). Refer
to the BSDs. Observe the components for any symptoms of abnormal operation, such as
a hesitation, or an unusual sound.
2.
Select Adjustments in the Service Entry Screen.
3.
The system displays one of the Read/Write Screens. dC131 NVM Read/Write is the
default screen.
4.
Select UI/Tools from the Vertical Left Tab List.
5.
default screen.
6.
Record and Retain NVM Values for the following locations:
11. Replace any components or consumables that are known to be a frequent cause of the
problem. When doing this, consider the cost and time required. If the suspected item is
inexpensive, can be installed quickly, and has a high probability of resolving the problem,
then it is reasonable to replace it.
12. Leave an accurate and detailed record of your actions in the service log. Describe what
you have observed, what actions you took, and the recommended next steps.
using the PWS.
702-180
702-181
702-182
702-183
702-184
702-185
Calculating the Administration Tools Password

1.
Exit from dC131 NVM Read/Write Mode.
2.
Exit the Diagnostic Mode.
3.
Using the PWS, go to Programs/Accessories/Scientific Calculator (This is the standard accessory in Microsoft Windows)
4.
a.
Calculator has two operating modes, select Scientific Format. To do this, on the
calculator icon, go to View and click Scientific.
b.
Make sure the Decimal and the Deg formats are selected.
c.
Enter decimal number.
Convert the numbers recorded from the list above to hexadecimal.

a.
5.
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Click the Hex format. (Select Dword on calculator) This will leave you with a pair of
two digit hex words.
Convert the hexadecimal numbers to their ASCII code equivalent. Refer to Table 1.
General Procedures
GP 4 Intermittent Problem RAP, GP 5 Verifying the
NOTE: The results from the above conversion will be the Administration Tools Password.
Each memory location holds two digits of the Administration Tools Password. The Administration Tools Password may be 4-12 digits long. Unused memory will hold the ASCII
code character for a space (20). Refer to Table 1.
Table 2 . 2 Digits Password / ASCI Code /

Hecadecimal Conversion Matrix
NOTE: If you DO NOT have the capability above, (Steps 6 through 8) on your PC or Laptop, please use the conversion matrix in Table 2.
Table 1 Hex/ASCII Conversion
NVM Value
(Decimal)
2 Digits
Password
(Hex. Dword) ASCII Code
12856
3238
28
12857
3239
29
13104
3330
30
13105
3331
31
HEX
ASCII
30
13106
3332
32
31
13107
3333
33
32
13108
3334
34
33
13109
3335
35
34
13110
3336
36
35
13111
3337
37
36
13112
3338
38
37
13113
3339
39
38
13360
3430
40
39
13361
3431
41
20
Space
13362
3432
42
13363
3433
43
13364
3434
44
13365
3435
45
13366
3436
46
13367
3437
47
13368
3438
48
13369
3439
49
13616
3530
50
13617
3531
51
13618
3532
52
13619
3533
53
13620
3534
54
13621
3535
55
13622
3536
56
13623
3537
57
13624
3538
58
13625
3539
59
13872
3630
60
13873
3631
61
13874
3632
62
13875
3633
63
13876
3634
64
13877
3635
65

NVM Value
(Decimal)
2 Digits
Password
12592
3130
10
12593
3131
11
12594
3132
12
12595
3133
13
12596
3134
14
12597
3135
15
12598
3136
16
12599
3137
17
12600
3138
18
12601
3139
19
12848
3230
20
12849
3231
21
12850
3232
22
12851
3233
23
12852
3234
24
12853
3235
25
12854
3236
26
12855
3237
27
General Procedures
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NVM Value
(Decimal)
2 Digits
Password
NVM Value
(Decimal)
2 Digits
Password
13878
3636
66
13344
3420
*4 + (SPACE)
13879
3637
67
13600
3520
*5 + (SPACE)
13880
3638
68
13856
3620
*6 + (SPACE)
13881
3639
69
14112
3720
*7 + (SPACE)
13888
3640
70
14368
3820
*8 + (SPACE)
13889
3641
71
14624
3920
*9 + (SPACE)
13890
3642
72
13891
3643
73
13892
3644
74
13893
3645
75
13894
3646
76
13895
3647
77
13896
3648
78
13897
3649
79
14384
3830
80
14385
3831
81
14386
3832
82
14387
3833
83
14388
3834
84
14389
3835
85
14390
3836
86
14391
3837
87
14392
3838
88
14393
3839
89
14640
3930
90
14641
3931
91
14642
3932
92
14643
3933
93
14644
3934
94
14645
3935
95
14646
3936
96
14647
3937
97
14648
3938
98
14649
3939
99
12320
3020
*0 + (SPACE)
12576
3120
*1 + (SPACE)
12848
3230
*2 + (SPACE)
13088
3320
*3 + (SPACE)
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* # + (SPACE) Key applies only on the last digit of the password, which was at 5th, 7th, 9th
or 11th.
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General Procedures
GP 6 Verifying the Auditron Password

This procedure will enable the CSE to read a machine Auditron password if the SA has forgotten their password or if the SA is unavailable.
CAUTION
Use this procedure only to read the password resident on the machine. Then use the password to access the Auditron Administrator Screen and change the password using the normal
procedure.
Procedure
1.
Enter the Service Diagnostics Mode, refer to: Entering the Service Diagnostic Mode
using the PWS
2.
3.
default screen.
4.
Select Other from the Vertical Left Tab List.
5.
default screen.
6.
Record and Retain NVM Values for the following locations:
850-001
850-002
850-003
850-004
850-005
850-006
850-007
Exiting from the Auditron Password

1.
Exit from dC131 NVM Read/Write Mode.
2.
Exit the Diagnostic Mode.
3.
Using the PWS, go to Programs/Accessories/Scientific Calculator (This is the standard accessory in Microsoft Windows)
a.
Calculator has two operating modes, select Scientific Format. To do this, on the
calculator icon, go to View and click Scientific.
b.
Make sure the Decimal and the Deg formats are selected.
c.
Enter decimal number.
4.
Convert the numbers recorded from the list above to hexadecimal (Select Dword on calculator)
5.
Convert the hexadecimal numbers to their ASCII code equivalent. Refer to Table 1.
a.
Click the Hex format. This will leave you with a pair of two digit hex words.
General Procedures
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NOTE: NVM Location 850-007 is a binary switch that turns Auditron ON and OFF. Its
value will be 0 or 1 only.
Table 2 2 Digits Password / ASCI Code /

Hexadecimal Conversion Matrix
NOTE: The results from the above conversion will be the Auditron Password. Each memory location holds two digits of the Auditron password. The Auditron password may be 412 digits long. Unused memory will hold the ASCII code character for a space (20). Refer
to Table 1.
NOTE: If you DO NOT have the capability above, (Steps 6 through 8) on your PC or Laptop, please use the conversion matrix in Table 2.
Table 1 Hex/ASCII Conversion
NVM Value
(Decimal)
2 Digits
Password
12853
3235
25
12854
3236
26
12855
3237
27
12856
3238
28
12857
3239
29
HEX
ASCII
13104
3330
30
30
13105
3331
31
31
13106
3332
32
32
13107
3333
33
33
13108
3334
34
34
13109
3335
35
35
13110
3336
36
36
13111
3337
37
37
13112
3338
38
38
13113
3339
39
39
13360
3430
40
20
Space
13361
3431
41
13362
3432
42

13363
3433
43
13364
3434
44
NVM Value
(Decimal)
2 Digits
Password
13365
3435
45
13366
3436
46
12592
3130
10
13367
3437
47
12593
3131
11
13368
3438
48
12594
3132
12
13369
3439
49
12595
3133
13
13616
3530
50
12596
3134
14
13617
3531
51
12597
3135
15
13618
3532
52
12598
3136
16
13619
3533
53
12599
3137
17
13620
3534
54
12600
3138
18
13621
3535
55
12601
3139
19
13622
3536
56
12848
3230
20
13623
3537
57
12849
3231
21
13624
3538
58
12850
3232
22
13625
3539
59
12851
3233
23
13872
3630
60
12852
3234
24
13873
3631
61
13874
3632
62
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General Procedures


NVM Value
(Decimal)
2 Digits
Password
NVM Value
(Decimal)
2 Digits
Password
13875
3633
63
12576
3120
*1 + (SPACE)
13876
3634
64
12848
3230
*2 + (SPACE)
13877
3635
65
13088
3320
*3 + (SPACE)
13878
3636
66
13344
3420
*4 + (SPACE)
13879
3637
67
13600
3520
*5 + (SPACE)
13880
3638
68
13856
3620
*6 + (SPACE)
13881
3639
69
14112
3720
*7 + (SPACE)
13888
3640
70
14368
3820
*8 + (SPACE)
13889
3641
71
14624
3920
*9 + (SPACE)
13890
3642
72
13891
3643
73
13892
3644
74
13893
3645
75
13894
3646
76
13895
3647
77
13896
3648
78
13897
3649
79
14384
3830
80
14385
3831
81
14386
3832
82
14387
3833
83
14388
3834
84
14389
3835
85
14390
3836
86
14391
3837
87
14392
3838
88
14393
3839
89
14640
3930
90
14641
3931
91
14642
3932
92
14643
3933
93
14644
3934
94
14645
3935
95
14646
3936
96
14647
3937
97
14648
3938
98
14649
3939
99
12320
3020
*0 + (SPACE)
General Procedures
* # + (SPACE) Key applies only on the last digit of the password, which was at 5th, 7th, 9th
or 11th.
1/05
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GP 7 Verifying Tools Mode Password
GP 8 IDFE Power OFF/Power ON (PO/PO) Procedure
Entering, exiting and changing the Tools Mode Password.
Description
Procedure
This procedure is used when a full PO/PO is required for the Integrated Digital Front End
(IDFE).
Entering Tool Mode
Procedure
NOTE: You can use the default password (11111) to enter the Tools mode the first time.
1.
Press the Administration button on the Control Panel.
2.
Select the Tools button on the Touch Screen.
3.
Use the keypad to key-in the password (default is 11111).
CAUTION
and the PO/PO process must be repeated.
NOTE: The IDFE will take approximately three to five minutes to load its software after performing the following steps:
Exit the Tool Mode

1.
Select the Close button to exit any Tools Mode function without saving.
2.
Select Close to return to the Basic Copy tab.

1.
Changing the Password

1.
CAUTION
Select Change Tools Access Number button on the Tools screen.
2.
Key-in a New Number in the New Number field.
3.
Key-in the same number in Confirm New Number in the Confirm New Number field.
4.
Press the Enter button.
5.
Select the Close button to return to System Administration Item.
Switch OFF the Main Switch for the Printer.
When power to the IOT is switched-off, the IDFE Hard Disk Drive goes into a software shutdown. Damage to the Hard Disk Drive could occur if the IDFE is not allowed to complete the
software shutdown process.
2.
3.
Switch ON the Main Switch for the Printer.

NOTE: The configuration report may take 2 or 3 minutes to print.
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General Procedures
GP 7 Verifying Tools Mode Password, GP 8 IDFE
GP 9 IDFE Software Installation (CD-ROM) Procedure
NOTE: The loading process should take less than 10 minutes. The CD-ROM will eject if
the software load was successful.
Description
NOTE: If the CD-ROM does not eject within 10 minutes, press the Eject Button, and
ensure that the CD-ROM is inserted correctly. Now, switch off power to the Printer, wait
for the LEDs on the IDFE to switch off and then switch on the Printer. Now, wait for the
software to load.
This procedure is used to install software for the IDFE by using a CD-ROM. Refer to GP 17
IDFE Software Update (CD-ROM) for the procedure to update software for the IDFE.
NOTE: The installation CD-ROM completely reformats the IDFE Hard Disk Drive and re-initializes the printers network configuration parameters. You will lose all information stored on the
Hard Disk Drive. You will also lose your network configuration parameter setups.
NOTE: After the software has successfully loaded, a configuration report may be printed
whenever the Printer is powered on.
Software installations will change network parameters and require that customers re-establish
Printer/IDFE network parameters. When in doubt always run a configuration report first and
verify that Printer/IDFE network parameters are correct.
11. Remove the CD-ROM and close the CD-ROM Tray.

12. Switch off power to the Printer and the IDFE.
13. Wait for the LEDs on the IDFE to switch off.
NOTE: After completing the following procedure, ensure that the CD-ROM has been removed
from the CD-ROM Drive. If the CD-ROM is not removed from the Drive the Controller will boot
from the CD-ROM each time the Controller is switched-on.
NOTE: The LEDs will switch off in 18-22 seconds. Allow 30 seconds to ensure complete
shutdown of the Hard Disk Drive.
14. Re-connect all network interface cables to the IDFE.
Procedure
15. Switch on power to the Printer/IDFE.

16. Wait for the IDFE to re-boot.
NOTE: Be sure to read and follow the instructions in the release documentation, which is
included with the software to be loaded.
NOTE: It takes approximately 5 to 7 minutes for the IDFE to reboot.
NOTE: Be sure to record the release version of the software being loaded.
NOTE: After the new software has been loaded a Configuration Report may print.

1.
2.
If necessary, switch on power to the Printer/Integrated Digital Front End (IDFE).
3.
Remove or open the Cover for the IDFE CD-ROM Drive.
17. Use the Configuration Report to verify that the new Controller Software Version is correct. If the new software version is not correct, perform steps 4-17 of this procedure again.
If the new software version is still not correct obtain a new installation CD-ROM and
repeat steps 4-17 of this procedure.
NOTE: If repeated (several occurrences of) Network Controller Disabled messages are
displayed on the Local User Interface, obtain a new installation CD-ROM and repeat
steps 4-17 of this procedure.
NOTE: The Cover is located on the right end of the IDFE.

NOTE: Some versions of the IDFE use a Cover and Screw to provide EME protection for
the IOT. Some versions of the IDFE use a hinged Cover Assembly to provide EME protection.
4.
Press the Eject button on the IDFE CD-ROM Drive.
5.
Carefully insert the CD-ROM, and press the Eject Button to close the CD-ROM Tray.
6.
Switch off power to the Printer/IDFE.
7.
Wait for the Light Emitting Diodes (LEDs) on the IDFE to switch off.
18. Ask your customer to perform the network setup procedures for re-establishing the Printer
and IDFE network parameters.
19. Ask your customer to perform the Printer Driver installation for the type of workstation you
have.
NOTE: If necessary, ask your customer to refer to the Document Centre ColorSeries 50
Printer Installation Guide for Print Driver installation instructions.
8.
20. Install or close the Cover for the CD-ROM Drive.
Disconnect all Network Interface Cables to the IDFE.

NOTE: Do Not disconnect the Digital to Digital Interface (DDI) Cables between the IDFE
and the Printer.
9.
Switch on power to the Printer/IDFE.
10. Wait for the software to load.
General Procedures
GP 9 IDFE Software Installation (CD-ROM)
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GP 10 Replacing Billing PWBs
GP 11 PWS (Diagnostics) Software Installation Procedure
Description
Procedure
This procedure is used to maintain serial number and billing data integrity when Billing PWBs
must be replaced.
NOTE: For the PWS S/W Upgrade Installation Procedure, go to the DocuColor 12 PWS / IOT
Software upgrade CD Installation Instructions, Section 1.
Procedure
CAUTION
To maintain the integrity of the serial number and billing data never replace all three PWBs at
once. If any of the following billing data PWBs needs replacing, only replace them ONE AT A
TIME according to this procedure:
IOT NVM PWB (PL 9.2).
IOT CPU PWB (PL 9.2).
Half Tone PWB (PL 9.2).
1.
Connect the PWS. Select dC 132 in the DC Quick Pull-down menu.
2.
Compare the serial numbers displayed for the three PWBs with the serial number on the
data plate. Note any that do not agree.
NOTE: If any of the following conditions exist, escalate the call to Field engineering or the
NTC:
The displayed serial numbers match each other but do not match the data plate.
Two or more numbers do not agree with the data plate and the third number
The displayed numbers are all different.
3.
If one serial number does not match the others, the Set Serial Number button will
become active. Click on the button. A series of pop-up windows will open. Follow the
instructions on the screen to synchronize the serial numbers.
CAUTION
To maintain the integrity of the serial number and billing data never replace all three PWBs at
once. Replacing all three PWBs at once will cause unrecoverable NVM corruption. If a PWB
needs replacing, only replace ONE AT A TIME. If the problem is not resolved, reinstall the original PWB and renter the serial number before attempting to replace a different PWB.
4.
If any PWB will not synchronize, replace that PWB (PL 9.2) and re-synchronize.
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General Procedures
GP 10 Replacing Billing PWBs ,
GP 12 Printing Configuration Reports
GP 13 Printing a Complex Test Page
Description
Description
This procedure describes how to print a Configuration Report. Printing Configuration Reports
can help you troubleshoot and configure the Printer.
This procedure describes how to print a Test Page. Printing Test Pages can help you troubleshoot the Printer and IDFE.
Procedure
Procedure
NOTE: You can print a configuration report by using CentreWare Internet Services. Use this
configuration report as a guide to help you re-establish network settings for the printer when
new software is installed.
NOTE: It is NOT possible to print the Complex Test Page from the PWS. Ask the customer to
perform steps 1-4 of this procedure.
NOTE: Test Pages can only be printed from the customers client or workstation to the printer.
NOTE: To access CentreWare Internet Services you will need to obtain the network IP
address. The IP address can be obtained from the Printer UI.
1.
Select the Print tab from the CentreWare Internet Services Home Page.
NOTE: Perform steps 6-9 of this procedure to print a Configuration Report directly from the
workstation.
2.
Select Reports from the Print window.
3.
Select Test Page from the Report Type pop up menu.
4.
Select the Print button.
NOTE: It is NOT possible to print a Configuration Report from the PWS. Ask the customer to
print a Configuration Report.
1.
Select the Properties tab from the CentreWare Internet Services Home Page.
2.
Select Printer Defaults
3.
Select Print Start Up Page
4.
Select Apply New Settings.
NOTE: Printing a Complex Test Page could take up to several minutes to print depending
on your Network Configuration.
NOTE: A password dialog box will appear. You must enter the correct user name and
password before the new settings are enabled.
5.
PO/PO the Printer and IDFE (GP 8 IDFE Power OFF/Power ON (PO/PO)).
NOTE: The configuration report may take 2 or 3 minutes to print.
NOTE: The configuration report will print every time the Printer and IDFE are powered off
and powered on.
NOTE: If the configuration report does not print ask the customer to enable it for you from
the web UI.
6.
Select the Print tab from the CentreWare Internet Services Home Page.
7.
Select Reports from the Print window.
8.
Select Configuration from the Report Type pop up menu.
9.
Select the Print button.
General Procedures
GP 12 Printing Configuration Reports, GP 13 Printing
1/05
6-14
Reissue
DocuColor 12/DCCS50
GP 15 Setting the Machine for a Time & Materials (T & M)

Account
GP 16 Setting the Machine to recognize the Sorter as a

Mailbox
Description
Description
This procedure sets the machine for a T&M Account.
This procedure configures the machine to recognize the Sorter as a Mailbox.
NOTE: If the Customer was on a FSWA and is now a T & M, the message Draw Type Mismatch will appear on the UI. To remove this message and continue the make copies, the Customer will need to order a T & M Xerographic CRU.
NOTE: This procedure cannot be used with a Copier only configuration.
Procedure
NOTE: This procedure uses the machine UI to set the machine to recognize the Sorter as a
Mailbox. To set the machine to recognize the Sorter as a Mailbox using the PWS, use the alternate procedure below.
1.
While holding down the 0" Button, press Start. A screen displays asking you to Enter
your Access Number.
Procedure
2.
Using the Keypad, enter 6789.
3.
Press Confirm when finished. If you make a mistake press C. The Customer Support
Engineer Tools screen will display.
4.
Press the NVM Read/Write button in the center of the top row. The NVM Read/Write
(dC131) screen will display.
5.
Press the Enter Number button to begin.
6.
Using the Keypad, enter 774-056.
7.
Press Start to bring up the current value. The Current Value will display in the box on the
Left. If the current value is 48 the machine setup for a Full Service Maintenance Agreement FSMA account.
8.
Using the Keypad press 49 to set the account to T & M.
9.
The number you entered will display in the New Value box on the right.
1.
10. Press Start to accept the change. The number should now appear in the Current Value
box.
While holding down the 0" Button, press Start. A screen will display, asking you to Enter
your Access Number.
2.
Using the Keypad, Enter 6789.
3.
Press Confirm when finished. If you make a mistake, press C". The Customer Support
4.
Press the NVM Read / Write button in the center of the top row.
5.
The NVM Read / Write (dC131) screen will display.
6.
Press the Enter Number button to begin.
7.
Using the Keypad, enter 780-001.
8.
Press Start to bring up the current value. The Current Value will appear in the box on the
left. If the current value is 0" the device is set up as a Sorter.
9.
Using the Keypad, press 1" to set the device up as a Mailbox. The number you entered
will appear in the New Value box on the right.
10. Press Start to accept the change. The new number should now appear in the Current
Value.
11. Press Close to exit this screen.
11. Press Close to exit this screen.
12. After you press Close, the machine will re-start.
12. After you press Close the machine will re-start.
13. When the screen returns, press Done to finish.
13. When the screen returns press Done to finish.
14. The machine will now re-start and will recognize the account as T & M.
14. The machine will re-start and will recognize the devise as a Mailbox.
NOTE: The procedure below is an alternate method for setting the machine to recognize the
Sorter as a Mailbox using the PWS.
Procedure
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1/05
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1.
Enter the Service Diagnostics Mode, refer to: Entering the Service Diagnostic Mode
using the PWS.
2.
Select Configuration Page (dC371) from the DC Quick pull down menu.
3.
Select Mailbox from Output Devices(s).
4.
Select the Save Button.
General Procedures
GP 15 Setting the Machine for a Time & Materials (T
GP 17 IDFE Software Update (CD-ROM)
NOTE: The loading process should take less than 10 minutes. The CD-ROM will eject if
the software load was successful.
Description
NOTE: If the CD-ROM does not eject within 10 minutes, press the Eject Button, and
ensure that the CD-ROM is inserted correctly. Now, switch off power to the Printer, wait
for the LEDs on the IDFE to switch off and then switch on the Printer. Now, wait for the
software to load.
This procedure is used to update software for the IDFE by using a CD-ROM. Refer to GP 9
IDFE Software Installation (CD-ROM) to install software for the IDFE by using a CD-ROM.
NOTE: The update CD-ROM does not format the IDFE Hard Disk Drive or re-initialize the
printers network configuration parameters. A software update or patch will not typically change
network parameters unless indicated in the release documentation.
NOTE: After the software has successfully loaded, a configuration report may be printed
whenever the Printer is switched on.
When in doubt always run a Configuration Report first and verify that Printer/IDFE network
parameters are correct.
11. Remove the CD-ROM and close the CD-ROM Tray.

12. Switch off power to the Printer and the IDFE.
13. Wait for the LEDs on the IDFE to switch off.
NOTE: After completing the following procedure, ensure that the CD-ROM has been removed
from the CD-ROM Drive. If the CD-ROM is not removed from the Drive the Controller will boot
from the CD-ROM each time the Controller is switched-on.
Procedure
14. Re-connect all Network Interface Cables to the IDFE.

15. Switch on power to the Printer/IDFE.
NOTE: Be sure to read and follow the instructions in the release documentation, which is
included with the software.
16. Wait for the IDFE to re-boot.
NOTE: Be sure to record the release version of the software being loaded.
NOTE: It takes approximately 5 to 7 minutes for the IDFE to re-boot.
NOTE: After the new software has been loaded a configuration report may print.
1.
2.
If necessary, switch on power to the Printer/Integrated Digital Front End (IDFE).
3.
Remove or open the Cover for the IDFE CD-ROM Drive.
17. Use the Configuration Report to verify that the new Controller Software Version is correct. If the new software version is not correct, perform steps 4-17 of this procedure again.
If the new software version is still not correct obtain a new installation CD-ROM and perform steps 4 -17 of GP 9 IDFE Software Installation (CD-ROM), then repeat steps 4-17 of
this procedure (GP 17).
NOTE: The Cover is located on the right end of the IDFE.

NOTE: Some versions of the IDFE use a Cover and Screw to provide EME protection for
the IOT. Some versions of the IDFE use a hinged Cover Assembly to provide EME protection.
4.
Press the Eject button on the IDFE CD-ROM Drive.
5.
Carefully insert the CD-ROM, and press the Eject Button to close the CD-ROM Tray.
6.
Switch off power to the Printer/IDFE.
7.
Wait for the Light Emitting Diodes (LEDs) on the IDFE to switch off.
NOTE: If repeated (several occurrences of) Network Controller Disabled messages are
displayed on the Local User Interface, obtain a new installation CD-ROM and perform
steps 4-17 of GP 9 IDFE Software Installation (CD-ROM), then repeat steps 4-17 of this
procedure (GP 17).
18. Ask your customer to perform the network setup procedures for re-establishing the Printer
and IDFE network parameters.
19. Ask your customer to perform the Printer Driver installation for the type of workstation you
have.
8.
Disconnect all Network Interface Cables to the IDFE.
9.
Switch on power to the Printer IDFE.
NOTE: If necessary, ask your customer to refer to the Document Centre ColorSeries 50
Printer Installation Guide for Print Driver installation instructions.
20. Install or close the Cover for the CD-ROM Drive.
10. Wait for the software to load.
General Procedures
GP 17 IDFE Software Update (CD-ROM)
1/05
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GP 18 IOT UI Language Change
GP 20 2nd BTR Service Procedure
Description
At assembly install or at first call after machine install:

Apply a small amount of Plastislip Grease (43E550) to both cams on the Cam Shaft Assembly
(PL 7.10, item # 11).
NOTE: For IOT UI Language Change Procedure, go to Appendix D of the IOT software
v6.00.2 Install Instructions or Appendix B in any other IOT software above 6.00.2. This procedure is located in the IOT software CD.
At 100k Interval:
Remove the Inlet Plate (PL 7.10, item #1), and thoroughly vacuum the assembly sump.
Refer to REP 7.9.1 as required.
Clean the plate, the 2nd BTR Roll and the Cleaning Blade with a clean, dry cloth.
Check all four locating pins to ensure they are secured firmly on the assembly frame.
Epoxy may be used for any loose pins.
At 200K Interval:
Perform the 100k Interval Maintenance
Check all drive gears on the rear of the assembly for wear or damage, and replace as
required (PL 7.10, item # 16, 22 and 23). Check the stub shaft which supports the drive
gear (# 22). If the shaft is loose, Epoxy may be applied to the inside frame where the shaft
attaches to the assembly.
At 300K Interval:
Perform the 100k Interval Maintenance.
Remove the front cover of the Assembly (1 screw), and check the copper contact points
at the front of the 2nd BTR Roll, and also below the large front camming spring. These
two contact points provide a ground path through the drawer frame for the 2nd BTR Roll.
If necessary, buff the contact points with an Emery cloth.
Check the condition of the 2nd BTR Roll, and replace if wear or damage is observed (PL
7.10, item # 8). Refer to REP 7.10.1 as required.
Replace the Cam Shaft Assembly (PL 7.10, item # 11).
Apply a small amount of Plastislip Grease (43E550) to both cams on the Cam Shaft
Assembly.
Replace the Zinc Stearate Bar (655N00080).

NOTE: A worn Zinc Stearate Bar will cause streaks in the process direction, because of
inconsistent stearate coating of the 2nd BTR Roll
Replace the Cleaning Blade (655N00081).

NOTE: A worn Cleaning Blade will cause streaks in the process direction, because of
inconsistent cleaning of the 2nd BTR Roll.
At 400K Interval:
Replace the 2nd BTR (REP 7.9.1). Reset HFSI Counter 009-809.
Reissue
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General Procedures
GP 18 IOT UI Language Change, GP 20 2nd BTR
General Procedures
GP 18 IOT UI Language Change, GP 20 2nd BTR Ser-
1/05
6-18
Reissue
DocuColor 12/DCCS50
Entering the Service Diagnostic Mode using the PWS
NOTE: A Cord Adapter must be used for 115V machines.
Procedure
NOTE: If the Service Outlet is being used by the Convenience Stapler and PWS power
must be supplied, unplug the Convenience Stapler and install Cord Adapter between the
machine and the PWS Power Cord.
The following procedure describe how to enter the Service Diagnostics Mode with the PWS.
CAUTION
3.
Switch on the PWS.
If the PWS power is supplied from the service outlet of the machine, take the following precautions:
4.
Make sure the machine is not copying or printing. The machine UI should display Ready
to Copy when there are no pending jobs.
5.
Enter the GSNLock Password and select OK.
6.
Double-click the Internet Explorer Icon.
Do not connect any device to this service outlet except the Convenience Stapler or the
PWS. Connecting another device to this outlet may cause a fire or result in electrocution.
This outlet is designed to be used by service personnel only. After service, place the cover
on the outlet to prevent customer use.
1.
Inform the customer that the machine will be undergoing service and will not be available.
(Copy jobs and local print jobs will be stopped)
2.
Connect the Portable Work Station (PWS) to the machine (Figure 1).
NOTE: The PWS Home Screen will display. Functions not available in the service mode
are displayed in gray.
PWS Connector
7.
Click on the Case Server not running Click here to Start box. Wait for the Case server
to load. If necessary, minimize the Case Server Box.
8.
On the Internet Explorer menu bar select the Contents Icon.
9.
Double-click the Product Tool Folder.
10. Scroll down and click Docu12 Diagnostics from Product Tools.
11. Select the Docu12 Diagnostics Button.
a.
Select Use Local DB from the opening screen.
b.
While the machine is connecting to the PWS, the machine UI will display the message, Please wait. Then the message will change to CE Remote Maintenance
Mode is working.
c.
After the PWS connects to the machine, the message will change to connecting to
the machine completed.
12. When the system starts obtaining the machine data, the system displays that data (at the
time you entered into the Service Mode) on the Service Entry Screen. When the system
has obtained the machine data, it displays Complete at the top left corner of the Service
Entry Screen. Table 1 list the Machine Data displayed at Service Entry
13. If communication is lost between the PWS and the machine, click Reconnect from the
main file menu.
Serial Cable
NOTE: The machine cannot exit from the Service Mode while in the PWS Service Diagnostic
Mode.
PWS Power Cord
14. To exit the Diagnostic Mode:

Service Outlet
Cord Adapter
a.
Select the Service Exit Tab.
b.
Click on the appropriate close-out buttons:
Complete Closeout
Temporary Closeout
Exit PWS
Figure 1 Connecting the PWS
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1/05
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General Procedures
Entering the Service Diagnostic Mode using the
DC Quick (CODE Number LIST)

Once in the Service Mode, dC Routines can be selected by dC Number or by selecting the
appropriate tabs starting at the Service Entry Screen.
Table 1 Machine Data displayed at Service Entry

Heading
Contents
Description
Machine Data
Product Code
Displays a 3-digit code allocated to each machine to

identify the machine.
Procedure
1.
using the PWS.
Serial Number
Displays a 6-digit number (09) allocated to each machine

type to identify the machine.
2.
Using the DC Quick pull-down menu (upper-right side of Diagnostics Service Entry
Screen), select the desired dC routine.
Total Copies
Displays the total number of

copies/prints
Copies Since Last Call
Displays the total number of

copies/prints since the last
CSE visit (complete closeout).
Non-Zero Jams
Software Version
Displays current IOT S/W Version
ID, Description, Occurrences
Displays the Jams that have

occurred since the last complete closeout.
HFSI Requiring Replacement ID, Description, Threshold,

Count.
Displays the component(s)

(HFSI) that has exceeded the
life Threshold).
Faults in Progress (Current

Faults)
Displays current (active) faults

in the machine.
ID, Description, Primary
General Procedures
Entering the Service Diagnostic Mode using the PWS,
Table 1 is a complete list of dC Routines that are available from the DC Quick pull-down
menu.
Table 1 dC Routines
1/05
6-20
dC Number
Name
100
Service Entry Screen
Description
1.
Displays the Service Routine

Tabs.
2.
Lists Active Faults
3.
Lists the item names of the

HFSIs that exceeded life expectancy.
4.
Lists the jams that have

occurred since the last Call
Closeout.
5.
Displays IOT S/W Version.
110
CRU data
Lists current and last 2 Xerographic

CRU data.
118
Jam Counter
Displays the following: Number of jam

events since the last Complete Closeout (performed in Service Exit) to the
current Number of jams.
120
Fail Counters
Displays the following: Number of

Fault events after the last Complete
Closeout (performed in Service Exit)
to the current copy count.
122
Shut-down History
1.
Displays the history in three categories: Document Jam, Paper

Jam and Other Fault.
2.
Displays the most recent 40

Faults (without categorizing)
129
Automatic Setting: Adjust System

Registration
The IOT lead registration and side

registration are matched.
131
NVM access: Read/Write NVM
You can reference or set/change the

NVM data.
Reissue
DocuColor 12/DCCS50
Table 1 dC Routines
Table 1 dC Routines
dC Number
Name
Description
dC Number
Name
Description
132
Set Machine Serial Number.

Read Billing Meter Information
If you have replaced the PWB that

has a Machine Serial Number, check
the PWB and set the Machine Serial
Number.
Reads Billing Meter Information for
the following:
IOT CPU PWB
351
NVM Background Processing
1.
135
Half-Tone PWB
IOT NVM PWB
Service Data
HFSI Counter
Displays the regular part replacement

life expectancy (threshold) and current value (usage). You can change
the replacement life expectancy to a
preset value in the PWS database
and reset the current value.
140
Component Check: Analog Monitor
Monitor the analog values of the sensors (A/D conversion) while operating
the components (e.g., C.C). You can
temporarily change the output value.
188
Service Mode Exit Screen
Displays the requirements for exit

from the Service Mode.
301
NVM access: NVM initialization
2.
Start and Stop background NVM

Read.
3.
Saves/restores machine settings. Saves NVM values listed:
4.
Resets all HFSI.
NVM access: Save/Restore NVM
Saves the machine NVM data in the

PWS. Restores the machine NVM
data (stored in the PWS) back to the
machine.
371
Configuration Page
Commands NVM Data initialization

for initialization of:
IISS
Allows viewing of current software

version and Market Place setting,
Machine Configuration, Output
Device(s), Accessories, Tray 1 Paper
Size setting, Feature Config., and
Input Device.
These settings can be changed to
align with the machine configuration.
391
Edit Pad
Can change the Edit Pad custom

color(s).
Post IPS
612
Color Test Pattern Print
1.
IOT
Outputs a test pattern to identify

a copy quality problem.
SYS
2.
UI
Generates a test pattern from

the Pattern Generator in the
machine.
System Test: Component Operation

Check UI Component Check
330
Component Check: Component Con- Displays the instructions and results

trol
of the Input Component Check and
Output Component Check
1. You can monitor each Input
Component or check the operation of each Output Component.
Checks the UI Screen and Component Panel Button operation.
2.
DocuColor 12/DCCS50
NOTE: Background Read must

complete prior to saving.
361
305
Reissue
Saves and restores values of all

NVM in PWS dC131 databank.
You can simultaneously check

multiple Input Components and
Output Components up to 11
total.
1/05
6-21
701
Other Adjust/Set: Fuser Nip Measure- Make a copy for a contact arc adjustment
ment and measure the fuser nip width
by a simple operation.
740
Tray 5 (Bypass) guide adjustment
1.
Re-calibrate Size Sensor
2.
Check if the Tray 5 guide size in

the width direction has been
properly detected.
915
Machine data output: XERO data dis- Displays the machine Xerographic
play
data in the PWS in a format that is
easy to see and understand.
918
IOT Highlight Setup
Uniform the Highlight Density Reproduction Starting Point (for each K, Y,

M, C) and the Highlight Density of In/
Out.
919
Color Balance Setup

(IIT machine only)
Make a 4C copy in the Photo mode.

Adjust the YMCK color balance.
General Procedures
dC100 Service Entry
Table 1 dC Routines
dC Number
Name
Description
920
Developer Unit Check
Rotate the Rotary Developer and set

it at the predetermined position.
922
TRC Control/Toner Density Adjustment
Measure the grayscale patch by the

ADC sensor. Make the LUT for IOT
TRC correction.
923
924
ProCon PG
TRC Adjustment
Product Code
Machine Serial Number
Print the ProCon PG.
Total Copies
Manually fine adjust each color (low/

mid/high density) in PG.
Copies since Last Call
IOT Software Version
Procedure
933
VH/VM Setup
Set VG, VD light amount, Developing

Bias and ASG Bias output.
934
ADC/AGC Setup
Execute automatic adjustment of the

ADC Sensor Gain.
939
TRC Check PG
Print the TRC Check PG.
945
IIT calibration
(IIT machine only)
1.
Calculate and set the white reference compensation coefficient.
2.
Correct the IIT sensitivity variation.
General Procedures
dC100 Service Entry
When entering Diagnostics, this routine allows you to view faults in progress, Non-Zero Jams
and HFSI items requiring replacement. Service entry allows you to view product information,
such as:
1/05
6-22
1.
using the PWS.
2.
Check the HFSI Requiring Replacement.
3.
Check the Non-Zero Jams. Jams that have occurred since the last service exit with the
Complete Closeout option selected. Check for any Jams that have a high number of
occurrences.
4.
Check the Faults In Progress. If any faults in progress are displayed, troubleshoot
accordingly.
5.
Select the Refresh button to have the PWS request and receive the latest information on
Total Copies, Copies Since Last Call, Non-Zero Jams or HFSI Requiring Replacement.
Reissue
DocuColor 12/DCCS50
dC110 Displaying the CRU-Related Data
dC118 Jam Counter
Purpose
Purpose
Displays the Xerographic CRU NVM data (current and previous data items) in a format that can
be easily understood for effective operation.
Displays the number of occurrences of Jams from time of previous Complete Closeout on service exit until present.
Procedure
The following screen information displays on the Jam Counters Screen:
1.
using the PWS.
All Jams
DADF Jams
2.
Paper Jams
3.
Select Other Adjustments in the Service Entry Screen.
Non-Zero Jams
4.
Select Display CRU Related Data (dC110).
5.
The system displays:

a.
NOTE: This procedure does not count jams detected while in the Service Mode.
Procedure
The Current-CRU Related Data and the Previous-CRU Related Data.
6.
Scroll the lists to review the displayed Current and Previous CRU Related Data.
All Jams
7.
Select the Refresh button to have the PWS request and receive the latest information on
CRU-Related Data.
1.
using the PWS.
2.
Select Maintenance on the Service Entry Screen. dC118 displays as the default screen.
3.
Select All Jams tab (default).
4.
The Diagnostic Screen displays all Fault codes in this category since the last Service Exit
with the Complete Closeout option selected.
DADF Jams
1.
2.
Select DADF Jams tab.
3.
The Diagnostic Screen displays all DADF Jams that have occurred since the last Service
Exit with the Complete Closeout option selected.
Paper Jam History

1.
using the PWS.
2.
3.
Select Paper Jams tab.
4.
The Diagnostic Screen displays all Paper Jams that have occurred since the last Service
Exit with the Complete Closeout option selected.
Non-Zero Jams
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1.
using the PWS.
2.
3.
Select Non-Zero Jams tab.
4.
The Diagnostic Screen displays all Jams that have occurred since the last Service Exit
with the Complete Closeout option selected.
General Procedures
dC110 Displaying the CRU-Related Data, dC118
dC120 Fail Counter
System Faults
Purpose
NOTE: This procedure displays System Faults only.
Displays the Number of occurrences of each fault since the last Service Exit with the Call
Closeout option selected.
NOTE: This procedure displays the list in the ascending order of ID number (fault code).
This procedure displays from the time when the machine last exited the Service Mode with
Complete Closeout until present.
NOTE:
1.
using the PWS.
2.
3.
Select Fail Counters dC120 on the Maintenance Screen. The "All Faults" screen is displayed.
The machine does not count the faults detected while in the Service Mode.
4.
Select the System Faults tab. The default is the ascending order of NVM ID number.
The machine does not count the interlock open detected while the Main Processor is
stopped.
5.
Click on Chain/Link ID Box in the table heading to change the order of the ID number
from maximum to minimum.
The data is obtained when opening the screen or entering the Service Mode.
6.
Click on Chain/Link ID Box again restores the original order of the ID number from minimum to maximum.
NOTE: If the previous call was saved and closed on diskettes when dC120 was read, and the
Diagnostic Mode was entered again with the read from diskettes option selected, the previous
fault history #Occurrence will display in the P1 column. If this same procedure was performed
previously, the fault history #Occurrence will display in P2, then P3, up to columns P7.
Xero Faults
NOTE: This procedure displays System Faults only.
Procedure
1.
using the PWS.
2.
1.
using the PWS.
3.
2.
4.
Select the Xero Faults tab. The default is the ascending order of NVM ID number.
3.
Select Fail Counters dC120 on the Maintenance Screen. The "All Faults" screen is displayed. The default is the ascending order of NVM ID number.
5.
4.
6.
5.
All Faults
DADF Faults
NOTE: This procedure displays DADF Faults only.
1.
using the PWS.
2.
3.
4.
Select the DADF Faults tab. The default is the ascending order of NVM ID number.
5.
6.
General Procedures
dC120 Fail Counter
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dC122 Shutdown History
2.
Purpose
1.
To display the Last 40 Faults (History) without categorization.
2.
To categorize the faults (document jams [DADF], paper jams and failures) and displays
their histories.
1.
A fault detected while in Service Mode is not counted. An Interlock Open detected while
the machine is being stopped is not counted.
2.
If multiple faults occurred in the machine, the primary fault is recorded. (Primary fault: The
first fault occurred.)
3.
To clear data select Complete Closeout in the Service Mode Exit screen (dC188). Exiting from the Service Mode clears all data in the Shut-Down History.
a.
Based on data read from the machine, the system displays the Paper Jam History.
b.
The system displays the last 20 Paper Jam Faults that occurred in Customer Mode
after the data was cleared upon completing the last operation.
Failures
NOTE:
1.
Select Paper Jams in the Shutdown History screen.
Select Fail on the Shutdown History Screen. The system displays the fault screen.
a.
The system displays the Non-paper faults that are included in the Last 40 Faults History.
Procedure
Last 40 Faults History
1.
using the PWS.
2.
Select the Diagnostics Tab.
3.
Select Last 40 Faults History in the Shut-down History screen. Last 40 Faults History is
the default screen.
4.
The information in the lower right corner of the screen (Input, Original, Paper, Tray, Output) reflects the fault highlighted in the Table.
a.
Based on data read from the machine, the system displays the copy count when
each of the last 40 faults occurred.
b.
The system displays the Last 40 Faults that occurred in Customer Mode after the
data was cleared upon completing the last Complete Closeout.
Last 40 Faults Occurrences

1.
Enter the Service Diagnostics Mode. Refer to Entering the Service Diagnostic Mode using
the PWS
2.
Select the Diagnostics Tab. dC122 displays as the default screen.
3.
Select Last 40 Fault Occurrences.

a.
Based on data read from the machine, the system displays the number of occurrences of the last 40 faults.
b.
The system displays the last 40 faults that occurred in Customer Mode after the data
was cleared upon completing the last operation.
DADF Jams
1.
Enter the Service Diagnostics Mode. Refer to Entering the Service Diagnostic Mode using
the PWS.
2.
Select DADF Jams in the Shutdown History Screen.

a.
Based on data read from the machine, the system displays the DADF Jams.
b.
The system displays the last DADF Jams that occurred in Customer Mode after the
data was cleared upon completing the last operation.
Paper Jams
1.
using the PWS.
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DocuColor 12/DCCS50
1/05
6-25
General Procedures
dC122 Shutdown History
dC129 System Registration Adjustment
dC131 NVM Read/Write
Purpose
Purpose
Performs the Lead Registration and Side Registration Adjustments by looking at the output of
the built-in Test Pattern for adjustment.
Reads, sets or changes the NVM data.

NOTE: You can access all NVMs including the NVM for a key operator. The billing forgery prevention function and the auditron administration password cannot be overwritten.
NOTE: For details on the dC129 System Registration adjustment, see ADJ 9.1.10: IOT Side/
Lead Edge Registration (dC129: System Registration Adjustment).
Procedure
Procedure
1.
Module Selection
using the PWS.
1.
2.
Select the Adjustments Tab on the Service Entry Screen.
2.
3.
Select Other Adjustments Tab on the Adjustment/Setup Screen. The System Registration Adjustment Screen is displayed.
3.
default screen.
4.
Specify the Tray at the Tray/Size pull-down and the number of copies at the Print Count
Window.
4.
Select a Sub-System from the Vertical Left Tab List. The default tab is All.
using the PWS.
Table 1 Module Selection
NOTE: Tray1 is the default Tray and cannot be changed to another Tray from the PWS.
Module item
Chain number allocation
All
700 - 999
UI/Tools
700,702
Select Print All. The message, executing System Registration Setup (dc129) is displayed.
IISS
715
Config
719
The specified number of built-in patterns is output and the message, Completed is displayed in the status area.
ROS
720
IPS
730
PHM
740, 749, 760, 761
System
752, 759
Xero
771, 774
Drives / Output
772, 780, 790
ProCon
773
Developer
776
Fuser
777
Other
775, 800, 850
Errors (number of errors)
Displays and NVM outside of the ranges listed

in the PWS database.
Changed (number pending change)
Displays any with new value entered in the

"New" column, but not written yet.
NOTE: Number of copies can be set between 1-99.

NOTE: Selecting Print All will print a test pattern from each tray.
5.
6.
a.
7.
8.
Add/Subtract the Registration Adjustment Value by looking at the copy. Using the arrows
for the Lead Reg and Side Reg, adjust the Lead and Side Registrations:
a.
Lead Reg. 1step (click) =.1100mm. Maximum steps (clicks) = 100
b.
Side Reg. 1step (click) = 0.0423mm. Maximum steps (clicks) = 300
Select Set Adjust Value after confirming the Registration Adjustment Value.
a.
9.
The message screen informing that the Main Processor is, abnormal will be displayed if Test Copy of the built-in pattern cannot be executed.
Current NVM Value of the Lead Registration/Side Registration are renewed when
this, Set Adjust Value and Save (LR) is selected. Restore (LR) and Restore (SR)
buttons will restore the Current NVM Value to the initial value.
b.
NVM Value at Save is displayed. This display will be changed when Save (LR) or
Save (SR) is selected again.
c.
Save (LR), Save (SR) will save LR or SR NVM in NVM Value at Save.
The message, In Progress is displayed.

a.
Reading NVM
When the machine cannot change the NVM value, the message, ! Unable to set up
adjustment value. Cancel Adjustment Value Setup is displayed on the Information
screen.
1.
10. Verify the adjustment by printing another pattern.
Select an ID from the Sub-System Table, then click Read NVM or double click on the line
ID (line) and the value will be read in the value column. The "Range Check" column will fill
in.
11. If the pattern does not meet Image Quality requirements, repeat steps 8-11 of this adjustment procedure.
General Procedures
dC129 System Registration Adjustment, dC131 NVM
1/05
6-26
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DocuColor 12/DCCS50
dC131 UI/Tools (700)
NOTE: Values that are out of range will cause the Error Tab to turn Red.
NOTE: While a value is highlighted, you can write an NVM value in it.
Table 1 UI/Tools (700)
Writing NVM
1.
To write a new value, first enter a new value in the "New" column
2.
Select Write NVM.

a.
ChainLink
If the input value is valid (within the range), the system writes the new NVM value in
the NVM code in the machine.
b.
If the input value is invalid, the system displays the following message in the information screen, The given NVM value is out of range. NVM was not changed.
c.
If the NVM cannot be changed (Write protected NVM), the system displays the following message, ! The specified NVM is read only.
d.
When the system writes the new value in the specified NVM code, the value is
updated in the New Box and reduces the count in the Changed Tab.
NOTE: When a value is written in the vertical Changed Tab, the tab will turn green.
The number in parenthesis() will count the number of pending NVM values. Clicking the tab once will show a list of all the changed values. If a new value is input but
not yet written, the changed value is captured in the Changed Vertical Left Tab List.
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DocuColor 12/DCCS50
1/05
6-27
Name
Default
Range
Description
700-091 Customer Paper Size FS 200
0-297
Free Paper Size Registration (FS)
700-092 Customer Paper Size SS 300
0-432
Free Paper Size Registration (SS)
700-093 Equal Magnification Fine Adjustment (FS)
20
0-40
98-102%. In 0.1% increments.

The equation is (98+(set value x
0.1)). Default of 20 = 100%
From IOT S/W 6.00.2, can be set in
tools mode
700-094 Equal Magnification Fine Adjustment (FS)
0-40
98-102%. In 0.1% increments.

The equation is (98+(set value x
0.1)). Default of 20 = 100%
700-096 PA Entry Key - Coin Kit
0-1
To enable or disable PA Entry Key

Display (for Coin Kit)
0= OFF
1= ON
700-097 ACS Platen Start Check
0-1
0= Check on
1= Check off
700-098 Tray 5 Paper Size
0-5
0= Heavyweight Paper/Tracking
film.
1= Heavyweight Paper, duplex (MN
default.
2= Labels.
3= Label/tracing paper.
4= Duplex middle weight.
5= Label/Duplex heavy weight
paper.
700-099 UI Post Flag
0-1
UI Flag - enables features such as

Posters, Cover Sheets, HCF
0= Poster Flag Off
1= Poster Flag On
700-100 Lighter - Darker Default
0-7
Copy Density Setup (Prevents

copying see-thru image)
700-101 Hue Control Default
0-5
1= 20
2= 10
3= 0
4= 10
5= 20
700-102 Chroma Control Default
0-5
700-103 Sharpness Default
0-5
700-104 Color Balance Default (Y 0

High)
0-7

copying see thru image)

Middle)
0-7

General Procedures
dC131 NVM Read/Write, dC131 UI/Tools (700)

ChainLink
Name
Default
Range

ChainLink
Description
Name
Default
Range
Description

Low)
0-7

700-127 Color Balance Default (C 0

Middle)
0-7

700-107 Color Balance Default (M 0

High)
0-7


Low)
0-7


Middle)
0-7

700-129 Color Balance Default (K 0

High)
0-7


Low)
0-7


Middle)
0-7


High)
0-7


Low)
0-7


Middle)
0-7

700-132 Lighter - Darker
0-5


Low)
0-7

0-5

High)
0-7


Middle)
0-7

1= 20
2= 10
3= 0
4= 10
5= 20
0-5

Low)
0-7

0-7
0-7
0-7


High)

0-5
1= 20
2= 10
3= 0
4= 10
5= 20

Middle)
0-7


Low)
0-7


High)
0-7


Middle)
0-7

0-5
0-5

High)
0-7


Low)
0-7


Middle)
0-7


High)
0-7


Low)
0-7


Middle)
0-7


High)
0-7


Low)
0-7


Middle)
0-7


High)
0-7


Low)
0-7


Middle)
0-7


High)
0-7


Low)
0-7

General Procedures
1/05
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DocuColor 12/DCCS50

ChainLink
Name
Default
Range

ChainLink
Description
Name
Default
Range
Description
0-7


Middle)
0-7

0-5
1= 20
2= 10
3= 0
4= 10
5= 20

Low)
0-7


High)
0-7


Middle)
0-7


Low)
0-7


High)
0-7


Middle)
0-7


Low)
0-7


High)
0-7


Middle)
0-7


Low)
0-7

700-180 Edit Clear Sure
0-1
Sure Screen with all Edit settings

cleared= ON/OFF
0= OFF
1=ON
700-181 Enhance Edit Number
0-1
Edit No. Extension Switching (4/8)

0= 4
1= 8
700-182 Tray 5 (Bypass) Paper

Type
0-65535 0= None
1= Plain Paper
2= Transparencies
4= Labels
5= Tack Paper
6= Translucent Paper
7= Heavyweight Paper (1)
8= Super Heavyweight Paper (2)
9= Tracing Paper
10= Postcards
700-183 Tray 5 (Bypass) Paper

Size Type
0-65535 0= Standard Setting

1= Manual Setting
0-5
0-5

High)
0-7


Middle)
0-7


Low)
0-7


High)
0-7


Middle)
0-7


Low)
0-7


High)
0-7


Middle)
0-7
Color Balance Setup (To stress

Bluish tone)

Low)
0-7
Color Balance Setup (To stress

Bluish tone)

High)
0-7


Middle)
0-7


Low)
0-7

0-7

0-5
1= 20
2= 10
3= 0
4= 10
5= 20
0-5
0-5

High)
0-7
Reissue
DocuColor 12/DCCS50
700-184 Tray 5 (Bypass) Standard 255

Size Code
0-65535 255= Undefined

1/05
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General Procedures
dC131 UI NVM List (702)

ChainLink
Name
Default
700-185 Tray 5 (Bypass) Fast

Scan Size
700-186 Tray 5 (Bypass) Slow

Scan Size
Range
Description
Table 1 UI NVM List (702)
0-65535 Only valid with Tray 5 manual setting selected. Range is 148 to 297.
Added with V7.3.3 IOT Software
ChainLink
0-65535 Only valid with Tray 5 manual setting selected. Range is 182 to 432.
Added with V7.3.3 IOT Software
General Procedures
dC131 UI/Tools (700), dC131 UI NVM List (702)
1/05
6-30
Name
Default
Range
Description
702-056
R/E Presets 7
(Upper)
[0.500]:
[0.250]:
25-400:
Fixed magnification 7 (every 1%).
(every 1%)
702-180
Key Operator Tools

Password1/6
[31h][31h] 0-65535
Password setting - see General Procedures
702-181
Key Operator Tools

Password2/6
[31h][31h] 0-65535
702-182
Key Operator Tools

Password3/6
[31h][20h] 0-65535
702-183
Key Operator Tools

Password4/6
[20h][20h] 0-65535
702-184
Key Operator Tools

Password5/6
[20h][20h] 0-65535
702-185
Key Operator Tools

Password6/6
[20h][20h] 0-65535
702-186
CSE Tools
Password1/6
[31h][31h] 0-65535
702-187
CSE Tools Password [31h][31h] 0-65535

2/6
CSE Tools password 2 of 6
702-188

3/6
702-189

4/6
702-190

5/6
702-191

6/6
702-200
Color Palette 1 (Y)
100
0-100(%)
Edit Pad CE registered color
702-201
Color Palette1 (M)
100
0-100(%)
702-202
Color Palette1 (C)
100
0-100(%)
702-203
Color Palette 2 (Y)
0-100(%)
702-204
Color Palette 2 (M)
0-100(%)
702-205
Color Palette 2 (C)
0-100(%)
702-206
Color Palette 3 (Y)
57
0-100(%)
702-207
Color Palette 3 (M)
64
0-100(%)
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default
Range

ChainLink
Description
Name
Default
Range
Description
702-208
Color Palette 3 (C)
0-100(%)
702-248
Color Palette17(Y)
17
0-100(%)
702-209
Color Palette 4 (Y)
20
0-100(%)
702-249
Color Palette17(M)
50
0-100(%)
702-210
Color Palette 4 (M)
0-100(%)
702-250
Color Palette17 (C)
41
0-100(%)
702-211
Color Palette 4 (C)
17
0-100(%)
702-251
Color Palette18 (Y)
39
0-100(%)
702-212
Color Palette 5 (Y)
0-100(%)
702-252
Color Palette18 (M)
19
0-100(%)
702-213
Color Palette 5 (M)
17
0-100(%)
702-253
Color Palette18(C)
12
0-100(%)
702-214
Color Palette 5 (C)
43
0-100(%)
702-254
Color Palette19 (Y)
28
0-100(%)
702-215
Color Palette 6 (Y)
0-100(%)
702-255
Color Palette19(M)
22
0-100(%)
702-216
Color Palette 6 (M)
31
0-100(%)
702-256
Color Palette19(C)
46
0-100(%)
702-217
Color Palette 6 (C)
41
0-100(%)
702-257
Color Palette 20(Y)
20
0-100(%)
702-218
Color Palette 7 (Y)
45
0-100(%)
702-258
Color Palette 20 (M) 26
0-100(%)
702-219
Color Palette 7 (M)
0-100(%)
702-259
Color Palette 20 (C) 60
0-100(%)
702-220
Color Palette 7 (C)
65
0-100(%)
702-260
Color Palette 21(Y)
37
0-100(%)
702-221
Color Palette 8 (Y)
31
0-100(%)
702-261
0-100(%)
702-222
Color Palette 8 (M)
0-100(%)
702-262
0-100(%)
702-223
Color Palette 8 (C)
44
0-100(%)
702-263
Color Palette 22 (Y) 21
0-100(%)
702-224
Color Palette 9 (Y)
20
0-100(%)
702-264
0-100(%)
702-225
Color Palette 9 (M)
25
0-100(%)
702-265
0-100(%)
702-226
Color Palette 9 (C)
60
0-100(%)
702-266
Color Palette 23(Y)
45
0-100(%)
702-227
0-100(%)
702-267
0-100(%)
702-228
0-100(%)
702-268
0-100(%)
702-229
0-100(%)
702-269
Color Palette 24(Y)
50
0-100(%)
702-230
Color Palette 11(Y)
29
0-100(%)
702-270
0-100(%)
702-231
0-100(%)
702-271
0-100(%)
702-232
Color Palette 11(C)
0-100(%)
702-272
0-100(%)
702-233
Color Palette 12(Y)
0-100(%)
702-273
0-100(%)
702-234
Color Palette12(M)
33
0-100(%)
702-274
0-100(%)
702-235
Color Palette12(C)
43
0-100(%)
702-275
Color Palette 26(Y)
0-100(%)
702-236
Color Palette13(Y)
0-100(%)
702-276
0-100(%)
702-237
Color Palette13(M)
48
0-100(%)
702-277
Color Palette26
40
0-100(%)
702-238
Color Palette13(C)
30
0-100(%)
702-278
Color Palette 27(Y)
71
0-100(%)
702-239
Color Palette14 (Y)
0-100(%)
702-279
0-100(%)
702-240
Color Palette14(M)
45
0-100(%)
702-280
0-100(%)
Edit Pad User registered color
702-241
Color Palette14(C)
48
0-100(%)
702-281
Color Palette 28(Y)
0-100(%)
702-242
Color Palette15(Y)
18
0-100(%)
702-282
0-100(%)
702-243
Color Palette15(M)
52
0-100(%)
702-283
0-100(%)
702-244
Color Palette15(C)
0-100(%)
702-284
0-100(%)
702-245
Color Palette16(Y)
21
0-100(%)
702-285
0-100(%)
702-246
Color Palette16(M)
11
0-100(%)
702-286
0-100(%)
702-247
Color Palette16(C)
0-100(%)
702-287
0-100(%)
Reissue
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1/05
6-31
63
100
General Procedures

ChainLink
Name
Default
Range

ChainLink
Description
Name
Default
Range
Description
702-288
0-100(%)
702-328
0-100(%)
702-289
0-100(%)
702-329
0-100(%)
702-290
0-100(%)
702-330
0-100(%)
702-291
0-100(%)
702-331
0-100(%)
702-292
0-100(%)
702-332
0-100(%)
702-293
Color Palette 32(Y)
60
0-100(%)
702-333
0-100(%)
702-294
0-100(%)
702-334
0-100(%)
702-295
0-100(%)
702-296
0-100(%)
702-297
0-100(%)
702-298
0-100(%)
702-299
0-100(%)
702-300
0-100(%)
702-301
0-100(%)
702-302
0-100(%)
702-303
0-100(%)
702-304
0-100(%)
702-305
0-100(%)
702-306
0-100(%)
702-307
0-100(%)
702-308
0-100(%)
702-309
0-100(%)
702-310
0-100(%)
702-311
0-100(%)
702-312
0-100(%)
702-313
0-100(%)
702-314
0-100(%)
702-315
0-100(%)
702-316
0-100(%)
702-317
0-100(%)
702-318
0-100(%)
702-319
0-100(%)
702-320
0-100(%)
702-321
0-100(%)
702-322
0-100(%)
702-323
0-100(%)
702-324
0-100(%)
702-325
0-100(%)
702-326
0-100(%)
702-327
0-100(%)
General Procedures
1/05
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DocuColor 12/DCCS50

ChainLink
Name
Default
Range
ChainLink
Description
800-001 ESS IP Address

(Upper)
0-255: 1Byte
+0-255: 1Byte
CP
800-002 ESS IP Address

(Lower)
0-255: 1Byte
+0-255: 1Byte
CP
800-003 ESS Sub-Net Address

(Upper)
0-255: 1Byte
+0-255: 1Byte
800-004 ESS Sub-Net Address

(Lower)
Name
Default
Range
Description
850-001 Auditron Admin.

Password1/6
[31h][31h] 0-65535

Password2/6
[31h][31h] 0-65535
CP
CP

Password3/6
[31h][20h] 0-65535
0-255: 1Byte
+0-255: 1Byte
0-255: 1Byte
+0-255: 1Byte
CP

Password4/6
[20h][20h] 0-65535
800-005 ESS Gateway Address (Upper)
0-255: 1Byte
+0-255: 1Byte
CP

Password5/6
[20h][20h] 0-65535
800-006 ESS Gateway Address (Lower)

Password6/6
[20h][20h] 0-65535
850-008 Auditron User

100Password
0=[802.2]
1=[802.3]
2=[Ethernet
II]
3=[802.5]
800-007 ESS Frame Type
0-3
CP
0=[802.2]
NOTE: User Account 101 or later:

Chain Link number search method
1=[802.3]
Assume the Password 1/6 Link Number of the Auditron User Account X
(100<X<=2099) is Y, then Y can be
obtained as follows:
2=[Ethernet
II]
3=[802.5]
800-008 ESS Source Routing
0-1
0-65535
CP
0=[Yes] 1=[No]
1.
Y=16(X-100)+8
(Link number: Lower 3 digits of
Y) Number with 4 digits or
more: Carried over to the Chain
number.
Ex:)
1. Password 1/6 Chain-Link number of the Auditron User
Account 2099:
Y=31992
Chain number =850 (Fixed) +
31(Upper 2 digits of Y)=881
Link number =992 (Lower 3 digits of Y): Chain-Link number
=881-992
Reissue
DocuColor 12/DCCS50
1/05
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General Procedures
dC131 UI NVM List (800), dC131 UI NVM List (850)

ChainLink
Name

100Password
Default
-
General Procedures
Range
0-65535

ChainLink
Description
3rd and 4th digit of the password see General Procedures
Name

100Password
Default
-
Range
0-65535
Description
5th and 6th digit of the password see General Procedures


1.
1.
Y=16(X-100)+9
Y=16(X-100)+10

number

number
Ex)
Account 2099:
Ex)
Account 2099:
Y=31993
Y=31994

=881-993

=881-994
1/05
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DocuColor 12/DCCS50

ChainLink
Name

100Password
Reissue
DocuColor 12/DCCS50
Default
-
Range
0-65535

ChainLink
Description
Name

100Password
Default
-
Range
0-65535
Description


1.
1.
Y=16(X-100)+11
Y=16(X-100)+12

number

number.
Ex)
Account 2099:
Ex)
Account 2099:
Y=31995
Y=31996

=881-995

=881-996
1/05
6-35
General Procedures

ChainLink
Name

100Password
Default
-
Range
0-65535

ChainLink
Description
850-014 Auditron User 100:

Copy Count Limit

Range
0-65535
Description
2Bytes: Color mode for every 100
pages. Default: Total pages of C/
L+B/W
Assume the Link number of the copy

count limit in the Auditron User
Account X (100<X<=2099), then Y
can be obtained as follows:
1.

number.
Y=16(X-100)+14
number.
Ex)
Account 2099:
Ex)
1. Chain-Link number of the copy
count limit in the Auditron User
Account 2099:
Y=31997
=881-997
General Procedures
Default

1. Y=16(X-100)+13
Name
Y=31998
=881-998
1/05
6-36
Reissue
DocuColor 12/DCCS50

ChainLink
Name
850-015 Auditron User 100:

Color Mode Limit
Default
-
Range
0= [No
limit]
1= [C/L
only]
2= [B/W
only]
ChainLink
Description
Chain Link Number search method
850-017
Y=16(X-100)+15
(Link Number: Lower 3 digits of
Number.
09999999:
Upper 2
bytes
Description
4Byte
Assume the Link number of the color
mode copy count limit in the Auditron
User Account X (100<X<=2099),
then Y can be obtained as follows:
Y=16(X-100)+17
number.
Ex)
1. Chain-Link number of B/W copy
counts in the Auditron User
Account 2099:
Y=31999
Chain Number =850 (Fixed) +
Link Number =999 (Lower 3
digits of Y): Chain-Link Number
=881-999
09999999:
Upper 2
bytes
Range
1.
Ex)
1. Chain-Link Number of the color
mode copy count limit in the
Auditron User Account 2099:
850-016 Auditron User:

100B/W copy count
Limit H
Default
-
Auditron User:
100B/W copy count
Limit L

1.
Name
Y=32001
=882-001
4Byte
1.
Y=16(X-100)+16
number.
Ex)
Account 2099:
Y=32000
=882-000
Reissue
DocuColor 12/DCCS50
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General Procedures

ChainLink
Name

100C/L copy count
Limit H
Default
-
Range
09999999:
Upper 2
bytes
General Procedures
ChainLink
Description
4Byte
Name

100C/L copy count
Limit L

Default
-

1.

Range
09999999:
Upper 2
bytes
Description
4Byte
1. Y=16(X-100)+19
Y=16(X-100)+18
number.

number.
Ex)
Account 2099:
Ex)
Account 2099:
Y=32002
Y=32003

=882-002

=882-003
1/05
6-38
850-020 Auditron User: 100

B/W Large copy
count
Limit H
0-9999999: Upper 2 bytes - Only

4Byte ESG (TBD)

(Lower) B/W Large
copy count
Limit L
0-9999999: lower 2bytes - Only

4Byte ESG (TBD)

(Upper) C/L Large
copy count
Limit H
0-9999999: Upper 2 bytes - Only

4Byte ESG (TBD)

(Lower) C/L Large
copy count
Limit L
0-9999999: Lower 2 bytes - Only

4Byte ESG (TBD)
Reissue
DocuColor 12/DCCS50
dC131 DADF NVM List (710)
Table 1 DADF NVM List (710)

ChainLink
Table 1 DADF NVM List (710)

ChainLink
Name
710-044 Feed Count

Name
Default
Range
Description
710-001 DADF Fail Bypass
0-1
Fault bypass= 1, No Fault

bypass= 0 (Used in DADF)
710-002 DADF Jam bypass
0-1
Jam bypass= 1, No Jam bypass=

0 (Used in DADF)
710-004 Document Lead Registration Timer value in the

DADF Simplex Mode
59
1-255
Adjustment value for document

registration (number of pulses
from Registration Sensor OFF to
Belt Motor Slow Down) (Used in
DADF)
710-005 DADF Feed Motor OFF

adjustment value
10
4-16
Time period from Registration

SNR ON to Feed Motor OFF
(5ms step, Default= 50ms) (Used
in DADF)
710-006 DADF B4 document size

threshold
373
360-460 Threshold to determine the B4S

or 11 X 17S in the RX mode.
(Used in DADF)
710-007 Document Lead Registra59

tion Timer value in the
DADF Duplex Mode (S: 8.5
X 11LEF or smaller)
0-100
Number of pulses from Registration Sensor OFF to Belt Motor

Slow Down
710-008 Document Lead Registration Timer value in the

DADF Duplex Mode (M:
A4SEF or smaller)
60
0-100

Slow Down
710-009 Document Lead Registra61

tion Timer value in the
DADF Duplex Mode (L: 8.5
X 13LEF or larger)
0-100

Slow Down
710-010 Belt Motor Stop Timer value 280

in DADF Duplex Mode
(Loop in reverse) (S: 8.5 X
11LEF or smaller)
200-400 Time period from Duplex Sensor

ON to Belt Motor OFF (Number of
pulses until Belt Motor Slow
Down)
710-011
Belt Motor Stop Timer value 285

in DADF Duplex Mode
(Loop in reverse) (M:
A4SEF or smaller)

Down)
710-012 Belt Motor Stop Timer value 290

in DADF Duplex Mode
(Loop in reverse) (L: 8.5 X
13LEF or larger)

Down)
710-043 Total Feed Count
0-65535 Write protected: Number of total

DADF Feeds
Reissue
DocuColor 12/DCCS50
1/05
6-39
Default
0
Range
Description
0-65535 Write protected: Accumulated

value of DADF Feeds after reset
General Procedures
dC131 DADF NVM List (710)
dC131 IIT NVM List (715, 719)
Table 1 IIT NVM List (715, 719)

ChainLink

ChainLink
Name
Default
Range
Description
715-012 BW/Color automatic rec- 2

ognition level adjustment
0-4
Level 0 (B/W) - Level 4 (Color)
715-023 PMadjF
0-100
Main scanning direction: Magnification correction value (Digital

correction by ASCI: Low ACS/TI
separation)
715-028 DADF FS offset
50
32
0-100
Side Registration Offset when

DADF is used (0.6mm/step)
Side Registration correction
value (Dot/setp)
Name
Default
Range
Description
715-119 CCD Calibration PK

read: Red
0-1023
CCD Calibration: PK patch read

- Red (Reflection rate LSB)

read: Green
0-1023

- Green (Reflection rate LSB)

read: Blue
0-1023

- Blue (Reflection rate LSB)
715-123 Side Registration Shift (- 0

)
0-256
Minus direction offset (Dot/step)

for Side Registration adjustment/
check
715-124 A6 document/Postcard
check
0-1
0= A6 document, 1= Postcard
715-125 Platen/ADF
0-1
0= Platen 1= ADF
715-126 A4S/Letter document

size detection
0-6
A4S/Letter document size

threshold
Default 3=213mm (Data 1=
2mm change)
715-132 Sub-scanning direction: 50

Registration correction
20-75
Sub-scanning direction: Lead

Registration correction
(0.076mm/step)
715-029 PRadjF
50
0-100
Main scanning direction - REJI

correction value (Dot)
715-062 AOCerr
0-255
Number of abnormal AOC flow

terminations
715-091 Pshad(1)
150
115-255
Red W-Ref correction factor
715-092 Pshad(2)
160
115-255
Green W-Ref correction factor
715-093 Pshad(3)
167
115-255
Blue W-Ref correction factor
715-103 SB SCAN
220
0-255
b* Correction standard value

(Upper 8 bits in the 10 bits)
715-133 Sub-scanning direction: 50

Magnification correction
44-56
Scan magnification correction

(0.1%/step)
715-106 HOSEI SCAN
0-6
Correction factor number
715-136 IIT Fault bypass
0-1
715-107 MB SCAN
0-511
Patch b* Measure value (9 bits

including overflow)
Fault bypass= 1, No fault

bypass=0
715-137 PreIPS fault bypass
0-1
715-110 CCD Calibration Y read: 0

Red
0-1023
CCD Calibration: Y patch read Red (Reflection rate LSB)
Fault bypass= 1, No fault

bypass=0
715-165 DSWTh
780
0-1023

Green
0-1023
CCD Calibration: Y patch read Green (Reflection rate LSB)
Platen half-open: White document detection threshold

0= White 1023= Black

Blue
0-1023
CCD Calibration: Y patch read Blue (Reflection rate LSB)
715-166 DSLTh
140
0-1023
715-113 CCD Calibration M read: 0

Red
0-1023
CCD Calibration: M patch read Red (Reflection rate LSB)
Main scanning direction: Ladder

document detection threshold
Data: B/W change (Ladder edge
change)

Green
0-1023
CCD Calibration: M patch read Green (Reflection rate LSB)
715-167 DSLNum
0-255

Blue
0-1023
CCD Calibration: M patch read Blue (Reflection rate LSB)
Main scanning direction - Number of ladder detection threshold

Number of changes obtained in
715-166 3 =< Document, <3= No
document
715-116 CCD Calibration C read: 0

Red
0-1023
CCD Calibration: C patch read Red (Reflection rate LSB)

Green
0-1023
CCD Calibration: C patch read Green (Reflection rate LSB)

Blue
0-1023
CCD Calibration: C patch read Blue (Reflection rate LSB)
General Procedures
dC131 IIT NVM List (715, 719)
0 (Letter) - 6(A4S)
1/05
6-40
Reissue
DocuColor 12/DCCS50
dC131 ROS NVM List (720)

ChainLink
Name
715-168 DSMMLimit
Default
100
Range
1-1023
Description
Document detection contrast
allowance
Document detection final check.
The document is detected by
checking the difference between
the maximum and minimum
between 97mm - 294mm. Difference =<100= Document, <100=
No document
715-171 DSBTh
700
0-1023
Platen closed: Black document

detection threshold
0= White, 1023= Black
719-005 IISS Major Version
0-65535
IISS SW Major Version number

(Write protected)
719-006 IISS Minor Version
0-65535
IISS SW Minor Version number

(Write protected)
719-007 IISS Revision Version
0-65535
IISS SW Revision Version number (Write protected)
719-008 IISS Patch Version
0 - 65535
IISS SW Patch Version number

(Write protected)
719-010 ADF Major Version
0-65535
ADF SW Major Version number

(Write protected)
719-011 ADF Minor Version
0-65535
ADF SW Minor Version number

(Write protected)
719-012 ADF Revision Version
0-65535
ADF SW Revision Version number (Write protected)
719-013 ADF Patch Version
0-65535
ADF SW Patch Version number

(Write protected)
Reissue
DocuColor 12/DCCS50
Table 1 ROS NVM List (720)

ChainLink
1/05
6-41
Name
Default
Range
Description
720-001 PS OFFSET 1
525
1-16383
[0.08461387.094
mm]
Number of lines (Unit= 2 lines) from

TR0 to the image write start position
(sub-scanning direction) [change per 1
step= about 0.0846mm] A side lead
registration adjustment
[525=44.45mm]
720-002 PS OFFSET 2
413
1-16383
[0.08461387.094
mm]
Number of lines (Unit= 2 lines) from

TR0 to the image write start position
(sub-scanning direction) [change per 1
step= about 0.0846mm] B side lead
registration adjustment
[413=34.967mm]
720-003 LS OFFSET T1
7406
71067706
Number of lines (Unit= 1 dot) from

Paper Registration to the image (main
scanning direction) [change per 1
step= about 0.0423mm] Tray 1 side
lead registration adjustment
[7406=311.05mm]
7406
71067706

7406
71067706

7406
71067706

720-007 LS OFFSET S
7406
71067706

step= about 0.0423mm] SMH (Tray 5)
side lead registration adjustment
720-008 LS OFFSET D
7406
71067706

step= about 0.0423mm] Duplex (Side
2) side lead registration adjustment
General Procedures
dC131 IIT NVM List (715, 719), dC131 ROS NVM List

ChainLink
Name
Default
Range

ChainLink
Description
720-018 ERASE LE
35
0-255 [0- Top edge erase (Unit= 2 lines)

21.59mm [35=2.96mm] [Change per step=
]
About 0.0846mm]
720-019 ERASE TE
35
0-255 [0- Bottom edge erase (Unit= 2 lines)

]
About 0.0846mm]
720-020 ERASE SIDE
70
0-255 [0- Side edge erase (Unit= 1 dot)

]
About 0.0423mm]
720-036 ROS FAIL BYPASS
0-1
ROS module fault bypass

0= Bypass 1= No bypass
720-155 MOT TIME OUT
600
0-65535
ROS MOT time out= Unit= 100msec/

step Default= 1 minute
720-170 AUTO HALF LIMIT
0-65535
Automatic gray-scale correction Range

0= Copy/Printer
Name
720-794 PRPS_DELAY
Default
0
Range
0-65535
Description
Use value of 62 for EPC
1= Copy
2= None
720-181 ERASE SIDE 12C
0-65535
Side edge erase= 12 X 18 paper Copy

Mode (Unit= dot)
720-182 ERASE SIDE 12P
271
0-65535
Side edge erase= 12 X 18 paper Print

Mode (Unit= dot)
720-185 ERASE LE 18
112
0-65535
Top edge erase= 18-inch paper (Unit:

SCAN) Erase LE 18 Top edge erase:
18-inch paper (Unit SCAN)
720-200 DEBUG (ASIC RW

ERR CODE)
0-65535
ASIC R/W CHECK ERROR: ERR

component details
0= Normal
1=PGD ASIC ERR
2=TIGER ASIC ERR
3=LAPD ASIC ERR
4=DIANA ASIC ERR
5=TIE ASIC ERR
6=PICUP ASIC ERR
720-269 SCRN300 180 ST
0-65535
300-line screen operation

0= 0 degree
1= 180 degrees
720-360 Max image area

adjust - FS direction
w/ TAG P39 S/W
0-1
0 = normal
1=enable increased image area (valid
for DC12 w/DFE only)
720-361 Max image area

adjust - SS direction
w/ TAG P39 S/W
0-1
0 = normal
1=enable increased image area (valid
for DC12 w/DFE only)
General Procedures
dC131 ROS NVM List (720)
1/05
6-42
Reissue
DocuColor 12/DCCS50
dC131 IPS NVM List (730)
Table 1 VM List (&30)

ChainLink
Table 1 VM List (&30)

ChainLink
Name
Default
Range
0-4
TIS parameter
730-002 MUC ADJ
0-8
MUL ADJ in Normal Paper Mode
730-003 MUL ADJ for OHP
0-8
MUL ADJ in OHP Mode
730-004 MUL M.Rate for Y-Y
128
0-255
Y Mono Color ratio: Y
730-005 MUL M.Rate for M-Y
0-255
Y Mono Color ratio: M
730-006 MUL M.Rate for C-Y
0-255
Y Mono Color ratio: C
730-007 MUL M.Rate for Y-M
0-255
M Mono Color ratio: Y
730-008 MUL M.Rate for M-M
128
0-255
M Mono Color ratio: M
730-009 MUL M.Rate for C-M
0-255
M Mono Color ratio: C
730-010 MUL M.Rate for Y-C
0-255
C Mono Color ratio: Y
730-011 MUL M.Rate for M-C
0-255
C Mono Color ratio: M
730-012 MUL M.Rate for C-C
128
0-255
C Mono Color ratio: C
730-013 MUL M.Rate for Y-B
0-255
B Mono Color ratio: Y
730-014 MUL M.Rate for M-B
128
0-255
B Mono Color ratio: M
730-015 MUL M.Rate for C-B
128
0-255
B Mono Color ratio: C
730-016 MUL M.Rate for Y-G
128
0-255
G Mono Color ratio: Y
730-017 MUL M.Rate for M-G
0-255
G Mono Color ratio: M
730-018 MUL M.Rate for C-G
128
0-255
G Mono Color ratio: C
730-019 MUL M.Rate for Y-R
128
0-255
R Mono Color ratio: Y
730-020 MUL M.Rate for M-R
128
0-255
730-021 MUL M.Rate for C-R
0-255
730-022 SB
230
0-255
b* Standard value
730-023 TH
12
0-30
Maximum allowance
730-024 TH-STE
0-15
Step allowance
730-025 HOSEI
0-6
Correction coefficient Number
730-026 MB
0-511
Measured patch
730-027 MB-Max
250
0-511
Patch measurement: Upper limit
730-028 MB-Min
190
0-255
Patch measurement: Lower limit
730-045 CBY
0-8
Y Color balance default setting

number
730-046 CBM
0-8
M Color balance default setting

number
730-047 CBC
0-8
C Color balance default setting

number
730-048 CBK
0-8
K Color balance default setting

number
730-049 X-Regi
50
0-100
Editor sub-scanning direction: Origin position correction (1=0.5mm)
Reissue
Default
Range
Description
730-050 Y-Regi
50
0-100
Editor main scanning direction: Origin position (1=0.5mm)
730-051 X-Mag
50
0-100
Editor sub-scanning direction:

Coordinate magnification correction (1=0.1%)
730-052 Sharpness Level
0-4
L/L (Enhanced black) Sharpness

level adjustment value
730-097 Photo Mode AE ON/OFF
0,1
0= Document type=AE OFF in

photo
1= Document type=AE ON in photo
730-098 Color Output Copy
0,1
0= Photo paper
1= Photo paper using the G function
730-116 Non Edit Board
0-1
Edit board (0= No/1= Yes) (Read

only)
730-117 Non Option MEM
0-1
Option MEM(0= No/1= Yes) (Read

only)
730-123 IPS Fail By Pass
0-1
Fail By Pass [0= No / 1= Yes]
Description
730-001 TIS PARAMETER
DocuColor 12/DCCS50
Name
730-126 PostIPS Major Version
PostIPS SW Version (1) (0-99)
730-127 PostIPS Minor Version
730-128 PostIPS Revision
730-129 PostIPS Patch
0-9
a-z
PostIPS SW Version 4 ASCII Code
R Mono Color ratio: M
730-141 V-Min Reg aC-Loop
64
0-255
Closed area detection
R Mono Color ratio: C
730-160 PLT-TH Reg
64
0-255
Binary level
1/05
6-43
General Procedures
dC131 IPS NVM List (730)
dC131 PH NVM List (749)
Table 1 PH NVM List (749)

ChainLink
Name
Default
Range

ChainLink
Description
749-001 B/W VARIABLE PITCH1 1200
None
Pitch width for paper size 8.5 or less

(Tray)
None
Pitch width for paper size B4S or less

(Tray)
None
Pitch width for paper size 17 or less

(Tray)
None

(Tray)
None
Pitch width for paper size 8.5 or less

(Tray 5)
None
Pitch width for paper size B4S or less

(Tray 5)
None

(Tray 5)
None

(Tray 5)
None
Pitch width for all thick paper sizes

(Tray 5)
749-010 B/W VARIABLE

PITCH10
3000
None
Pitch width for ultra thick paper longer

148mm (Tray 5)
749-011 B/W VARIABLE

PITCH11
3000
None
Pitch width for ultra thick paper

148mm or shorter (Tray 5)
Name
Default
760-001 Tray 5 SIZE SENSOR 0

ANALOG VALUE
Range
Description
0-65535 Always saves the current Tray 5 sensor

analog value.
Default=0V
Range=0-5V (0-1023)
Unit=0.0048V

ANALOG SMALLEST VALUE
0-65535 Saves the Tray 5 size sensor analog

value of the minimum position.
Default=0V
Range=0-5V (0-1023)
Unit=0.0048V

ANALOG GREATEST VALUE
0-65535 Saves the Tray 5 size sensor analog

value of the maximum position.
Default=0V
Range=0-5V (0-1023)
Unit=0.0048V
760-004 TRAY 1 PAPER SIZE 1=FX/

AP/
NASG
2=NAS
G
0-3
Tray 1 paper size

0=B5 LEF (257 X 182mm)
1=A4 LEF (297 X 210mm)
2=8.5 x 11.0 LEF (279.4 X
215.9mm)
3=A5S (210 x 148mm)
Higher=Free
760-007 TRAY 2 PAPER

SIZE(SS)
0-65535 Tray 2: Free size - feed length (SS

direction)
Default=0mm (Automatic detection)
Range=182-432mm
Other: Determined by the Tray
Size S/W (AD value). (0-65535)
Unit=1mm

SIZE(FS)
0-65535 Tray 2: Free size width (FS direction)

Default=0mmb (Automatic detection)
Range=148-297mm
Other: Detected by the Tray Size
S/W (AD value). (0-65535)
Unit=1mm
General Procedures
dC131 PH NVM List (749), dC131 PH NVM List (760)
1/05
6-44
Reissue
DocuColor 12/DCCS50

ChainLink
Name

SIZE(SS)
Default
0
Range

ChainLink
Description
0-65535 Tray 3: Free size - Feed length (SS

direction)
0-65535 Saves the lifter-up accumulation time

from Tray 2 insertion.
Default=0ms
Unit=10ms/step

S/W (AD value). (0-65535)
Default DATA=0 (10msRTMR)

(Supplement)
760-016 TRAY 3 PAPER THE 0
REST


Default=0ms
Range=None (0-65535)
Range=148-297mm
Unit=10ms/step

S/W (AD value). (0-65535)

(Supplement)
REST
0-65535 Tray 4: Free size - feed length (SS

direction)
760-018 TRAY 1 STATE

Default=0ms
Saves the Tray 1 status.

0=Tray dislocation
3=Tray lifter up - interrupted

4=Tray lifter up (READY)
5=Fault
6=Last P-OFF - Tray dislocation
7=Last P-OFF - Lifter down
Unit=1mmDefault DATA=0
REST
None
2=Tray lifter up

Other: Detected by the Tray Size S/W
(AD value).
Range=148-297mm (0-65535)
None
1=Tray lifter down (e.g. Insertion)
Unit=1mm
760-013 Tray 5 PAPER WIDTH 0

Unit=10ms/step
(Supplement)

S/W (AD value). (0-65535)
0
Description
Range=None (0-65535)
Range=182-432mm

SIZE(FS)
Range
Range=182-432mm
Unit=1mm
SIZE(SS)
Default

REST
Unit=1mm
SIZE(FS)
Name
8=Last P-OFF - Lifter up
Tray 5 size sensor size (mm)
9=Last P-OFF - Lifer up interrupted

Range=None ()
11=Last P-OFF - Fault
Unit=10ms/step
Other=Unknown

(Supplement)
Reissue
DocuColor 12/DCCS50
1/05
6-45
General Procedures

ChainLink
Name
Default
0
Range
None

ChainLink
Description
0=Tray dislocation
None
Range
None
Description
0=Tray dislocation
2=Tray lifter up
2=Tray lifter up
5=Fault
5=Fault
9=Last P-OFF - Lifter up interrupted

Other=Unknown
0
Default

Name
Other=Unknown

0 =Tray dislocation
2=Tray lifter up
5=Fault
Other=Unknown
General Procedures
1/05
6-46
Reissue
DocuColor 12/DCCS50
dC131PH NVM List (761)

ChainLink

ChainLink
Name
Default
761-001 PRE FEED START 590

TIMING-TRAY1
Range
565-615
#1 Tray: Time from Pre-Feed Start to

Regi-Feed (Except B side)
Default=1180ms
Range
754-804

Regi-Feed (B side feed length: Less than
190mm (*))
Default=1118ms
885-935
Unit=2ms/step
TIMINGTRAY4(PANEL B)
854-904
Unit=2ms/step
(*) Applied in the Nudger Roll 2-Drops

Mode
761-010 TRAY1 NUDGER

ROLL SOLENOID
ON TIME

Regi-Feed (B side feed length: 190 mm or
longer (*))
Default=1118ms
0-45
#2 Tray Pre-Feed: Nudger Roll SOL ON

time
Default=390ms
Range=0-450ms (0-45)
Unit=10ms/step
Default DATA=39 (10ms RTMR)
Unit=2ms/step
#2 Tray: Time from Pre-Feed start to
Regi-Feed (B side)
Default=1358ms

ROLL SOLENOID
ON TIME
39
0-45

time
Unit=10ms/step

ROLL SOLENOID
ON TIME
39
0-45

time
Unit=10ms/step
761-014 ADJUST TRAY 1

PRE FEED STOP
POSITION(FEED
ROLL 1 SPEED
300mm/s)
24
4-39
Time from #1 Feed Out SNR ON to #1

Feed Motor OFF (Feed Roll 300mm/s Stop timing)
Default=48ms
Range=50ms (25)
Unit=2ms/step
785-835
39

Default=1420ms
Range=50ms (25)

TIMING-TRAY3

time
Default=390ms

ROLL SOLENOID
ON TIME
Unit=2ms/step
654-704
0-45
Unit=10ms/step
(*) Applied in the Double Pre Feed Mode.

39
Range=0-450ms (0 - 45)
Range=50ms (25)
685-735

Regi-Feed (B side)
Default=1758ms
Range=50ms (25)
Default DATA=559 (Quadrant

Machine CLOCK)

TIMING-TRAY2

Default=1820ms
Range=50ms (25)
Unit=2ms/step
534-624

Regi-Feed (B side)
Default=1558ms
Unit=2ms/step

TIMING-TRAY4
Range=50ms (25)
761-003 DOUBLE PRE

559
FEED START TIMING-TRAY1
Description
Range=50ms (25)
Unit=2ms/step
534-624
Default

Description
Range=50ms (25)
Name

Default=1620ms
Range=50ms (25)
Unit=2ms/step
Range=8-78ms (4-39)
Unit=2ms/step
Reissue
DocuColor 12/DCCS50
1/05
6-47
General Procedures

ChainLink
Name

PRE FEED STOP
POSITION(TAKE
AWAY ROLL 1
SPEED 220mm/s)
Default
24
Range
0-39

ChainLink
Description
Take Away Feed Clutch OFF (Take Away
Roll 220mm/s- Stop timing)
Default=48ms
Name

PRE FEED STOP
POSITION(TAKE
AWAY ROLL 4
SPEED 450mm/s)
Range=0-78ms (0-39)
Default
10
Range
10-31
Unit=2ms/step

20
10-31

Feed Motor OFF (Feed Roll 300mm/sStop timing)
Default=40ms
761-022 TRAY 1 LIFTER UP 5

TIME(DURING
FEED)
0-23
Unit=10ms/step

10
0-31

TIME(DURING
FEED)

Roll 450mm/s - Stop timing)
Default=20ms
20
10-31

TIME(DURING
FEED)

Feed Motor OFF (Feed Roll 300mm/sStop timing)
Default=40ms

Default=20ms

TIME(DURING
FEED)
0-23
#4 Lift Up time (Applied only to Lift Up

during Feed)
Unit=10ms/step
761-026 TRAY 1 FEED

START TIMING
227-277
Time from #1 Take Away Feed Clutch ON

to Registration Motor ON (Feed start)
(Except B side)
Default=504ms

252
Range=0-62ms (0-31)
Unit=2ms/step
Range=50ms (25)

PRE FEED STOP
POSITION(FEED
ROLL 4 SPEED
300mm/s)
20
10-31

during Feed)
Default=50ms
Unit=10ms/step
Unit=2ms/step
0-31
0-23
Range=0-230ms (0-23)
Range=20-62ms (10-31)
10

during Feed)
Default=50ms
Unit=10ms/step
Range=0-62ms (0-31)

PRE FEED STOP
POSITION(TAKE
AWAY ROLL 3
SPEED 450mm/s)
0-23
Range=0-230ms (0-23)
Unit=2ms/step
PRE FEED STOP
POSITION(FEED
ROLL 3 SPEED
300mm/s)

during Feed)
Default=50ms
Range=0-230ms (0-23)
Range=20-62ms (10-31)
Unit=2ms/step

PRE FEED STOP
POSITION(TAKE
AWAY ROLL 2
SPEED 450mm/s)

Default=20ms
Range=0-62ms (0-31)
Unit=2ms/step
PRE FEED STOP
POSITION(FEED
ROLL 2 SPEED
300mm/s)
Description
Unit=2ms/step

Feed Motor OFF (Feed Roll 300mm/s Stop timing)
Default=40ms
761-027 TRAY 1 FEED

START TIMING(PANEL B)
245
220-270

to Registration Motor ON (Feed start) (B
side)
Default=490ms
Range=20-62ms (10-31)
Range=50ms (25)
Unit=2ms/step
Unit=2ms/step
General Procedures
1/05
6-48
Reissue
DocuColor 12/DCCS50

ChainLink
Name
761-028 TRAY 2 FEED

START TIMING
761-029 TRAY 2 FEED

Default
364
357
Range
Description
347-397
Time from #2 Take Away Feed ClutchON

(Except B side)
Default=728ms
340-390
ChainLink
Name
Default
761-035 ADJUST REGI

32
LOOP(FROM TRAY
& NORMAL
PAPER)
Range
7-57
Range=50ms (25)
Unit=2ms/step
Unit=2ms/step

side)
Default=714ms

761-036 ADJUST REGI
32
LOOP(FROM TRAY
& THICK PAPER)
7-57
Unit=2ms/step
464
447-497
Unit=2ms/step
761-038 ADJUST REGI
LOOP(FROM Tray
5 & NORMAL
PAPER)
Unit=2ms/step
457
440-490

side)
Default=914ms
547-597
540-590
42-92

(Except B side)
Default=1128ms
Unit=2ms/step
761-040 ADJUST REGI
LOOP(FROM Tray
5 & STRONG
THICK PAPER)
Time from #4 Take Away Feed ClutchON

side)
Default=1114ms
67
42-92
Unit=2ms/step
Unit=2ms/step
0-1
Time from Registration SNR ON to Main

Motor 2 OFF (Registration Loop adjustment - Tray 5) (Ultra thick paper)
Default=134ms
Range=50ms (25)
Range=113050ms (56525)
761-034 FRAME OHP
0
ENABLE/DISABLE

Motor 2 OFF (Registration Loop adjustment - Tray 5) (Thick paper)
Default=134ms
Range=50ms (25)
Unit=2ms/step
557

Motor 2 OFF (Registration Loop adjustment - Tray 5) (Normal paper)
Default=134ms

761-039 ADJUST REGI
67
LOOP(FROM Tray
5 & THICK PAPER)
Range=114450ms (57225)
761-033 TRAY 4 FEED
42-92
Unit=2ms/step
Unit=2ms/step
564
67
Range=50ms (25)
Range=93050ms (46525)
761-032 TRAY 4 FEED
START TIMING

Motor 2 OFF (Registration Loop adjustment - TRAY) (Thick paper)
Default=64ms
Range=50ms (25)

(Except B side)
Default=928ms
Range=94450ms (47225)
761-031 TRAY 3 FEED


Motor 2 OFF (Registration Loop adjustment - TRAY) (Normal paper)
Default=64ms
Range=74450ms (37225)
Range=73050ms (36525)
761-030 TRAY 3 FEED
START TIMING
Description
761-041 ADJUST REGI

LOOP(FROM Tray
5 & OHP)
Enable/Disable the B/W OHP (with frame)

0= Disable
1=Enable
67
42-92

Motor 2 OFF (Registration Loop adjustment - Tray 5) (OHP)
Default=134ms
Range=50ms (25)
Unit=2ms/step
Reissue
DocuColor 12/DCCS50
1/05
6-49
General Procedures

ChainLink
Name
761-042 ADJUST REGI

LOOP(DUPLEX
MODE)
Default
32
Range
7-57

ChainLink
Description
Time from Registration SENSOR ON to
Main Motor 2, DUP Motor OFF (Registration Loop adjustment - Duplex)
Default=64 ms
Name
761-048 ADJUST REGI

MOTOR ON TIMING (DUPLEX
MODE)
Default
1000
Range
9001100
Range=50ms (25)
Unit=2ms/step
38624062
Unit=0.5ms/step, 0.11mm/step
Time from the last image Pitch generation

to Registration Motor ON (Applied to all
modes.)
Default=1981ms
761-049 ADJUST REGI

MOTOR ON TIMING(OHP FULL
COLOR MODE)
Range=50ms (100)
4800
47004900
761-044 ADJUST REGI
86
MOTOR ON TIMING(PANEL B & 17
INCH PAPER)
0-186

to Registration Motor ON
(Adjusting value when the B side feed
length is longer than A3) B side or feed
length is longer than 420mm=(761-043) (761-044)
Default=43ms
4800
47004900

(Thick paper adjusting value) Thick paper
Timing (420mm or less)=(761-043) +
(761-045) Thick paper Timing (longer
than 420mm)=(761-043) + (761-045) (761-044)
Default=2400ms
761-050 ADJUST REGI

2680
MOTOR
SPEED(NORMAL
PAPER:221.168mm
/s)
25462814
Registration Feed: Registration Motor

speed
(Normal paper) Dividing
ratio=20MHzOctant divisionFrequency2+1
Default=2680PPS
761-051 ADJUST REGI

MOTOR
SPEED(STRONG
THICK PAPER:
130mm/s)
1583
15031662

speed
(Thick paper) Dividing
ratio=20MHzOctant divisionFrequency2+1
Default=1583PPS
761-052 ADJUST REGI

MOTOR
SPEED(OHP:
60.301mm/s)
731
694-768

speed
(OHP) Dividing ratio=20MHzOctant divisionFrequency2+1
761-053 Tray 5 FEED

CLUTCH ON TIMING
None
Time from Tray 5 Nudger Solenoid ON to

Tray 5 Feed Clutch OFF
unit=10ms/step
Range=2546-2814PPS (2546-2814)
Range=50ms (100)
Range=1503-1662PPS (1503-1662)
761-046 ADJUST REGI
MOTOR ON TIMING(STRONG
THICK PAPER)
4800
47004900

(4C OHP adjusting value) OHP Timing
(420mm or less)=(761-043)+(761049)OHP Timing (Longer than
420mm)=(761-043) +(761-049) -(761044)
Default=2400ms
Range=50ms (100)
Range=0-93ms (0-186)
761-045 ADJUST REGI
MOTOR ON TIMING(THICK
PAPER)

(Duplex Mode adjusting value) Duplex
Registration Feed Timing=(761043)+(761-048)-1000
Default=0ms
Range=50ms (100)

761-043 REGI MOTOR ON 3962
TIMING(PANEL A &
B)
Description

(Ultra thick paper adjusting value) Ultra
thick paper Timing (420mm or less)=(761043)+(761-046) Ultra thick paper Timing
(Longer than 420mm)=(761-043)+(761046) -(761-044)
Default=2400ms
Range=50ms (100)
General Procedures
1/05
6-50
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default
761-054 ADJUST PRE

0
FEED STOP POSITION(TRAY 1
NUDGER ROLL)
Range
0-31

ChainLink
Description
Nudger Roll OFF (PRE Feed stop position
- Adjustment)
Default=0ms
Name
761-063 INVERT MOTOR

OFF TIMING(DUPLEX
MODE)
Default
51
Range
38-68
Range=0-62ms (0-31)
Unit=2ms/step

0-39

ON TIMING(DUPLEX
MODE:PITCH
1200ms ONLY)

- Adjustment)
Default=0ms
328
325-331
0-39
Range=3250-3310ms (30ms) (325331)
Unit=2ms/step
Unit=10ms/step
(*1)LETL, A4L, B5L B/W, 4C MODE

- Adjustment)
Default=0ms

ON TIMING(DUPLEX
MODE: PITCH
2400ms ONLY)
Range=0-78ms (0-39)
Unit=2ms/step
426
423-429
0-39
Unit=10ms/step

- Adjustment)
Default=0ms

(*2) B/W Mode except LETL, A4L, B5L
and B4S, and, 4C Mode except LETL,
A4L and B5L
Range=0-78ms (0-39)
ON TIMING(DUPLEX
MODE: PITCH
2083ms ONLY)
Unit=2ms/step
761-058 FUSER ENTRANS 1
SENSOR ON JAM
TIMER SELECT
None
Switches the Fuser Entrance Sensor On

Jam Timer
0:PM1
91-121

ON TIMING(FACE
DOWN MODE)
40-70
395
392-398
Time from Registration Motor ON using

Pitch 2083ms Single Leaf Duplex(*3) to
Invert Motor ON (Duplex inversion start
timing)
Default=3950ms
Range=3920-3980ms (30ms) (392398)
Non 0: PM2 or later

761-061 ADJUST INVERT
101
MOTOR STOP
POSITION(FROM
FUSER EXIT SENSOR OFF)

Pitch 2400ms Duplex(*2) to Invert Motor
ON (Duplex inversion start timing)
Default=4260ms
Range=4230-4290ms (30ms) (423429)

761-057 ADJUST PRE
0
NUDGER ROLL)

Pitch 1200ms Duplex(*1) to Invert Motor
ON (Duplex inversion start timing)
Default=3280ms
Range=0-78ms (0-39)
761-056 ADJUST PRE
0
NUDGER ROLL)
Time from Invert Path SNR OFF to Invert

Motor OFF (Duplex Invert Point stop position - Adjustment)
Default=102ms
Range=76-136ms (38-68)
Unit=2ms/step
761-055 ADJUST PRE
0
NUDGER ROLL)
Description
Time from Fuser Exit SNR OFF to Invert

Motor OFF (Exit Invert Point stop position
- Adjustment)
Default=202ms
Unit=10ms/step
(*3)B4S B/W MODE
Range=182.-242ms (91-121)
Unit=2.ms/step
55
Time from Invert Motor OFF to Invert

Motor ON (Exit Invert Point stop time)
Default=110ms
Range=80-140ms (40-70)
Unit=2ms/step
Reissue
DocuColor 12/DCCS50
1/05
6-51
General Procedures

ChainLink
Name
Default
761-067 ADJUST DUPLEX 16

OUT MOTOR OFF
TIMING(FROM
DUPLEX OUT
SENSOR ON)
Range
0-85

ChainLink
Description
Time from Duplex Out Sensor ON to
Duplex Out Motor OFF (Duplex Wait Point
stop position - Adjustment)
Default=32ms
246
221-271
Range
10-20
Range=100-200ms (10-20)
Unit=10ms/step
761-095 ADJUST REGI
58
LOOP(From Tray 5
Postcard)
Duplex Out Motor ON start time to send

paper from the Duplex Tray (Duplex Feed
start timing)
Default=492 ms
33-83
Unit=2ms/step
761-101 ARRIVE AT TRAY 1 0
PRE FEED SENSOR 1(USED
TRAY 1)

Pitch 1500ms Single Leaf Duplex(*4) to
Invert Motor ON (Duplex inversion start
timing)
Default=3830ms
Last storage location - see 761-351.

TRAY 1)

(*4)40 PPM MODE
None

to #3 Take Away Feed Clutch ON
Default=150ms
Unit=0.5ms/step (Normal paper)
Unit=10ms/step

15-25
Measurement result: Timing from #1 Tray

Pre-Feed start to #1 Pre-Feed SENSOR
ON
Theoretical value=115ms
JAM TIMER=408ms (50PPM,
12.5PPM B side) = 458ms (Other)
Range=100-200ms (10-20)
761-091 TAKE AWAY 2

20
CLUTCH ON TIMING(USED TRAY 4)

ON
Unit=10ms/step
10-20
None

Range=3800-3860ms (30ms) (380386)
761-090 TAKE AWAY 3

15

Motor 2 OFF (Registration Loop adjustment - Tray 5: Postcard)
Default=116ms
Range=50ms (25)
Default DATA=246 (Quadrant MC

CLK)
380-386

to #2 Take Away Feed Clutch ON (Feed
from #3 Tray)
Default=150ms
Unit=2ms/step
Range=442-542ms (50ms) (221271)
383
Description
Range=0-170ms (40ms) (0-85)
Unit=2ms/step
761-069 SPAREINVERT
MOTOR ON TIMING(DUPLEX
MODE: PITCH
1500ms ONLY)
Default
761-092 TAKE AWAY 2

15
Default DATA=16 (Quadrant MC

CLK)
761-068 ADJUST DUPLEX
OUT MOTOR ON
START TIMING(FROM
DUPLEX TRAY)
Name

TRAY 1)

to #2 Take Away Feed Clutch ON (Feed
from #4 Tray)
Default=200ms
None

ON
Range=150-250ms (15-25)

Unit=10ms/step

General Procedures
1/05
6-52
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default

TRAY 1)
Range
None

ChainLink
Description
ON
Name
Default

TRAY 1)
Range
None

Description
ON


TRAY 1)
None

TRAY 1)

ON
None



761-111

TRAY 1)
None

ON
ARRIVE AT TRAY 2 0
TRAY 2)
None
Unit=0.5ms/step (Normal paper),

0.8458ms/step (Thick paper)

TRAY 2)

None

ON
None


TRAY 2)

None

Pre-Feed start to #2 Pre-Feed Sensor ON


TRAY 1)



TRAY 1)

ON

ON
None



Reissue
DocuColor 12/DCCS50
1/05
6-53
General Procedures

ChainLink
Name
Default

TRAY 2)
Range
None

ChainLink
Description
Name
Default

TRAY 2)

Range
None


None


TRAY 2)

None


None


TRAY 3)

None


None


TRAY 3)

None


None


TRAY 3)

General Procedures
None

Pre-Feed start to #3 Pre-Feed SNR ON


TRAY 2)


TRAY 2)


TRAY 2)


TRAY 2)
Description
1/05
6-54
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default

TRAY 3)
Range
None

ChainLink
Description
Name
Default

TRAY 3)

Range
None


None


TRAY 3)

None


None


TRAY 4)

None


None


TRAY 4)

None

None

Default=0ms
Range=None

TRAY 3)


TRAY 3)


TRAY 3)


TRAY 3)
Description




TRAY 4)

None

Reissue
DocuColor 12/DCCS50
1/05
6-55
General Procedures

ChainLink
Name
Default

TRAY 4)
Range
None

ChainLink
Description
Name
Default

TRAY 4)

Range
None


None


TRAY 4)

None


None


FEED OUT SENSOR 1(USED
TRAY1)

None


None

TRAY 1)

None

TRAY 1)

None

Pre-Feed start to #1 Feed Out SNR ON


TRAY 4)


TRAY 4)


TRAY 4)


TRAY 4)
Description

None


General Procedures
1/05
6-56
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default

TRAY 1)
Range
None

ChainLink
Description
Name
Default

TRAY 1)

Range
None

None



TRAY 2)

None

None



TRAY 2)

None


None


TRAY 2)


TRAY 1)
None



TRAY 2)

None
None


TRAY 1)


TRAY 1)


TRAY 1)


TRAY 1)
Description

None



Reissue
DocuColor 12/DCCS50
1/05
6-57
General Procedures

ChainLink
Name
Default

TRAY 2)
Range
None

ChainLink
Description
Name
Default

TRAY 2)

Range
None


None


TRAY 3)

None


None


TRAY 3)

None


None


TRAY 3)A

None


None


TRAY 3)

General Procedures
None



TRAY 2)


TRAY 2)


TRAY 2)


TRAY 2)
Description
1/05
6-58
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default

TRAY 3)
Range
None

ChainLink
Description
Name
Default

TRAY 3)

Range
None


None


TRAY 4)

None


None


TRAY 4)

None


None


TRAY 4)

None


None


TRAY 4)

Reissue
None

DocuColor 12/DCCS50


TRAY 3)


TRAY 3)


TRAY 3)


TRAY 3)
Description
1/05
6-59
General Procedures

ChainLink
Name
Default

TRAY 4)
Range
None

ChainLink
Description
Name
Default

TRAY 4)

Range
None


None

761-181 ARRIVE AT PRE

REGI SENSOR
1(USED TRAY 1)
None
None

REGI SENSOR
2(USED TRAY 1)

None

REGI SENSOR
3(USED TRAY 1)

None

REGI SENSOR
4(USED TRAY 1)

None

Feed start to Pre-Registration SNR ON
JAM TIMER=80-180ms

None

JAM TIMER=80-180ms


TRAY 4)

JAM TIMER=80-180ms

None

JAM TIMER=80-180ms

TRAY 4)


TRAY 4)


TRAY 4)
Description


REGI SENSOR
5(USED TRAY 1)
DSP: ARRV
PreRegiSNR5
Tray1

None

JAM TIMER=80-180ms
General Procedures
1/05
6-60
Reissue
DocuColor 12/DCCS50

ChainLink
Name

REGI SENSOR
6(USED TRAY 1)
Default
0
Range
None

ChainLink
Description
Name

REGI
SENSOR2(USED
TRAY 2)
JAM TIMER=80-180ms
Default
0
Range
None

0.8458ms/step (Thick paper1)

0
None


REGI
SENSOR3(USED
TRAY 2)
JAM TIMER=80-180ms
None
None



REGI
SENSOR4(USED
TRAY 2)
JAM TIMER=80-180ms
REGI SENSOR
9(USED TRAY 1)
None


None
None

JAM TIMER=320-420ms

REGI
SENSOR6(USED
TRAY 2)

0
JAM TIMER=320-420ms

JAM TIMER=80-180ms

REGI SENSOR
1(USED TRAY 2)


REGI
SENSOR5(USED
TRAY 2)

None
None


0

JAM TIMER=80-180ms

REGI SENSOR
10(USED TRAY 1)

JAM TIMER=320-420ms

REGI SENSOR
8(USED TRAY 1)

JAM TIMER=320-420ms

REGI SENSOR
7(USED TRAY 1)
Description

None

JAM TIMER=320-420ms
JAM TIMER=320-420ms

Reissue
DocuColor 12/DCCS50
1/05
6-61
General Procedures

ChainLink
Name

REGI
SENSOR7(USED
TRAY 2)
DSP: ARRV
PreRegiSNR7
Tray2
Default
0
Range
None

ChainLink
Description
Default=0ms

REGI SENSOR
2(USED TRAY 3)
Range
None


None

REGI
SENSOR3(USED
TRAY 3)

None

REGI
SENSOR4(USED
TRAY 3)

None

None
None
JAM TIMER=320-420ms

REGI
SENSOR5(USED
TRAY 3)

None

JAM TIMER=320-420ms
JAM TIMER=320-420ms


REGI
SENSOR6(USED
TRAY 3)

None


REGI SENSOR
1(USED TRAY 3)
JAM TIMER=320-420ms

0
REGI
SENSOR10(USED
TRAY 2)

JAM TIMER=320-420ms
JAM TIMER=320-420ms

JAM TIMER=320-420ms
JAM TIMER=320-420ms
Description

REGI
SENSOR9(USED
TRAY 2)
Default
Range=None

REGI
SENSOR8(USED
TRAY 2)
Name

None

JAM TIMER=320-420ms
AM TIMER=520-620ms


REGI
SENSOR7(USED
TRAY 3)
None

JAM TIMER=320-420ms
General Procedures
1/05
6-62
Reissue
DocuColor 12/DCCS50

ChainLink
Name

REGI
SENSOR8(USED
TRAY 3)
Default
0
Range
None

ChainLink
Description
Name

REGI SENSOR
4(USED TRAY 4)
Default
0
Range
None
JAM TIMER=320-420ms
Unit=0.5ms/step

0
None

REGI SENSOR
5(USED TRAY 4)

None
Unit=0.5ms/step
REGI SENSOR
6(USED TRAY 4)

None
Unit=0.5ms/step
REGI SENSOR
7(USED TRAY 4)

Unit=0.5ms/step

REGI SENSOR
8(USED TRAY 4)
None


JAM TIMER=720-820ms
Unit=0.5ms/step
JAM TIMER=720-820ms

REGI SENSOR
9(USED TRAY 4)
Unit=0.5ms/step
None
None
JAM TIMER=720-820ms

Unit=0.5ms/step
None

JAM TIMER=720-820ms

REGI SENSOR
3(USED TRAY 4)
None
JAM TIMER=320-420ms
JAM TIMER=720-820ms

0


REGI SENSOR
2(USED TRAY 4)
None
JAM TIMER=720-820ms


REGI SENSOR
1(USED TRAY 4)
JAM TIMER=320-420ms

0
REGI
SENSOR10(USED
TRAY 3)

JAM TIMER=720-820ms

REGI
SENSOR9(USED
TRAY 3)
Description
None


JAM TIMER=720-820ms
Unit=0.5ms/step
JAM TIMER=720-820ms

REGI SENSOR
10(USED TRAY 4)
Unit=0.5ms/step
None

JAM TIMER=720-820ms
Unit=0.5ms/step
Reissue
DocuColor 12/DCCS50
1/05
6-63
General Procedures

ChainLink
Name
761-221 ARRIVE AT REGI

SENSOR 1(USED
TRAY 1)
Default
0
Range
None

ChainLink
Description
#1 Tray: Measurement result - Registration Sensor ON timing after Feed start.
Name

SENSOR 6(USED
TRAY 1)
Default
0
Range
None
JAM TIMER=316-416ms (50PPM,

12.5PPM B side), 296-436ms
(Other)
0
None



SENSOR 7(USED
TRAY 1)
None

12.5PPM B side), 296-436ms
(Other)
0
None



SENSOR 8(USED
TRAY 1)
None

12.5PPM B side), 296-436ms
(Other)
0
None



SENSOR 9(USED
TRAY 1)
None

12.5PPM B side), 296-436ms
(Other)
0
None


761-230 ARRIVE AT REGI 0

SENSOR 10(USED
TRAY 1)

12.5PPM B side), 296-436ms
(Other)
General Procedures
None

12.5PPM B side), 296-436ms
(Other)

12.5PPM B side), 296-436ms
(Other)

SENSOR
5(USEDTRAY 1)

12.5PPM B side), 296-436ms
(Other)

SENSOR
4(USEDTRAY 1)

12.5PPM B side), 296-436ms
(Other)

SENSOR 3(USED
TRAY 1)

12.5PPM B side), 296-436ms
(Other)

SENSOR 2(USED
TRAY 1)
Description
1/05
6-64
Reissue
DocuColor 12/DCCS50

ChainLink
Name

SENSOR 1(USED
TRAY 2)
Default
0
Range
None

ChainLink
Description
Name

SENSOR 5(USED
TRAY 2)
Default
0
Range
None
None

12.5PPM B side), 536-676ms
(Other)

0.8458ms/step (This paper 1)



SENSOR 6(USED
TRAY 2)
None
None

12.5PPM B side), 536-676ms
(Other)




SENSOR 7(USED
TRAY 2)
None
None

12.5PPM B side), 536-676ms
(Other)




SENSOR 8(USED
TRAY 2)
Reissue
None


12.5PPM B side), 536-676ms
(Other)

12.5PPM B side), 536-676ms
(Other)


DocuColor 12/DCCS50


12.5PPM B side), 536-676ms
(Other)

SENSOR 4(USED
TRAY 2)

theoretical value=607ms

12.5PPM B side), 536-676ms
(Other)

SENSOR 3(USED
TRAY)


12.5PPM B side), 536-676ms
(Other)

SENSOR 2(USED
TRAY 2)
Description
1/05
6-65
General Procedures

ChainLink
Name

SENSOR 9(USED
TRAY 2)
Default
0
Range
None

ChainLink
Description
Name

SENSOR 3(USED
TRAY 3)
Default
0
Range
None
None

12.5PPM B side), 736-876ms
(Other)




SENSOR 4(USED
TRAY 3)
None
None

12.5PPM B side), 736-876ms
(Other)




SENSOR 5(USED
TRAY 3)
None
None

12.5PPM B side), 736-876ms
(Other)




SENSOR 6(USED
TRAY 3)
General Procedures
None


12.5PPM B side), 736-876ms
(Other)

12.5PPM B side), 736-876ms
(Other)




12.5PPM B side), 736-876ms
(Other)

SENSOR 2(USED
TRAY 3)


12.5PPM B side), 536-676ms
(Other)

SENSOR 1(USED
TRAY 3)


12.5PPM B side), 536-676ms
(Other)

SENSOR 10(USED
TRAY 2)
Description
1/05
6-66
Reissue
DocuColor 12/DCCS50

ChainLink
Name

SENSOR 7(USED
TRAY 3)
Default
0
Range
None

ChainLink
Description
Name

SENSOR 1(USED
TRAY 4)
Default
0
Range
None
None
AM TIMER=956-1056ms (50PPM,
12.5PPM B side), 936-1076ms
(Other)




SENSOR 2(USED
TRAY 4)
None
None
12.5PPM B side), 936-1076ms
(Other)




SENSOR 3(USED
TRAY 4)
None
None
12.5PPM B side), 936-1076ms
(Other)




SENSOR 4(USED
TRAY 4)
Reissue
None


12.5PPM B side), 736-876ms
(Other)
12.5PPM B side), 936-1076ms
(Other)


DocuColor 12/DCCS50


12.5PPM B side), 736-876ms
(Other)

SENSOR 10(USED
TRAY 3)


12.5PPM B side), 736-876ms
(Other)

SENSOR 9(USED
TRAY 3)A


12.5PPM B side), 736-876ms
(Other)

SENSOR 8(USED
TRAY 3)
Description
1/05
6-67
General Procedures

ChainLink
Name

SENSOR 5(USED
TRAY 4)
Default
0
Range
None

ChainLink
Description
Name

SENSOR 9(USED
TRAY 4)
Default
0
Range
None
None
12.5PPM B side), 936-1076ms
(Other)




SENSOR 10(USED
TRAY 4)
None
None
12.5PPM B side), 936-1076ms
(Other)



761-261 PASS REGI SENSOR 1(USED

TRAY 1)
None
12.5PPM B side), 936-1076ms
(Other)

TRAY 1)

0
None
Measurement result: Register Sensor

OFF timing from the Registration Feed
(paper fed from Tray 1).
Theoretical value=Paper
length221.168mm/S
Unit=2ms/step

SENSOR 8(USED
TRAY 4)

12.5PPM B side), 936-1076ms
(Other)

SENSOR 7(USED
TRAY 4)

12.5PPM B side), 936-1076ms
(Other)

SENSOR 6(USED
TRAY 4)
Description

None

length221.168mm/S
Unit=2ms/step
12.5PPM B side), 936-1076ms
(Other)

TRAY 1)

None

length221.168mm/S
Unit=2ms/step
General Procedures
1/05
6-68
Reissue
DocuColor 12/DCCS50

ChainLink
Name

TRAY 1)
Default
0
Range
None

ChainLink
Description
length221.168mm/S
Name

TRAY 1)
Default
0
Range
None
Unit=2ms/step
0
None

length221.168mm/S

TRAY 2)
None
Unit=2ms/step
0
None

length221.168mm/S
Unit=2ms/step (Normal paper)

Unit=3.3832ms/step (This paper 1)
TRAY 2)
Unit=2ms/step
TRAY 1)
None
None

length221.168mm/S
Unit=2ms/step
None


length221.168mm/S

TRAY 2)
Unit=2ms/step
TRAY 1)
None

length0.221168mm/s (Normal
paper)
length0.130mm/s (This paper 1)

TRAY 1)

paper)

TRAY 1)

length221.168mm/S
Unit=2ms/step

TRAY 1)
Description
None

paper)

length221.168mm/S

Unit=2ms/step
Reissue
DocuColor 12/DCCS50
1/05
6-69
General Procedures

ChainLink
Name

TRAY 2)
Default
0
Range
None

ChainLink
Description
paper)
Name

TRAY 2)
Default
0
Range
None


0
None

paper)

TRAY 2)
None


0
None

paper)

TRAY 2)
None


0
None

paper)

TRAY 3)
None

paper)


General Procedures

paper)
TRAY 2)

paper)
TRAY 2)

paper)
TRAY 2)
Description
1/05
6-70
Reissue
DocuColor 12/DCCS50

ChainLink
Name

TRAY 3)
Default
0
Range
None

ChainLink
Description
paper)
Name

TRAY 3)
Default
0
Range
None


0
None

paper)

TRAY 3)
None


0
None

paper)

TRAY 3)
None


0
None

paper)
761-289 PASS REGI

SENSOR9(USED
TRAY 3)
None

paper)


Reissue
DocuColor 12/DCCS50

paper)
TRAY 3)

paper)
TRAY 3)

paper)
TRAY 3)
Description
1/05
6-71
General Procedures

ChainLink
Name

TRAY 3)
DSP: Pass
RegiSNR10 Tray3
Default
0
Range
None

ChainLink
Description
Default=0ms
Name

TRAY 4)
Default
0
Range
None
Range=None
paper)


TRAY 4)

0
None

paper)
None


TRAY 4)

0
None

paper)

TRAY 4)

paper)

TRAY 4)
Description

paper)
None

paper)

TRAY 4)
None

paper)
General Procedures
1/05
6-72
Reissue
DocuColor 12/DCCS50

ChainLink
Name

TRAY 4)
Default
0
Range
None

ChainLink
Description
paper)
Name

TRAY 4)
DSP: Pass
RegiSNR10 Tray4
Default
0
Range
None
paper)

0
None

paper)

761-301 ARRIVE AT FUSER 0
EXIT SENSOR 1
DSP: ARRV Fuser
Exit SNR 1
None
Theoretical value=1815ms, 3071ms

(This paper 1), 6655ms (Thick paper
2)

0
None
Measurement result: Fuser Exit Sensor

ON timing from Registration Feed start.
Default=0ms
Range=None

TRAY 4)
DSP: Pass
RegiSNR9 Tray4

Default=0ms
Range=None

TRAY 4)
Description
Unit=10ms/step

Default=0ms

EXIT SENSOR 2
DSP: ARRV Fuser
Exit SNR 2
Range=None
paper)
None

Default=0ms
Range=None
2)
Unit=10ms/step

Reissue
DocuColor 12/DCCS50
1/05
6-73
General Procedures

ChainLink
Name
Default

EXIT SENSOR 3
DSP: ARRV Fuser
Exit SNR 3
Range
None

ChainLink
Description
Default=0ms
Name
Default

EXIT SENSOR 7
Range
None
Range=None
2)
Unit=10ms/step
EXIT SENSOR 8
None

None

Default=0ms
Unit=10ms/step
Range=None

EXIT SENSOR 9
None
Unit=10ms/step

Default=0ms

EXIT SENSOR 10
None
Range=None
2)
Unit=10ms/step
761-311 PASS Machine
EXIT SENSOR 1

None

2)
Unit=10ms/step

EXIT SENSOR 6
DSP: ARRV Fuser
Exit SNR 6

2)
Unit=10ms/step

None

2)

2)

EXIT SENSOR 5
DSP: ARRV Fuser
Exit SNR 5

2)
Unit=10ms/step

EXIT SENSOR 4
DSP: ARRV Fuser
Exit SNR 4
Description

2)
None
Measurement result (Last 10): Machine

Exit Sensor OFF timing from Fuser Exit
Sensor OFF.
Theoretical value=221ms (Straight
ejection), 509.7ms+(Paper
lengthmm+7.1mm) / 0.350mm/ms
(Reverse ejection)
Unit=10ms/step
Unit=10ms/step
General Procedures
1/05
6-74
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default

0
EXIT SENSOR 2
DSP: Pass Machine
Exit SNR 2
Range
None

ChainLink
Description
Sensor OFF.
Default=0ms
Name

EXIT SENSOR 6
Default
0
Range
None
Range=None
(Reverse ejection)
Unit=10ms/step
EXIT SENSOR 7
None

0
None

Sensor OFF.
(Reverse ejection)
Unit=10ms/step
EXIT SENSOR 8
None

0
None

Sensor OFF.
(Reverse ejection)
Unit=10ms/step
EXIT SENSOR 9
None

0
None

Sensor OFF.
(Reverse ejection)
Unit=10ms/step
EXIT SENSOR 5

Sensor OFF.
(Reverse ejection)
Unit=10ms/step
EXIT SENSOR 4

Sensor OFF.
(Reverse ejection)
Unit=10ms/step

EXIT SENSOR 3
Description

Sensor OFF.
(Reverse ejection)

Sensor OFF.
(Reverse ejection)
Unit=10ms/step

EXIT SENSOR 10
Unit=10ms/step
None

Sensor OFF.
(Reverse ejection)
Unit=10ms/step
Reissue
DocuColor 12/DCCS50
1/05
6-75
General Procedures

ChainLink
Name
761-321 1PASS INVERT

PATH SENSOR 1
761-322 PASS INVERT

PATH SENSOR 2
761-323 PASS INVERT

PATH SENSOR 3
761-324 PASS INVERT

PATH SENSOR 4
761-325 PASS INVERT

PATH SENSOR 5
Default
0
General Procedures
Range
None
None
None
None
None

ChainLink
Description
Measurement result (Last 10): Invert Path
Sensor OFF timing from Fuser Exit Sensor OFF.
Name
761-326 PASS INVERT

PATH SENSOR 6
Default
0
Range
None
Description
JAM TIMER=250-532ms
JAM TIMER=250-532ms
Unit=10ms/step
Unit=10ms/step

761-327 PASS INVERT

PATH SENSOR 7
None

JAM TIMER=250-532ms
JAM TIMER=250-532ms
Unit=10ms/step
Unit=10ms/step

761-328 PASS INVERT

PATH SENSOR 8
None

JAM TIMER=250-532ms
JAM TIMER=250-532ms
Unit=10ms/step
Unit=10ms/step

761-329 PASS INVERT

PATH SENSOR 9
None

JAM TIMER=250-532ms
JAM TIMER=250-532ms
Unit=10ms/step
Unit=10ms/step

761-330 PASS INVERT

0
PATH SENSOR 10
None

JAM TIMER=250-532ms
JAM TIMER=250-532ms
Unit=10ms/step
Unit=10ms/step
1/05
6-76
Reissue
DocuColor 12/DCCS50

ChainLink
Name
761-331 ARRIVE AT
DUPLEX PATH
SENSOR 1
Default
0
Range
None

ChainLink
Description
Measurement result (Last 10): Dup Path
Sensor ON timing from Dup In Sensor
ON.
Name
761-337 ARRIVE AT
DUPLEX PATH
SENSOR 7
Default
0
Range
None
Unit=10ms/step
761-332 ARRIVE AT
DUPLEX PATH
SENSOR 2
None
None
Unit=10ms/step

ON.
761-338 ARRIVE AT
DUPLEX PATH
SENSOR 8
None
None
Unit=10ms/step

ON.
761-339 ARRIVE AT
DUPLEX PATH
SENSOR 9
None
761-336 ARRIVE AT
DUPLEX PATH
SENSOR 6
None
Unit=10ms/step

ON.
761-340 ARRIVE AT
DUPLEX PATH
SENSOR 10
None
None
Unit=10ms/step

ON.
761-341 ARRIVE AT
DUPLEX OUT
SENSOR 1
Reissue
None
Measurement result (Last 10): Duplex Out

Sensor ON timing from Duplex Path Sensor ON.
Unit=10ms/step

ON.
761-342 ARRIVE AT
DUPLEX OUT
SENSOR 2
Unit=10ms/step
DocuColor 12/DCCS50

ON.
Unit=10ms/step

ON.
Unit=10ms/step
761-335 ARRIVE AT
DUPLEX PATH
SENSOR 5
DSP: ARRV DUP
Path SNR 5

ON.
Unit=10ms/step
761-334 ARRIVE AT
DUPLEX PATH
SENSOR 4

ON.
Unit=10ms/step
761-333 ARRIVE AT
DUPLEX PATH
SENSOR 3
Description
None

Unit=10ms/step
1/05
6-77
General Procedures

ChainLink
Name
761-343 3ARRIVE AT
DUPLEX OUT
SENSOR 3
DSP: ARRV DUP
out SNR 3
Default
0
Range
None

ChainLink
Description
Default=0ms
Name
761-348 ARRIVE AT
DUPLEX OUT
SENSOR 8
Default
0
Range
None
Range=None
Unit=10ms/step
761-349 ARRIVE AT
DUPLEX OUT
SENSOR 9

0
None

None

761-350 ARRIVE AT
0
DUPLEX OUTSENSOR 10

0
None

None


0
None

Unit=10ms/step
761-347 ARRIVE AT
DUPLEX OUT
SENSOR 7
None

Unit=10ms/step
General Procedures

Unit=10ms/step
Unit=10ms/step
761-346 ARRIVE AT
DUPLEX OUT
SENSOR 6

Unit=10ms/step
Unit=10ms/step
761-345 ARRIVE AT
DUPLEX OUT
SENSOR 5

Unit=10ms/step
761-344 ARRIVE AT
DUPLEX OUT
SENSOR 4
Description
1/05
6-78

PRE FEED SENSOR INDICATE
POINT
0-9
Shows the location of the latest timings

(761-101-110) (#1 Pre-Feed Sensor
arrival timings 1-10)
e.g.; If the value is 5, the latest data is
saved in 5, the previous data is saved in
4, and the data prior to the previous data
is saved in 3.

POINT
0-9

(761-111-120) (#2 Pre-Feed Sensor
e.g.;: If the value is 5, the latest data is
is saved in 3.

POINT
0-9

(761-121-130) (#3 Pre-Feed Sensor
arrive timings 1-10)
is saved in 3.
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default
Range

ChainLink
Description
Name
Default
Range
Description
761-354 ARRIVE AT TRAY4 0

POINT
0-9

(761-131-140) (#4 Pre-Feed Sensor
is saved in 3.

REGI SENSOR
INDICATE
POINT(USED
TRAY 2)
0-9

(761-191-200) (#2 Pre-Regi Sensor
is saved in 3.

FEED OUT SENSOR INDICATE
POINT
0-9

(761-141-150) (#1 Feed Out Sensor
is saved in 3.

REGI SENSOR
INDICATE
POINT(USED
TRAY 3)
0-9

(761-201-210) (#3 Pre-Regi Sensor
is saved in 3.

POINT
0-9

(761-151-160) (#2 Feed Out Sensor
is saved in 3.

REGI SENSOR
INDICATE
POINT(USED
TRAY 4)
0-9

(761-211-220) (#4 Pre-Regi Sensor
is saved in 3.

POINT
0-9

(761-161-170) (#3 Feed Out Sensor
is saved in 3.

SENSOR INDICATE
POINT(USED
TRAY 1)
0-9

(761-221-230) (#1 Regi Sensor arrival
timings 1-10)
is saved in 3.

POINT
0-9

(761-171-180) (#4 Feed Out Sensor
is saved in 3.

SENSOR INDICATE
POINT(USED
TRAY 2)
0-9

timings 1-10)
is saved in 3.

REGI SENSOR
INDICATE
POINT(USED
TRAY 1)
0-9

(761-181-190) (#1 Pre-Regi Sensor
is saved in 3.

SENSOR INDICATE
POINT(USED
TRAY 3)
0-9

timings 1-10)
is saved in 3.
Reissue
DocuColor 12/DCCS50
1/05
6-79
General Procedures

ChainLink
Name
Default
Range

ChainLink
Description
Name
Default
Range
Description

SENSOR INDICATE
POINT(USED
TRAY 4)
0-9

timings 1-10)
is saved in 3.
761-372 Machine EXIT

SENSORINDICATE POINT
0-9

(761-311-320) (Machine Exit Sensor
is saved in 3.
761-367 PASS REGI SENSOR INDICATE

POINT(USED
TRAY 1)
0-9

(761-261-270) (#1 Regi Sensor pass timings 1-10)
is saved in 3.
761-373 PASS A INVERT

PATH SENSOR
INDICATE POINT
0-9

(761-321-330) (Invert path Sensors 1-10)
is saved in 3.
0-9
0-9

is saved in 3.
761-374 ARRIVE AT
DUPLEX PATH
SENSOR INDICATE POINT

POINT(USED
TRAY 2)

(761-331-340) (Invert path Sensors 1-10)
is saved in 3.
761-375 ARRIVE AT
DUPLEX OUT
SENSOR INDICATE POINT
0-9

(761-341-350) (Duplex Out Sensors 1-10)
is saved in 3.

POINT(USED
TRAY 3)
0-9

is saved in 3.

POINT(USED
TRAY 4)
0-9

is saved in 3.
761-371 FUSER EXIT SEN- 0

SORINDICATE
POINT
0-9

(761-301-310) (#1 Fuser Exit Sensor
is saved in 3.
General Procedures
1/05
6-80
Reissue
DocuColor 12/DCCS50
dC131SYS NVM List (752)
Table 1 SYS NVM List (752)

ChainLink

ChainLink
Name
752-001 MARKET
752-002 EPSV EXIST
Default
-
Range
0-3
0-1
0=FX
1=AP
2=NASG
3=ESG
Machine determines the market
from this parameter. This area is
not initialized.
0= No
1= Yes
0-1
0= No
1= Yes This is sent as optional
data when entering into the PWS
Service Mode.
752-004 MDSS EXIST
0-1
0 = No MDSS
1 = MDSS Connected
752-005 XJ CODE PIN Number 1
0-255
Factory management code
0-255
0-255
752-008 Machine CONFIG
0-4
0=DC
1=CP
2=CPS
3=P
4=P (with UI)
For the optional data sent when
entering into the PWS Service
Mode
752-009 DADF EXIST
0-1
0= None (Platen)
1= DADF
Mode (Automatically set at Power
On)
752-010 OUTPUT CONFIG
0-3
0= No (Top tray),
1= Offset Catch Tray,
2= Sorter,
3= Mail Box
For the option data sent when
On)
Reissue
Default
Range
1/05
6-81
Description
752-011 MULTI TRAY CONFIG
0-1
0= No,
1= HCF
On)
752-012 (Spare)
0-1
752-013 PRODUCT CODE No 1
0-255
Product code (ASCII Code)
0-255
0-255
0-255
752-017 EPC Option Config
0-2
0 = no EPC
1 = EPC @ 1st DDI
2 = EPC @ 2nd DDI
752-018 Auto Upgrade NVM
0-65535 NVM automatic upgrade function

after introduction in the market.
Description
752-003 TELEPHONE LINE

EXIST
DocuColor 12/DCCS50
Name
General Procedures

ChainLink

ChainLink
Name
759-054 Scan ESS INFO

Name
Default
Range
Default
0
Range
0-5
Description
759-005 FORCED FACE UP EXIT
0-1
0= Invert ejection
1= Straight ejection
759-006 REPEAT MARGIN
0-1
0= Repeat margin= 3mm

1= Repeat margin= 0mm
759-011 APS PRIORITY
0-1
The meaning differs depending on

the Market data in SYS NVM number 752-001.
(FX/AP, RX) 0= AB 1= Inch
(TBD)
759-018 A-I/F SET
0-1
0= No A-I/F KIT, 1= with A-I/F KIT

(MN unique FX/FXAP is not used.)
759-021 DADF MODE MAG100

ADJ
0-1
0= Equal magnification - Fine adjust

1= Equal magnification - No fine
adjustment
759-023 GRADATION ADJ RST

SEL
0-2
2= 1st, 2nd I/F Port connection

3= 1st I/F Port connection
(+Scan to File Job)
4= 2nd I/F Port connection
(+Scan to File Job)
(+Scan to File Job)
759-073 Accessory Kit Control 1
0-1
0= No Tools setup/No MAXSETUP
759-074 Accessory Kit Control 2
0-1
2= Tools reset/MAXSETUP
reset
0
0-2
2= Infinite Copy
759-051 ESS PORT PRIORITY
0
0
0-1
0-1
0 = 4 digit Product Code

1 = 8 digit Product Code
0= 1st I/F Port connection ESS priority
1= 2nd I/F Port connection ESS priority
759-052 Job Acceptance Prohibition Timer
30
759-053 Print ESS INFO
1-255
0-2
(Unit= Second) Max= 4 minutes 15

seconds
Valid if Machine Config is P, P(with
UI), CP, or CPS, and sets the Print
ESS connection status.
General Procedures
Sets the Print Job accessory (2nd

DDI Port).
0= With Card, No Job permission without job count card
0= No Paper Run - Not

selected
1= Stop at page count limit
759-042 Product Code Switch
Sets the Print Job accessory (1st

DDI Port).
1= Tools reset/No MAXSETUP
759-024 NO PAPER RUN SEL
Valid if Machine Config is CPS, and

sets the Print ESS connection status.
(NASG) 0= Inch 1= AB
759-014 NVM VERSION (for EP)
Description
1/05
6-82
759-075 Billing Counter Display
0-1
0= Not displayed, 1= Displayed
759-113 SET Major Version
SW Set Version 1 (0-99)
759-114 SET Minor Version
759-115 SET Revision
759-116 SET Patch
0-9
a-z
SW Set Version 4
759-117 IOSS Major Version
IOSS SW Version1 (0-99)
759-118 IOSS Minor Version
759-119 IOSS Revision
759-120 IOSS Patch
0-9
a-z
IOSS SW Version
759-121 UI-P Major Version
UI Program SW Version1 (0-99)
759-122 UI-P Minor Version
759-123 UI-P Revision
759-124 UI-P Patch
0-9
a-z
UI Program SW Version4
759-125 UI-F Major Version
UI Frame SW Version1 (0-99)
759-126 UI-F Minor Version
759-127 UI-F Revision

Reissue
DocuColor 12/DCCS50
dC131 BILLING NVM List (990)

ChainLink
Name
Default
Range
Description
759-128 UI-F Patch
0-9
a-z
UI Frame SW Version4
759-139 IOT-SYS ROM VER 1
(Initialization/Write: prohibited) Cap

(ex: a ->10, b->11)
759-140 IOT-SYS ROM VER 2
(Initialization/Write: prohibited)
VERSION (0-999)
759-141 P-SYS 1 ROM VER 1
759-145 S-SYS 1 ROM VER 1
759-149 JOB CON ROM VER 1
759-150 JOB CON ROM VER 2
Reissue
DocuColor 12/DCCS50
Table 1 Billing NVM List (900)

ChainLink
1/05
6-83
Name
Default
Range
Description
990-001 Full Color Copy billing meter

(Upper) (IOT EEP-ROM)
Full Color Copy electronic

billing (001& 002: One billing)

(Lower) (IOT EEP-ROM)
(001& 002: One)
990-003 Full Color Print billing meter

Full Color Print electronic


(003& 004: One)
990-005 B/W Copy billing meter (Upper)

(IOT EEP-ROM)
B/W Copy electronic billing

(005& 06: One billing)
990-006 B/W Copy billing meter (Lower)

(IOT EEP-ROM)
(005& 006: One)
990-007 B/W Print billing meter (Upper)

(IOT EEP-ROM)
B/W Print electronic billing

990-008 B/W Print billing meter (Lower)

(IOT EEP-ROM)
(007& 008: One)
990-009 Large Size Full Color billing meter (Upper) (IOT EEP-ROM)
Large Size Full Color electronic billing (009& 010: One

billing)
990-010 Large Size Full Color billing meter (Lower) (IOT EEP-ROM)
(009& 010: One)
990-011 Large Size B/W billing meter

Large Size B/W electronic


(011& 012: One)

(Upper) (Half-Tone EEP-ROM)


(Lower) (Half-Tone EEP-ROM)
(013& 014: One)

Full Color Print electronic


(015& 016: One)
990-017 B/W Copy billing meter (Upper)

(Half-Tone EEP-ROM)
B/W Copy electronic billing

990-018 B/W Copy billing meter (Lower)

(Half-Tone EEP-ROM)
(017& 018: One)
General Procedures
dC131SYS NVM List (759), dC131 BILLING NVM
dC131 Procon1 NVM List (773)
Table 1 Billing NVM List (900)

ChainLink
Name
Default
Range
Description
990-019 B/W Print billing meter (Upper)

(Half-Tone EEP-ROM)
B/W Print electronic billing

990-020 B/W Print billing meter (Lower)

(Half-Tone EEP-ROM)
(019& 020: One)
990-021 Large Size Full Color billing meter (Upper) (Half-Tone EEP-ROM)
Large Size Full Color electronic billing (021& 022: One

billing)
990-022 Large Size Full Color billing meter (Lower) (Half-Tone EEP-ROM)
(021& 022: One)

Large Size B/W electronic


(023& 024: One)

(Upper) (NVM)

Table 1 Procon 1 NVM List (773)

ChainLink
Name
773-001 DISP SW
Default
1
Range
Description
0-65535 Toner control switch

0= Display control by NVM
timer
1= Display control by
ADC+ICDC
2 or more= Display control by
ICDC
773-002 ELEC SW
0-65535 Potential/Light control switch

0= Fixed NVM (773-401 - 773404): VG control, Fixed NVM
(773-421): LD control, Fix
NVM: BIAS/ASG control (VH/
VM Setup and LDCONT functions: Not done) (VH/VM patch:
Created and measured,
LDCONT VM patch: Not created)
1= VH/VM Setup - VG/BIAS/
ASG value corrected, LD
CONT-LD value corrected
2 or more= VH/VM Setup - VG/
BIAS value/LD value corrected
(LDCONT function not done.
No VM patch is created)
773-007 TRC SW
0-65535 Gray scale control switch

0= LUT through - ADC patch is
measured.
1= LUT calculation in the Gray
scale control (TRC CONT MIN/
JOB)
2= LUT calculation only in TRC
CONT MIN. ADC measurement.
3 or more= LUT is not calculated. ADC patch is measured.
General Procedures
dC131 BILLING NVM List (990), dC131 Procon1 NVM
1/05
6-84
773-011 Vclean Fail
0-65535 Vclean measurement= Number of

Faults (Hidden Fault)
773-012 VHVM Fail
0-65535 VH/VM Setup= Number of Faults

(Hidden Fault)
773-013 LDCONT Fail
0-65535 LD CONTROL= Number of Faults

(Hidden Fault)
773-014 Hum Fail
0-65535 Humidity measurement= Number of

Faults (Hidden Fault)
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default
Range
773-016 ADC Vp Fail (Y)
0-65535 ADC patch Fault (Y)
773-017 ADC Vp Fail (M)
0-65535 ADC patch Fault (M)
773-018 ADC Vp Fail (C)
0-65535 ADC patch Fault (C)
773-019 ADC Vp Fail (K)
0-65535 ADC patch Fault (K)
773-071 VGS Fail
Number of VGS Faults
773-072 VHS FAIL
Number of VHS Faults
773-073 LDS FAIL
Number of LDS Faults
773-074 VMS FAIL
773-231 AGCS S
300
0-1023
773-251 ADC Vclean S A
0-65535 ADC non development output: Asurface measurement (Mirror surface element)
773-252 ADC Vclean S B
0-65535 ADC non development output: Bsurface measurement (Mirror surface element)
180
0-65535 K-color: Correction target ADC

patch density (after correction) at
VH/VM SETUP
773-382 VGS CALC
710
0-1023
VGS calculated value (VH/VM

SETUP)
Number of VMS Faults
773-384 LDS CALC
126
0-255
Gain output for ADC SNR mirror finished surface element
LDS calculated value (VH/VM

SETUP)
773-421 LD JOB
126
0-255
LD light amount during copy

(Updated: VH/VM SETUP and
LDCONT)
773-516 Kicdc [Y]
0-65535 Y-color: ICDC supply calculation

coefficient (positive only)
773-517 Kicdc [M]
0-65535 M-color: ICDC supply calculation

773-518 Kicdc [C]
0-65535 C-color: ICDC supply calculation

773-519 Kicdc [K]
10
0-65535 K-color: ICDC supply calculation

773-571 Kadc posi [Y]
250
0-65535 Y-color: ADC toner supply calculation coefficient (for positive value)
773-572 Kadc posi [M]
250
0-65535 M-color: ADC toner supply calculation coefficient (for positive value)
773-573 Kadc posi [C]
250
0-65535 C-color: ADC toner supply calculation coefficient (for positive value)
773-574 Kadc posi [K]
350
0-65535 K-color: ADC toner supply calculation coefficient (for positive value)
773-576 Kadc nega [Y]
375
0-65535 Y-color: DSP: ADC toner supply calculation coefficient (for negative
value)
773-577 Kadc nega [M]
375
0-65535 M-color: DSP: ADC toner supply calculation coefficient (for negative
value)
773-578 Kadc nega [C]
375
0-65535 C-color: DSP: ADC toner supply calculation coefficient (for negative
value)
773-579 Kadc nega [K]
500
0-65535 K-color: DSP: ADC toner supply calculation coefficient (for negative
value)
773-591 ADC Vpatch S [Y]
0-65535 Y-color: ADC patch measurement

value (Mirror element)
0-65535 ADC non development output: Bsurface measurement (diffusion element)
773-261 VHS target
717
0-65535 Target VH potential (before correction) at VH/VM SETUP: 700v
773-266 Radc SET [Y]
250
0-65535 Y-color - Target ADC patch density

(before correction) at VH/VM
SETUP
773-267 Radc SET [M]
250
0-65535 M-color - Target ADC patch density

SETUP
0-65535 C-color - Target ADC patch density
SETUP
0-65535 K-color - Target ADC patch density
SETUP
773-276 VHS Adj
717
0-65535 Correction target VH potential (after

correction) at VH/VM SETUP
773-281 Radc SET Adj [Y]
250
0-65535 Y-color: Correction target ADC patch

density (after correction) at VH/VM
SETUP
773-282 Radc SET Adj [M]
250
0-65535 M-color: Correction target ADC

VH/VM SETUP
Reissue
DocuColor 12/DCCS50
Description
773-284 Radc SET Adj [K]
773-257 ADC Vclean D B
180
Range
0-65535 C-color: Correction target ADC

VH/VM SETUP
0-65535 ADC non development output: Asurface measurement (diffusion element)
773-269 Radc SET [K]
Default
280
280
Name
773-283 Radc SET Adj [C]
773-256 ADC Vclean D A
773-268 Radc SET [C]
ChainLink
Description
1/05
6-85
General Procedures

ChainLink
Name
Default
Range
Description
773-592 ADC Vpatch S [M]
0-65535 M-color: ADC patch measurement

773-593 ADC Vpatch S [C]
0-65535 C-color: ADC patch measurement

773-594 ADC Vpatch S [K]
773-596 ADC Vpatch D [Y]
Table 1 Procon2 NVM List (774)

ChainLink
Name
Default
Range
Description
774-001 CC I TOT
717
0-1023
0-65535 K-color: ADC patch measurement

Current total CC electric current

(0=0 micro ampere 1023=1000
micro ampere)
774-004 CC V GRID
717
0-1023
0-65535 Y-color: DSP: ADC patch measurement value (Diffusion element)
Current grid CC voltage (0=0V

1023=1000V)
774-005 CC V GRID DFLT
717
0-1023
773-597 ADC Vpatch D [M]
0-65535 M-color: DSP: ADC patch measurement value (Diffusion element)
Grid voltage to check the CC

output (0=0V 1023=1000V)
773-598 ADC Vpatch D [C]
0-65535 C-color: DSP: ADC patch measurement value (Diffusion element)
773-599 ADC Vpatch D [K]
0-65535 K-color: DSP: ADC patch measurement value (Diffusion element)
773-606 Radc patch [Y]
0-65535 Y-color: ADC patch measurement

density
773-607 Radc patch [M]
0-65535 M-color: ADC patch measurement

density
773-608 Radc patch [C]
0-65535 C-color: ADC patch measurement

density
773-609 Radc patch [K]
0-65535 K-color: ADC patch measurement

density
774-008 BOTTLE NOT IN POSI- 0

TION
Waste bottle (0=Yes 1=No)
774-015 BOTTLE EMP

COUNTER
EMPTY counter
774-017 BOTTLE EMP HOLD
EMP Counter record when the

Bottle Goal was determined.
774-018 BOTTLE FULL
Collection status FLG (0= Empty

1= Near Full 2= Full)
774-019 BOTTLE FULL

COUNTER
Near Full Counter
774-020 BOTTLE GOAL
300
0-65536
Threshold to generate a Bottle

Full Fault
774-029 PCC dC 12
130
0-255
DC current to reduce cycle 1-2

(0=0 micro ampere 255=800
micro ampere)
(If out of the range, MAX value is
output.)
774-033 PCC dC ER
96
0-255
DC current for elimination= Nominal (0=0 micro ampere 255=800

micro ampere)
(If out of the range, MAX value is
output.)
774-056 X CRU TYPE
48=FSMA 0-255
49=T&M
Drum unit type (0XAA)
774-057 CRU COUNT MODE
Shut-down condition setting flag

0= Shut-down with the set
count value.
0-1
1= Shut-down when
exceeding the set count
value.
General Procedures
dC131 Procon1 NVM List (773), dC131 Procon2 NVM
1/05
6-86
774-070 DRUM CYCLEUPPER

L
Drum cycle count: L side count

(0-99)
774-071 DRUM CYCLEUPPER

H
3400
Drum cycle count: H side count

(0-65535)
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default
Range
Description
774-074 DISP TIMELOWER
Toner dispense time: L side

value (0-3599/Unit: 0.1 second)
774-075 DISP TIMEUPPER
2000
Toner dispense time: H side

value (0-65535/Unit: 0.1 hour)
775-001 Vclean TRC Fail
0-65535
TRC ADC non-development: Output Fault counter
774-081 SIGN DRUM
Drum cycle counter: Counter

sign (0: Positive, 256: Negative)
Upper byte: Drum cycle counter
sign
775-002 TRC MINI Fail [Y]
0-65535
TRC patch fault counter (Y)
775-003 TRC MINI Fail [M]
0-65535
TRC patch fault counter (M)
775-004 TRC MINI Fail [C]
0-65535
TRC patch fault counter (C)
775-005 TRC MINI Fail [K]
0-65535
TRC patch fault counter (K)
775-019 MINI Timer SW
0-1
For Run Length=0 uncontrollable fault at Maxsetup

(Tone Up/Down)
0= Tone Up/Down
minimum run pages=3
(Mixing)
774-173 AUGER STOP
0-3
Auger rotation detection Status

flag
0= Normal
1= Normal now but abnormal
rotation before
2= Abnormal
3= Machine stop)
774-174 AUGER COUNTER
0-65535
Collection Auger Stop counter

(Unit= Print)
774-175 AUGER GOAL
200
0-65535
Threshold to generate the

Cleaning AUGER Broken Fault
Reissue
DocuColor 12/DCCS50
ChainLink
Name
Default
Range
Description
1 or more= Tone Up/

Down minimum run
page=0
<1 or more= Not available
in PWS. Cannot be set.>
1/05
6-87
General Procedures
dC131 Procon2 NVM List (774), dC131 Procon3
dC131 IBT NVM List (771), dC131 Drive NVM List (772)
Table 1 IBT/Drive NVM List (771, 772)

ChainLink

ChainLink
Name
771-003 ENV CTL ON
Default
0
Range
0-65535
Env. Control On/Off

0= Controls the environment.
Other= No environment control (Determines the Environment Number based on

temperature/humidity data
specified in DBG TMP DAT
and DBG HUM DATA)
32
5-65535
Default
Range
1st BTR Remote output unit:

micro ampere (Valid range= 400800)
Description
771-046 IBTCLN CAM TIME
650
0-65535
IBT Cleaner Blade cam - One

rotation time (Unit: MC)
771-051 BTR1 CD1 DUMMY
60
0-65535
1st BTR output correction (Thick

paper dummy cycle) Unit:% (Valid
range: 0-100)
771-052 BTR1 CD2 DUMMY
30
0-65535
1st BTR output correction (Ultra

thick paper dummy cycle) Unit:%
(Valid range: 0-100)
771-053 BTR1 OHP DUMMY
30
0-65535
1st BTR output correction (OHP

dummy cycle) Unit:% (Valid
range: 0-100)
771-054 BTR1 BW REVISE
10
0-65535
1st BTR output correction (B/W

mode) Unit:% (Valid range: 0-200)
771-055 BTR1 COL REVISE
100
0-65535
1st BTR output correction (Color

771-056 BTR1 SIMP REVISE
100
0-65535
1st BTR output correction (Simplex mode) Unit:% (Valid range:

0-200)
771-057 BTR1 DUP REVISE
100
0-65535
1st BTR output correction (Duplex

771-063 OIL TONER BAND

OFFSET
32
0-65535
Oil Roll stripe - Toner band write

(Valid range: 1-258)
Unit: mm
771-064 OIL TONER BAND FS 303
0-65535
Oil Roll stripe - Toner band SF

direction (Valid range: 1-303)
Unit: mm
Description
1= Does not control the environment (Uses the Environment Number in ENV NO
SET.)
771-012 BTR1 HV
Name
771-013 BTR2 HV
18
10-65535
2nd BTR Remote output unit: 0.1kV (Valid range: 10-75)
771-014 DTS dC HV
30
10-65535
DTS dC Remote output unit: 0.1kV (Valid range: 10-45)
771-017 BTR1 REVISE
100
0-65535
1st BTR Remote correction value

Unit:% (Valid range: 0-100)
771-018 BTR2 REVISE
100
0-100
2nd BTR Remote correction value

771-019 DTS dC REVISE
100
0-65535
DTS dC Remote correction value

771-074 DTS MONITOR
Monitor value (Storage)
771-026 ENV NO
Environment Table No (Storage)
771-083 BTR1 ON ADJ
0-65535
771-037 BTR1 HV REM
1st BTR HV output (Storage) unit:

micro ampere
1st BTR HV ON time adjustment

Unit: MC
771-038 BTR2 HV REM
2nd BTR HV output (Storage)

unit: -0.1kV
771-085 BTR2HV ON ADJ NP
1121
0-65535
771-039 DTS dC REM
DTS dC HV output (Storage) unit:

-0.1kV
2nd BTR HV ON time adjustment

(Normal paper/Second original)
Unit: MC
771-086 BTR2HV OFF ADJ NP 3
0-65535
771-042 BTR2 FAILBYPASS
0-65535
2nd BTR Contact/Retract Fail

Bypass (Valid range: 0-1)
0: Yes 1: No
2nd BTR HV Off time adjustment

Unit: MC
771-087 BTR2HV ON ADJ CD1 1121
0-65535

(Thick paper) Unit: MC
0-65535

0-65535

(Ultra thick paper) Unit: MC
771-043 IBTCLN FAILBYPASS
0-65535
IBT Cleaner Contact/Retract Fail

Bypass (Valid range: 0-1)
0: Yes 1: No
771-088 BTR2HV OFF ADJ

CD1
771-045 BTR2 CAM TIME
500
0-65535
2nd BTR cam - One rotation time

(Unit: MC)
771-089 BTR2HV ON ADJ CD2 1121

DSP: BTR 2 HV ON
ADJ S-HVY
General Procedures
dC131 IBT NVM List (771), dC131 Drive NVM List (772)
1/05
6-88
Reissue
DocuColor 12/DCCS50

ChainLink
Name
Default
Range

CD2
0-65535

771-091 BTR2HV ON ADJ

POST
1121
0-65535

(Post card) Unit: MC

POST
0-65535

771-093 BTR2HV ON ADJ OHP 1121
0-65535

(OHP/Tuck film) Unit: MC

OHP
0-65535

(OHP/ Tuck film) Unit: MC
771-095 DTS ON ADJ NP
1155
0-65535
DTS dC HV ON time adjustment

Unit: MC
771-096 DTS OFF ADJ NP
0-65535
DTS dC HV Off time adjustment

Unit: MC
771-097 DTS ON ADJ CD1
1155
0-65535

771-098 DTS OFF ADJ CD1
0-65535

771-099 DTS ON ADJ CD2
1155
0-65535

771-100 DTS OFF ADJ CD2
0-65535

771-101 DTS ON ADJ POST
1155
0-65535

771-102 DTS OFF ADJ POST
0-65535

771-103 DTS ON ADJ OHP
1155
0-65535

(OHP/Tuck film) Unit: MC
771-104 DTS OFF ADJ OHP
0-65535

(OHP/ Tuck film) Unit: MC
771-109 BTR2CONT ON ADJ

NP
203
0-65535
2nd BTR Contact On(Contact

start) time adjustment (Normal
paper/2nd original) Unit: MC
771-114 BTR2CONT OFF ADJ
0-65535
2nd BTR Contact Off(From Home

SNR start-up detection to Clutch
stop) time adjustment Unit: MC
771-120 BTR2RET OFF ADJ
0-65535
2nd BTR Retract Off(From Home

SNR stop detection to Clutch
stop) time adjustment Unit: MC
Reissue
DocuColor 12/DCCS50
ChainLink
Description
1/05
6-89
Name
Default
Range
Description
771-122 IBTCLN CONT OFF

ADJ
0-65535
IBT Cleaner Blade Contact

Off(From Home SNR start-up
detection to Clutch stop) time
adjustment Unit: MC
771-124 IBTCLN RET OFF

ADJI
0-65535
IBT Cleaner Retract Off(From

Home SNR stop detection to
Clutch stop) time adjustment Unit:
MC
772-238 nvm sp updn
1000
0-65535
Magnification storage NVM for

IOT vertical magnification
(Input range: 996-1004)
General Procedures
dC131 IBT NVM List (771), dC131 Drive NVM List
dC131 Developer NVM List (776)
Table 1 Developer NVM List (776)

ChainLink

ChainLink
Name
776-372 NVM TNR STS Y

Name
Default
776-367 RESERVE TANK STS 0

K
Range
0-3
Default
0
Range
0-65535
Description
2=TONER NEAR EMPTY

3=TONER EMPTY
776-373 NVM TNR STS M
0-65535
NEAR EMPTY=2
EMPTY=3
0-65535
0-65535
0= dispense ready.
1= dispense near broken.
2= dispense broken.
776-062 NVM dispense status 0

(C)
0-65535
0= dispense ready.
2= dispense broken.

(K)
0-65535
0= dispense ready.
2= dispense broken.

Y
0-3
2=TONER NEAR EMPTY

3=TONER EMPTY
Toner Cartridge - Empty status management: Y

FULL=0
LOW=1
NEAR EMPTY=2
EMPTY=3

M
0-3
Toner Cartridge - Empty status management: M

FULL=0
LOW=1
NEAR EMPTY=2
EMPTY=3

C
0-3
Toner Cartridge - Empty status management: C

FULL=0
LOW=1
NEAR EMPTY=2
776-374 NVM TNR STS C
0-65535
Toner Cartridge - Empty detection: C
776-375 TONER NEAR

EMPTY
250 (X
100ms)
0-65535
Toner Cartridge - Empty detection:

NEAREMPTY threshold - K default:
25s
776-376 TONER EMPTY
1000 (X
100ms)
0-65535

EMPTY threshold - K default: 100s
776-377 K DISP SUM
0-65535

DISPENSE accumulation time
776-378 Y DISP SUM
0-65535

776-379 M DISP SUM
0-65535

776-380 C DISP SUM
0-65535

776-381 K TNR LCK
0-65535
DISPENSE Black Dispense time

accumulation (up to LOW TONER)
776-382 Y TNR LCK
0-65535
DISPENSE Yellow Dispense time

776-383 M TNR LCK
0-65535
DISPENSE Magenta Dispense time

776-384 C TNR LCK
0-65535
DISPENSE Cyan Dispense time

776-385 K WRN COUNT
0-65535
DISPENSE Black Dispense amount

(up to NEAR EMPTY)
776-386 Y WRN COUNT
0-65535
DISPENSE Yellow Dispense amount

(up to NEAR EMPTY)
776-387 M WRN COUNT
0-65535
DISPENSE Magenta Dispense

amount (up to NEAR EMPTY)
776-388 C WRN COUNT
0-65535
DISPENSE Cyan Dispense amount

(up to NEAR EMPTY)
EMPTY=3
776-371 NVM TNR STS K
0-65535
Toner Cartridge - Empty detection M

0=TONER FULL
1=LOW TONER
0= dispense ready.
2= dispense broken.

(M)
Toner Cartridge - Empty detection: Y

0=TONER FULL
1=LOW TONER
Toner Cartridge Empty status management: K

FULL=0
LOW=1

(Y)
Description
Toner Cartridge - Empty detection: K

0=TONER FULL
1=LOW TONER
2=TONER NEAR EMPTY
3=TONER EMPTY
General Procedures
1/05
6-90
Reissue
DocuColor 12/DCCS50

ChainLink
Name
776-395 DISPENSER STS K
Default
0
Range
0-65535

ChainLink
Description
Dispenser status detection STATUS
management - K
READY=0
Name
Default
Range
776-441 DISP TIMER K
90
Timer Dispense (K)

Dispense time/Unit: 1ms
776-442 DISP TIMER Y
90
Timer Dispense (Y)

776-443 DISP TIMER M
90
Timer Dispense (M)

776-444 DISP TIMER C
90
Timer Dispense (C)

DOUBT=1
NEAR BROKEN=2
BROKEN=3
776-405 NVM SUB CHK SW
0-2
Subsystem Check (Rotary movement)

I/O component check switch:
sw/0 component check= 0
Description
Angle specification= 1
Target color - Move= 2
776-406 NVM SUB CHK
RPOF
0-2
Subsystem Check (Rotary movement) Profile selection

Fast= 0
Middle= 1
Slow= 2
776-407 NVM SUB CHK AGL
90
45,90,135, Subsystem Check (Rotary move180,225

ment) rotation angle
270,315,3
45= 45 degrees
60(degree)
225= 225 degrees
90= 90 degrees
135= 135 degrees
180= 180 degrees
225= 225 degrees
270= 270 degrees
315= 315 degrees
360= 360 degrees
776-408 NVM SUB CHK H
0-1
Subsystem Check (Rotary movement) Home Position - Move

0= (default) - K-color move
776-409 NVM SUB CHK 90
0-1
Subsystem Check (Rotary movement) - 90 degree rotation pattern

selection
0= 1 rotation
776-410 NVM SUB CHK 360
Subsystem Check (Rotary movement) - 360 degree rotation pattern

selection
0= 315+45-2 rotations
776-436 ROTARY HOMEADJ

FAIL
8(step)
0-65535
Home Position correction fault - generation threshold
1= HomePosition move
1= 45+45 rotations
Reissue
DocuColor 12/DCCS50
1/05
6-91
General Procedures
dC131 Fuser NVM List (777)
Table 1 Fuser NVM list (777)

ChainLink
Table 1 Fuser NVM list (777)

ChainLink
Name
Default
Range
Name
Default
Range
Description
777-109 SIZE MIX TIME
1-15
Threshold to determine whether

to do a dry run for size mix paper
feed interval. (Unit= Minute)
777-110 SIZE MIX DEF
0-1
Determines whether to do a dry

run for size mix paper feed interval.
0= Yes 1= No
Description
777-001 TEMP1
160
150-165
H/R1st temperature control

(Unit:degree (C))
777-002 TEMP2
130
70-135
P/R1st temperature control

(Unit:degree (C))
777-003 TEMP3
178
170-198
Ext H/R1st temperature control

(Unit: degree (C))
777-135 TH0 4C NOR
193
100-200
777-006 TEMP8
143
100-160
H/R Power save temperature

(Unit: degree (C))
HR & PR Not Ready temperature

start threshold: 4C/Normal paper
777-136 TH0 BW NOR
170
100-200
BW, Normal paper
777-137 TH0 4C HVY
190
100-200
4C, Thick paper
777-138 TH0 BW HVY
183
100-200
BW, Thick paper
777-007 TEMP9
130
70-135
P/R Power save temperature

(Unit: degree (C))
777-008 TEMP10
165
100-180
Ex. H/R Power save temperature

(Unit: degree (C))
777-139 TH0 4C OHP
195
100-200
4C, OHP
777-140 TH0 BW OHP
213
100-200
BW, OHP
777-160 LAMP OVHT FAIL
0-7
Overheating fault
0= None
777-010 TEMP12
158
150-160
H/R Ready temperature (Unit:

degree (C))
777-011 TEMP13
115
70-130
P/R Ready temperature (Unit:

degree (C))
1=HR
777-012 TEMP14
165
165-180
Ex. H/R Ready temperature (Unit:

degree (C))
3=PR
777-051 OIL PUMP ON
3000
4010000
OIL PUMP ON time (ms)
777-055 OIL CV CNTR
2=HR Safety
4=PR Safety
5=Ext HR
6=Ext HR Safety
Number of pages ejected after

OIL NEAR EMPTY (Max: 5000)
777-056 OIL NEAR TO EMP
2000
5003000
Number of pages allowed from

NEAR EMPTY to EMPTY.
777-058 OIL LIMIT TIME
10
1-20
Time allowed after OIL NEAR

EMPTY/EMPTY (Unit: Minute)
777-075 WEB NEMP
1994
0-65534
Accumulated ON time threshold

to detect WEB NEAR EMPTY
(Minute)
777-077 WEB STATE
Displays the WEB status.

0=Full
7= Environment sensor
777-231 HR TEMP
HR temperature: Current calculated value
777-232 PR TEMP
PR temperature: Current calculated value
777-233 Ext HR TEMP
Ext HR temperature: Current calculated value
777-321 Auto Set Up NVM
0-1
Automatic Set Up
0= Yes (default)
1= No
1=Near Empty
2=Empty
777-079 WEB MOT ON TIME (L) 0
0-65535
Indicates Web material used.

7000 = 1 inch of Web.
777-081 AIR TMP
Environment temperature
777-082 ENV TIME
30
Environment temperature monitoring interval (min)
777-083 ENV TARGET
20
Environment temperature correction threshold
General Procedures
dC131 Fuser NVM List (777)
1/05
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dC131 Sorter/Finisher NVM List (780)(790)
dC132 Serial Number/Billing Meter Synchronization

Purpose
Table 1 Sorter/Finisher NVM List (780, 790)

ChainLink
Name
Default
Range
Checks the Billing Meters and sets the Machine Serial Number when fault 3-397 occurs. This
routine also reads the Billing Meters and can be accessed at any time for this purpose.
Description
Procedure
780-001 Sorter Mail Box switching
0-1
0= Sorter, 1= MailBox
780-002 JAM counter (011-145)
0-99
number of jams
CAUTION
780-003 JAM counter (011-146)
0-99
number of jams
780-004 JAM counter (011-142)
0-99
number of jams
Failure to comply with the board replacement procedure in GP 10 Replacing Billing PWBs ,
could result in catastrophic NVM corruption.
780-005 JAM counter (011-144)
0-99
number of jams
Follow the procedure described in GP 10 Replacing Billing PWBs .
780-006 JAM counter (011-143)
0-99
number of jams
780-007 JAM counter (011-115)
0-99
number of jams
780-008 JAM counter (011-116)
0-99
number of jams
780-009 JAM counter (011-107)
0-99
number of jams
780-010 JAM counter (011-109)
0-99
number of jams
780-011 JAM counter (011-108)
0-99
number of jams
780-012 Fail counter (011-273)
0-99
number of jams
780-013 Fail counter (011-274)
0-99
number of jams
780-020 Humidity (%)
0-100
Current humidity data

(Detected by the environment
sensor)
780-021 Toner ratio: Zl Side1 (%)
0 - 100
Last Copy Side1: Toner ratio

of first 1/3
780-022 Toner ratio: Zl Side2 (%)
0 - 100

of first 1/3
780-023 Toner ratio: Zt Side1 (%)
0 - 100

of last 1/3
780-024 Toner ratio: Zt Side2 (%)
0 - 100

of last 1/3
780-028 Decurler: Forced control
0-3
0= AUTO
1= Dec1 Only
2= Dec2 Only
3= Release Only
790-032 Stacker Capacity
0-1
0= 100 sets
1= 60 sets
790 -033 Set Eject
0-1
0= 50 sheets
1= 25 sheets
Reissue
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1/05
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General Procedures
dC131 Sorter/Finisher NVM List (780), dC132 Serial
dC135 HFSI Counters
dC135 HFSI Counter List
Purpose
NOTE: Refer to Detailed Maintenance Activities in Section 1.
This routine displays the service life (Threshold) and the current value (count) of the periodic
replacement parts. Replacement life change, and current value resets are possible.
Procedure
1.
using the PWS.
2.
Select Maintenance on the Service Entry Screen. The All Jams screen displays as the
default screen.
3.
Select HFSI Counters (dC135) tab on the Maintenance screen.
4.
The HFSI Counters screen displays the replacement life (Threshold) and the current
value (count) of the periodic replacement parts. Two vertical tabs allow display of all HFSI
counters, or only those counters that are over threshold.
5.
Refer to Detailed Maintenance Activities in Section 1. Perform the listed Service Action for
all HSFI counters that are at or near threshold.
6.
To reset the count after replacing the parts, select the appropriate HFSI item, then select
the Reset Counter button.
General Procedures
dC135 HFSI Counters, dC135 HFSI Counter List
1/05
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dC140 Analog Monitor
3.
Purpose
Monitors the analog values of the A/D converter sensors by driving each component (e.g.;,
C.C). Temporary change of output values is possible. Output component check is also possible.
Increment or decrement the output level by 1. The new output level is input into the system and the Analog Monitor shows the new output level in the Level column. If the output
level entered is out of the range, the Information screen shows the following message: !
Invalid value. Enter again. (A value that is out of the range is a value that is higher than
the upper limit or lower than the lower limit defined by the machine.)
Procedure
1.
using the PWS.
2.
Select Diagnostics in the Service Entry Screen.
3.
Select the Analog Monitor (dC140) Tab in the Diagnostics Screen."
4.
The system displays the Analog Monitor Screen.
5.
a.
The system displays the analog output component names and the analog input component names with the Chain Link Numbers (ID column) in the table in the order of
Chain Link number.
b.
The status of all output components show Disabled. The Level columns are blank.
Run the output component check:

a.
Select a component to check.
b.
Select Start in the output component check.
c.
The output component in the machine turns ON.
d.
The PWS changes the output component status to Enable.
e.
Turn ON another component to check the output component in the machine.

NOTE: If the component has ON Time Restriction, the component is turned ON
for that period and automatically turned OFF.
NOTE: Some components cannot be turned ON at the same time another component is turned ON. If you turn ON a component, the first component turned ON
will be automatically turned OFF.
NOTE: If the component cannot be automatically turned OFF, the following message appears: ! Cannot check the component. Stop another output component.
Check Multiple Components

1.
To check multiple components simultaneously, repeat Step 5a through 5e.
2.
To stop the check, select Stop while the component is selected, or select Stop All which
turns OFF all output components.
NOTE: The output component is turned OFF. The status shows Disabled.
Changing Output Levels

1.
If you temporarily change the output level, you can check the output component by using
the [+] or [-] to increment/decrement the output level by 1.
2.
Select the component whose output level you want to change. Select [+] to increment or [] to decrement.
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General Procedures
dC140 Analog Monitor
dC188 How to Exit from Service Mode
dC301 NVM Initialization
Procedure
Purpose
1.
using the PWS.
2.
Select the Service Exit Tab on the Screen.
This procedure may be needed when the machine cannot recover for some unknown reasons,
including problems such as producing blank copies/prints, Xerographic CRUs not recognized,
continuously giving system fault, etc.
3.
The Service Exit Screen (dC188) displays.
4.
The exit options are:
Complete Closeout
Temporary Closeout
Prerequisites
Ensure that the following conditions are met:
NOTE: Selecting Complete Closeout resets the Shutdown History (dC122), Fault
Counter (dC120), Jam Counters (dC118) and the numbers of copies since the last call.
5.
IOT software level is v7.06.3 or higher.
The PWS is running Next Generation PWS Tool Set Release 8.1 or higher.
The PWS is running DC 12 PWS Tools v 7.1 or higher.
The current IOT SW Upgrade CD (Tag P39 or higher) is available.
Select Complete Closeout. The machine reboots. The UI Message Ready to Copy displays.
The customer has recorded any settings from Tools Mode, and all Auditron account data.
NOTE: Selecting Temporary Closeout exits from the Service Mode without resetting the
Shutdown History (dC122), Fault Counter (dC120), Jam Counter (dC118) and the number
of copies since last call.
1.
Procedure
2.
Disconnect any Foreign Interface devices. Disregard the FI fault codes that will be
declared at power-up.
Obtain the following data:
6.
Select Temporary Closeout.
NVM Value Factory Setting Report (typically it is located in the Tray 1 pocket).
7.
Select Exit PWS to exit from the PWS Diagnostic Tool even if the PWS has been disconnected from the machine.
Any setting changes (specifically NVM settings) shown on the machines service log.
Any previously-saved machine NVM data on floppy disk.
8.
After Exit PWS is selected, the following message will display, Would you like to copy
Machine Data to the a:drive? Yes or No.
3.
using the PWS.
If "Yes" is selected, insert a diskette into a:drive and the PWS will write Machine Data
to a:drive and the Diagnostics Tool will close.
4.
Go to dC371 Configuration Page. Verify the machine configuration. Correct any errors
before continuing.
If "No" is selected the Diagnostics Tool will close.
5.
Go to dC351 NVM Background Processing. Select Save Machine Settings to save

NVM data. If the process is successful, proceed to step 7. If the NVM data was not saved
correctly, continue with step 6.
NOTE: If the PWS is disconnected from the machine after the machine entered the Service Mode, the PWS and the machine does not automatically exit from the Service Mode.
If the machine is disconnected from the PWS, Power-OFF/ON to exit from the Service
Mode.
NOTE: You may be unable to read or save NVM values using the PWS Diagnostics Tool due
to either a failed IOT CPU PWB or a failed NVM PWB. If you were sent here by the IOT PWB
replacement procedure, it may be possible to save NVM after the PWB is replaced.
If the NVM PWB has failed you will be required to re-enter the values from the Factory NVM
Settings or from a previous floppy disk database, and any other NVM changes retrieved in Initial Actions. You may need to perform setup and alignment procedures after initialization.
6.
General Procedures
dC188 How to Exit from Service Mode, dC301 NVM
1/05
6-96
Go to dC131 NVM R/W. Record the values for the following locations:
749-030 Fault detection
759-053 Print ESS data
759-054 Scan ESS data
771-138 IBT Cleaner retract start time
772-017 Fuser Fan fail detection
773-004 Target Density switch
775-731 ATC Enable
775-750 ATC Calibration successful
775-815 TC set average
775-851 ADC change by ATC (Y)

Reissue
DocuColor 12/DCCS50
7.
775-852 ADC change by ATC (M)
775-853 ADC change by ATC (C)
Table 1 NVM Initialization
Go to dC131 NVM R/W:
Name
Description
Remarks
IOT (IOSS)
Default: See dC131.

a.
Record the value in location 759-039 (v7.06.3 software only)
The following NVM will be initialized.

a. ROS NVM: Chain720 (All)
If IOT software v11.50.3 is loaded, set NVM location 752-017 to 0.
b.
If a Foreign Interface was enabled, record the value in NVM location 759-015, then
set location 752-002 to 0.
PH NVM: Chain740, 749,

760, 761 (All)
c.
Marking NVM: Chain770 (All

except 087-100)
DO NOT use the Select All button to perform a complete NVM Initialization! If a full initialization is indicated, reset each area one-at-a-time, in the following sequence:
d.
IBT NVM: Chain771 (All)
e.
Drive NVM: Chain772 (All)
IISS
f.
POST IPS
Procon NVM: Chain773,

774, 775, 779 (All)
IOSS
g.
Deve NVM: Chain776 (All)
Sys
h.
Fuser NVM: Chain777 (All)
UI
i.
SorterNVM: Chain780 (All)
Sys (again)
j.
8.
Select dC301 NVM Initialize.
9.
Select the appropriate area(s) to be initialized. Table 1 lists the NVM locations that are initialized with each area selection.
Billing NVM: Chain990: 037,

293, 294, 295, 296, 297,
298, 299, 300, 301, 302
a.
SYS NVM: Chain752 (All

except the following codes)
b.
SYS NVM: Chain759 (All

except the following codes)
Record the value in location 990-302 (v7.06.3 software only)
CAUTION
SYS
Table 1 NVM Initialization

Name
Description
Remarks
IISS (PreIPS)
The following NVM will be initialized.

a. IIT NVM: Chain710 (All)
Default: See dC131.

a.
POST IPS
b.
IIT NVM: Chain715 (All)
c.
IIT NVM: Chain719 (All)
Default: See dC131.

a.
(752-001-016)
(759-130-150)
UI
The following NVM will be initial- Default: See dC131.

ized.
a.
a. IPS NVM:Chain730-001-169
The following NVM will be initialized:

a. UI NVM: Chain700 (All)
b.
UI NVM: Chain702 (All)
c.
UI NVM: Chain850 (1-006)
Default: See dC131. Chain802 is

not initialized.
a.
10. After all initializations are complete, go to dC131 NVM R/W. Re-enter the values for those
locations (759-015, 759-039, and/or 990-302) that were saved in step 7.
11. If NVM was successfully saved in step 5, go to dC351 and select Restore Machine Settings. If NVM was not successfully saved, use the date a from step 2 and step 6 to manually restore NVM.
12. Re-enter the values in the following tables even if the display indicates that the values are
already correct.
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1/05
6-97
General Procedures
Table 3 v7.06.3 software

Location
Value
700-191
700-193
700-099
710-062
710-063
720-794
62
730-027
260 (C/P only)
752-002
0 = no Foreign Interface
752-012
0 = No Edit Pad
1 = Edit Pad Installed
752-017
759-004
0 = DC12 with DFE

1 = DCCS 50
Use default for DC12 w/o DFE
759-047
759-051
759-041
759-042
761-424
990-302
990-303
Value
759-004
0 = DC12 with DFE

1 = DCCS 50
Use default for DC12 w/o DFE
13. Go to dC371 Configuration Page. Verify the machine configuration. Correct any errors
before continuing.
14. Exit the Diagnostic Mode. To exit Diagnostic Mode, refer to dC188 How to Exit from Service Mode.
15. Reconnect any Foreign Interface devices.
16. Run several copies/prints to confirm normal machine behavior.
17. Re-enter the Diagnostic Mode.
NOTE: When F/I is plugged in at

power-up, software will automatically enable F/I (value=1).
752-004
Location
18. Set NVM location 715-001 to 0.

Set NVM location 720-368 to 0
19. Perform Max Setup (ADJ 9.1.1).
20. Exit the Diagnostic Mode.

Location
Value
710-062
710-063
752-002
0 = no Foreign Interface
NOTE: When F/I is plugged in at
power-up, software will automatically enable F/I (value=1).
752-012
0 = No Edit Pad
1 = Edit Pad Installed
General Procedures
1/05
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dC305 UI Component Check
dC330 Component Control
Purpose
Purpose
Checks the operations of the UI Screen and Control Panel buttons.
The purpose of the dC330 Component Control is to display the logic state of input signals and
to energize output components.
Procedure
1.
NOTE: Refer to Table 1 for a list of all Input Components listed by Chain/Link ID number. Refer
to Table 2 for a list of all Output Components listed by Chain/Link ID number.
using the PWS.
2.
Select the Diagnostics Tab in the Service Entry Screen.
Procedure
3.
Select the System Test Tab in the Diagnostics Screen. The System Test Screen displays. The UI Component Check dC305 is the default screen.
1.
4.
Select Start. The following message displays, Perform the UI Component Check on the
Machine. When complete, select Stop.
2.
Select the Diagnostics Tab on the Service Entry Screen.
3.
Select Component Control (dC330) on the Diagnostic Entry Screen.
4.
The dC330 Screen is displayed. The display indicates the following:
5.
Select OK.
6.
Touch the UI Screen in a different locations. The highlighted point moves to the new location.
7.
All LEDs should be illuminated when the dC305 Touch Screen Test is displayed. Select
Stop to Turn-OFF all LEDs.
8.
Select Stop on the Component Check Screen.
9.
The Touch Screen Test Screen on the machine UI closes.
using the PWS.
Input/Output Components
ID Number (chain/function order)
Active Stack (including ID and state of component)
NOTE: The Component Control Codes can be selected in categories by their related system, such as: Processor, System, Sorter / OCT / Mailbox, Finisher, DADF, HCF and ITT.
5.
Activate the desired component code by double clicking on the Chain/Link ID number or
by clicking once on the Chain/Link ID number then selecting the Start Button.
NOTE: The IDs will display on the "Active Stack."
6.
Press the Stop button or double click the active component in the active stack box to end
the test. The ID and Active Stack components are removed from the Active Stack
box.
Stacking Component Codes
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1.
Tostack several codes, select the first code and press Start, then select the next code
and press Start. Continue to enter up to eleven codes.
2.
The selected ID appears in the ID column of the Active Stack box and the state changes
to Run; H or L as applicable.
3.
Stop a highlighted component by pressing Stop or double click the active component in
the Active Stack Box
4.
To switch Off all components and clear the screen press Stop All.
General Procedures
dC305 UI Component Check, dC330 Component
NOTE: Components that are currently running are shaded in Green. Components that have
been run are shaded in Yellow.
NOTE: When exiting dc330, the machine resets and communication between the PWS and
the machine is momentarily lost. The PWS will reconnect automatically.
Input CC Codes
Table 1 Input Component Control Codes
ID
Description
Module_I
D
ID
Description
Module_I
D
In_Out
Smart Help
005-301 TOP COVER I/L

SWITCH
Input
High: Open
Low: Closed
DADF
006-201 SHEET ABORT
Input
IIT
006-212 REGI SENSOR
Input
H: Light block
L: Light reception
IIT
006-240 DADF EXIST
Input
H: No DADF
L: DADF
IIT
006-251 APS SENSOR 1
Input
High: No document
Low: Document
IIT
006-253 APS SENSOR 3
Input
APS Sensor3
DSP: APS Sensor3
IIT
006-272 PW-0
Input
IIT
In_Out
Smart Help
Input
High: Button press

Low: Button release
System
001-201 FOREIGN INTERFACE Input

EXIST
High: Not Connected

Low: Connected
System
001-202 PWS EXIST
High: Not Connected

Low: Connected
System
001-300 FRONT DOOR INTER- Input

LOCK
High: Open
Low: Closed
Processor
006-280 FAN FAIL
Input
H: Failure
L: No Failure
IIT
001-304 LEFT HAND COVER

INTERLOCK
Input
High: Open
Low: Closed
Processor
006-300 PLATEN I/L SWITCH
Input
High: Open
Low: Closed
IIT
001-306 DRAWER HANDLE

INTERLOCK
Input
H: Mark detected
L: Not a mark
Processor
006-301 ANGLE SENSOR
Input
H: Light block
L: Light reception
IIT
003-213 TRO SENSOR
Input
Run Drum Motor (004-021) simulta- Processor

neously.
High: Mark detected
Low: Not a Mark
007-100 HCF FEED TAR SENSOR
Input
High: Paper
Low: No Paper
Detects the presence / absence of
a sheet in the HCF paper path.
HCF
005-102 DOCUMENT SENSOR Input
High: No document
Low: Document
DADF
007-185 HCF Exist
Input
HCF
005-110
REGI SENSOR
Input
High: Document
Low: No document
DADF
High: Stack is NOT home

Low: Stack is home
Detects the height of the HCF
paper stack.
005-115
EXIT SENSOR
Input
High: Document
Low: No document
DADF
007-186 HCF STACK HEIGHT

SENSOR
Input
HCF
005-119
DUP SENSOR
Input
High: Document
Low: No Document
DADF
High: Stack is NOT home

Low: Stack is home
Detects the height of the HCF
paper stack.
005-150 1 SIZE SENSOR
Input
High: No document
Low: Document
DADF
007-187 HCF 8.5x11 / A4

SWITCH
Input
HCF
005-151 2 SIZE SENSOR
Input
High: No document
Low: Document
DADF
High: 8.5 x 11
Low: A4
Detects the size of the paper
loaded in the HCF.
007-188 NO PAPER SENSOR
Input
Input
High: Document Exchange IISS

exchange to DADF
DADF
005-300 PLATEN I/L SWITCH
Input
High: Open
Low: Closed
DADF
High: Paper
Low: Now paper
Detects the presence / absence of
a sheet in the HCF paper path.
HCF
005-201 EXCHANGE FROM

IISS
001-200 POWER SAVE BUTTON
Input
General Procedures
1/05
6-100
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ID
Description
007-189 TRAY CLOSED

SWITCH
007-190 HCF FEED HOT LINE
In_Out
Smart Help
Input
High: Drawer / Tray is closed

Low: Drawer / Tray is open.
Detects when the HCF paper
Drawer / Tray is closed.
Input

Module_I
D
ID
HCF
Signal from the IOT to initiate paper HCF

feed from the HCF. In run mode a
high to low transition on this signal
will cause the HCF to feed paper. In
the diagnostic mode, this signal has
no effect on the HCF.
007-301 #1 TRAY SENSOR
Input
High: Tray Inserted

Low: Tray out
Processor
007-308 HCF INTERLOCK

SWITCH
Input
High: HCF is docked

Low: HCF is not docked.
Detects that the HCF is properly
docked to the IOT.
HCF
008-104 #1 PRE FEED SENSOR
Input
High: No Paper
Low: Paper
Processor
008-105 #1 FEED OUT SENSOR
Input
High: No Paper
Low: Paper
Processor
008-109 #2 PRE FEED SENSOR
Input
High: No Paper
Low: Paper
Processor
008-110
#2 FEED OUT SENSOR
Input
High: No Paper
Low: Paper
Processor
008-114
#3 PRE FEED SENSOR
Input
High: No Paper
Low: Paper
Processor
008-115
#3 FEED OUT SENSOR
Input
High: No Paper
Low: Paper
008-119
#4 PRE FEED SENSOR
Input
008-120 #4 FEED OUT SENSOR
Description
Module_I
D
In_Out
Smart Help
008-163 BEHIND REGI JAM

SENSOR
Input
High: No Paper
Low: Paper
Processor
008-198 TRANSPERENCY
(OHP) 1 SENSOR
Input
High: No Transparency
Low: Transparency
Processor
008-199 OHP 2 SENSOR
Input
High: No Transparency
Low: Transparency
Processor
008-221 #1 TRAY STACK

Input
HEIGHT (LEVEL) SENSOR
High: Light block

Low: Light reception
Processor

Input
High: Light block

Processor

Input
High: Light block

Processor

Input
High: Light block

Processor
008-226 #5 TRAY BYPASS)

Input
STACK HEIGHT LEVEL
UP SENSOR
Run #5 (Bypass) Nudger Roll Sole- Processor

noid Simultaneously.
High: Lift up state
Low: Lift down State
008-227 #5 TRAY (BYPASS)

Input
STACK HEIGHT LEVEL
DOWN SENSOR
High: Lift Down State

Low: Lift Up State
Processor
Processor
008-231 #1 TRAY NO PAPER

SENSOR
Input
High: No Paper
Low: Paper
Processor
High: No Paper
Low: Paper
Processor

SENSOR
Input
High: No Paper
Low: Paper
Processor
Input
High: No Paper
Low: Paper
Processor

SENSOR
Input
High: No Paper
Low: Paper
Processor
008-135 TRAY 5 FEED SENSOR
Input
High: Paper
Low: No Paper
Processor

SENSOR
Input
High: No Paper
Low: Paper
Processor
008-150 TAKE AWAY SENSOR
Input
High: No Paper
Low: Paper
Processor
008-236 TRAY 5 PAPER SENSOR
Input
High: No Paper
Low: Paper
Processor
008-153 PRE REGI SENSOR
Input
High: No Paper
Low: Paper
Processor
008-240 #2 TRAY SIZE S/W 1
Input
Processor
008-155 REGI SENSOR
Input
High: No Paper
Low: Paper
Processor
High: Switch on (soft data)

Cannot run with Tray 3 size switch
1,2,3,4
1,2,3,4
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General Procedures

Module_I
D
ID

1,2,3,4
1,2,3,4
Processor
Input

1,2,3,4
1,2,3,4
008-243 #2 TRAY SIZE S/W4
Input
Input
ID
Description
In_Out
Smart Help
008-241 #2 TRAY SIZE S/W 2
Input
008-247 #3 TRAY SIZE S/W 3
008-248 #3 TRAY SIZE S/W 4
008-250 #4 TRAY SIZE S/W 1
Input
Input
Input
Input
Description
Smart Help
008-251 #4 TRAY SIZE S/W 2
Input
High: Switch on (Soft data)

1,2,3,4
1,2,3,4
Processor
Processor
008-252 #4 TRAY SIZE S/W 3
Input

1,2,3,4
1,2,3,4
Processor

1,2,3,4
1,2,3,4
Processor
008-253 #4 TRAY SIZE S/W 4
Input

1,2,3,4
1,2,3,4
Processor

1,2,3,4
1,2,3,4
Processor
008-305 Tray 5 Interlock
Input
High: Tray 5 (bypass) feeder open. Processor

Low: Tray 5 feeder closed.
008-306 DRAWER HANDLE

INTERLOCK
Input
High: Open
Low: Close
Processor

1,2,3,4
1,2,3,4
Processor
009-215 2ND BELT TRANSFER Input

ROLL HOME POSITION SENSOR
High: Light block

Processor
Input
High: Home detected
Processor

1,2,3,4
1,2,3,4
Processor
009-216 IBT CLEANER

RETRACT HOME
POSITION
009-217 OIL ROLL RETRACT
HOME POSITION
Input
High: Light block

Processor
009-220 ROTARY HOME POSI- Input

TION SENSOR
High: Home detected
Processor

1,2,3,4
1,2,3,4
Processor
009-237 ROTARY LOCK MECH Input

SENSOR
High: Latch
Low: Release
Processor
009-245 CRU POSITION
Input
High: If CRUM (X CRU Type) is cor- Processor

rectly read

1,2,3,4
1,2,3,4
Processor
009-246 CRU TYPE
Input
High: If CRUM (X CRU Type) is cor- Processor

rectly read and NVM (CRU type)
matches.
009-248 WASTE AUGER

ROTATE SENSOR
Input
Processor
High: Set
Low: Not Set
Processor
009-249 WASTE BOTTLE POSI- Input

TION SENSOR
General Procedures
Module_I
D
In_Out
1/05
6-102
Reissue
DocuColor 12/DCCS50
ID
Description
In_Out
Smart Help

Module_I
D
ID
Description
In_Out
Smart Help
Module_I
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009-250 WASTE BOTTLE FULL Input

SENSOR
High: Full
Low: Not Full
Processor
010-296 OCT DETECT
Input
High: OCT not connected

Low: OCT connected
Processor
009-251 TRICKLE BOTTLE

SENSOR
Input
High: Trickle Bottle Full

Low: Not Full
Processor
010-297 OCT FULL SENSOR
Input
High: Empty
Low: Not Empty
Processor
009-255 LOW TONER SENSOR K
Input
High: Toner
Low: No Toner
Processor
010-298 OCT HOME SENSOR
Input
High: Home position detected
Processor
Input
High: Offset position detected
Processor
009-257 LOW TONER SENSOR Y
Input
High: Toner
Low: No Toner
Processor
010-299 OCT POSITION SENSOR
High: Toner
Low: No Toner
Processor
High: Open
Low: Close
Processor
Input
010-300 INVERT COVER

INTERLOCK
Input
009-258 LOW TONER SENSOR M
011-107
OCT EXIT SENSOR
Input
009-259 LOW TONER SENSOR C
Input
High: Toner
Low: No Toner
Processor
010-100 FUSER ENTRANCE

SENSOR
Input
High: No Paper
Low: Paper
Processor
High: Paper
Sorter
Low: No Paper
Checks the paper ejection detection
sensor input (OCT)
011-115
Input
010-105 FUSER EXIT SENSOR Input
High: No Paper
Low: Paper
Processor
MAILBOX VERTICAL
SENSOR
010-110
MACHINE EXIT SENSOR
Input
High: Paper
Low: No Paper
Processor
High: Paper
Sorter
Low: No Paper
Checks the paper ejection detection
sensor input
011-117
Sorter
010-115
EXIT PATH SENSOR
Input
High: Paper
Low: No Paper
Processor
DECURLER EXIT SEN- Input

SOR
011-142
Input
High: Paper
Low: No Paper
Processor
High: Paper
Low: No Paper
Checks the paper ejection sensor
input. (Bin 1-10)
Sorter
010-125 INVERT PATH SENSOR
VERTICAL TRANSPORT IN SENSOR
010-130 DUPLEX IN SENSOR
Input
High: Paper
Low: No Paper
Processor
011-250
OCT DEVICE DETECT Input
Sorter
010-132 DUPLEX PATH 1 SEN- Input

SOR
High: Paper
Low: No Paper
Processor
011-273
OCT OFFSET HOME

SENSOR
Input
High: Home
Sorter
010-133 DUPLEX OUT SENSOR
Input
High: Paper
Low: No Paper
Processor
011-274
OCT OFFSET POSITION SENSOR
Input
High: Offset
Checks the OCT Offset position
detection sensor input
Sorter
010-220 PRESSURE ROLL

RETRACT SENSOR
Input
High: Release Position

Low: NIP Position
Processor
011-275
OCT FULL STACK

SENSOR
Input
High: Not Full

Low: Full
Sorter
010-221 EXTERNAL HEAT

Input
ROLL RETRACT SENSOR
High: Retract Position

Low: Contract Position
Processor
011-276
DECURLER CAM
Input
POSITION SENSOR A
Checks the Decurler Cam Position Sorter

sensor A input
010-222 OIL SENSOR
Input
High: Empty
Low: Oil Not Empty
Processor
011-277
DECURLER CAM
Input
POSITION SENSOR B
Sorter
010-223 WEB CRU HOME
Input
High: No CRU
Low: CRU
Processor
011-281
BIN 1 FULL SENSOR
Sorter
010-224 IIT HOTLINE
Input
Normal state is Low
Processor
High: Not Full

Low: Full
Checks Bin 1 full detection sensor
status
Reissue
DocuColor 12/DCCS50
1/05
6-103
Input
Input
General Procedures

Module_I
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ID
Description
High: Not Full

Low: Full
status.
Sorter
011-303
MBX DOCKING INTLK Input

SWITCHES
High: Not full

Low: Full
status
Sorter
ID
Description
In_Out
Smart Help
011-282
BIN 2 FULL SENSOR
Input
011-283
BIN 3 FULL SENSOR
Input
011-284
BIN 4 FULL SENSOR
Input
High: Not full

Sorter
Low: Full
Checks the Bin 4 full detection sensor status
011-285
BIN 5 FULL SENSOR
Input
High: Not full

Low: Full
status
Sorter
011-286
BIN 6 FULL SENSOR
Input
High: Not full

Low: Full
status
Sorter
High: Not full

Low: Full
status
Sorter
High: Not full

Low: Full
status
Sorter
High: Not full

Low: Full
status
Sorter
011-287
011-288
BIN 7 FULL SENSOR
BIN 8 FULL SENSOR
Input
Input
011-289
BIN 9 FULL SENSOR
Input
011-290
BIN 10 FULL SENSOR Input
High: Not full

Sorter
Low: Full
status
011-301
MAILBOX FRONT
COVER INTERLOCK
SWITCH
Input
High: Open
Low: Close
Sorter
011-302
DECURLER FRONT
COVER INTERLOCK
SWITCH
Input
High: Open
Low: Close
Checks the Front Cover B
Sorter
General Procedures
1/05
6-104
In_Out
Module_I
D
Smart Help
High: Docking
Low: Open
Checks the IOT docking
Sorter
012-107 SCT EXIT SENSOR
Input
High: Paper sensed

Finisher
Low: No paper sensed
Senses Paper Ejected to SCT Tray
012-115
Input
High: Paper detected

Finisher
Low: No paper detected
Detects paper ejected to Bins 1-10
012-120 COMPILER EXIT SEN- Input

SOR

Finisher
INTERRUPT TAMPER MOTOR
drive starting signal, EJECT
CLAMP & OFFSET MOTOR drive
starting signal, STAPLER MOVE
MOTOR drive starting signal, COMPILER TRAY UP/DOWN SOLENOID drive starting signal.
012-142 MAILBOX ENTRANCE Input

SENSOR

Senses paper ejected to Mailbox
Finisher
012-145 DECURLER EXIT SEN- Input

SOR

Senses paper ejected to Decurler
Exit
Finisher
012-200 MACHINE EXIT SENSOR
Input
HOTLINE
Finisher
012-210 STACKER FULL SENSOR
Input
High: Paper sensed

Low: Paper not Sensed
Senses STACKER TRAY full of
small sized paper.
Finisher
012-212 STACKER FULL

Input
(MIXED SET SENSOR
High: Paper sensed

Low: Paper not Sensed
Senses STACKER TRAY full of
large sized paper.
Finisher
012-240 EJECT CLAMP SENSOR
High: Sensed
Low: Not Sensed
Senses EJECT ROLL UP/DOWN
Position.
STAPLER MOVE MOTOR drive
starting signal, END WALL OPEN/
CLOSE MOTOR drive-for-open
starting signal.
Finisher
VERTICAL SENSOR
Input
Reissue
DocuColor 12/DCCS50
ID
Description
In_Out
Smart Help

Module_I
D
012-241 EJECT CLAMP HOME Input

SENSOR
High: Not Sensed

Low: Sensed
Senses SET CLAMP HOME Position. SET CLAMP MOTOR drive
stopping signal.
012-250 STACK HEIGHT SENSOR
Input
High: Not Sensed

Finisher
Low: Sensed
STACKER TRAY drive stopping signal.
012-252 COMPILER PAPER

SENSOR
Input
012-253 STACKER PAPER

SENSOR
Input
012-259 STACKER UPPER

LIMIT SENSOR
Input
012-260 STACKER LOWER

LIMIT SENSOR
Input
012-265 TAMPER HOME SENSOR
Input
012-269 STAPLER FRONT

CORNER SENSOR
Input
012-270 END WALL OPEN

SENSOR
Input
Reissue
DocuColor 12/DCCS50
ID
Processor
High: Paper sensed

Low: No paper sensed
Senses paper (un)available on
COMPILER TRAY.
Finisher
High: Paper sensed

Low: No paper Available
Senses paper (un)available on
STACKER TRAY.
Finisher
High: Sensed
Low: Not Sensed
Senses STACKER TRAY up limit.
Finisher
High: Sensed
Low: Not Sensed
Senses STACKER TRAY down
limit.
Finisher
High: Sensed
Finisher
Low: Not Sensed
Senses INTERRUPT FRONT CORNER Position. STAPLER MOVE
MOTOR drive stopping signal.
Smart Help
Input
High: Sensed
Low: Not Sensed
Senses Staple Head Home Position. Stapler Motor stop signal
(hardware stops driving). Eject
Motor drive starting signal.
Finisher
012-272 LOW STAPLE SWITCH Input
High: Sensed
Low: Not Sensed
Senses Low Staple status (40 or
less staples remain).
Finisher
012-273 STAPLE READY SEN- Input

SOR
High: Not closed

Finisher
Low: Closed
Senses a staple at front end of Staple Head.
012-274 CARTRIDGE SET

SWITCH
Input
High: Sensed
Finisher
Low: Not Sensed
Senses Staple Cartridge is properly
installed.
012-275 SCT FULL SENSOR
Input
High: Tray not full

Low: Tray full
Senses SCT Tray full of paper.
Finisher
012-276 DEC CAM POSITION

SENSOR
Input
High: Reflector sensed

Low: Reflector not sensed
Checks Decurler Cam Position
Sensor inputting.
Finisher
012-277 OFFSET HOME SENSOR
Input
High: Not sensed

Low: Sensed
Senses Eject Roll Home Position.
Eject Clamp & Offset Motor drive
starting signal.
Finisher
012-278 STAPLE FRONT

STRAIGHT SENSOR
Input
High: Sensed
Low: Not Sensed
Interrupt Front Straight Position.
Stapler Move Motor drive stopping
signal.
Finisher
012-279 STAPLE REAR

STRAIGHT SENSOR
Input
High: Sensed
Finisher
Low: Not Sensed
Senses Rear Straight Position. Stapler Move Motor drive stopping signal.
Finisher
1/05
6-105
Module_I
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In_Out
012-271 STAPLE HEAD HOME

SENSOR
High: Sensed
Finisher
Low: Not Sensed
Senses INTERRUPT TAMPER
HOME Position. TAMPER MOTOR
drive stopping signal.
High: Sensed
Low: Not Sensed
Senses End Wall open. Stapler
Move Motor drive starting signal.
Description
General Procedures
ID
Description

Module_I
D
In_Out
Smart Help
012-281 BIN 1 FULL SENSOR
Input
High: Bin not full

Low: Bin full
Checks Bin 1 Full Detection SNR
inputting.
Finisher
Input
High: Bin not full

Low: Bin full
inputting.
Finisher
Input
High: Bin not full

Low: Bin full
inputting.
Finisher
High: Bin not full

Low: Bin full
inputting.
Finisher
High: Bin not full

Low: Bin full
inputting.
Finisher
Input
Input
Input
High: Bin not full

Low: Bin full
inputting.
Finisher
Input
High: Bin not full

Low: Bin full
inputting.
Finisher
Input
High: Bin not full

Low: Bin full
inputting.
Finisher
High: Bin not full

Low: Bin full
inputting.
Finisher
Input
012-291 UNLOAD WHITE RUN

SWITCH
High: Open
Low: Closed
IOT Feed stop signal.
General Procedures
Module_I
D
In_Out
Smart Help
012-300 COMPILER COVER

INTERLOCK SWITCH
Input
High: Open
Low: Closed
Senses Compiler Cover Interlock
Open. IOT Feed stop signal.
Finisher
012-301 MAILBOX DOOR

INTERLOCK SWITCH
Input
High: Open
Low: Closed
Front Cover A Interlock Switch.
Finisher
012-302 DECURLER DOOR

INTERLOCK SWITCH
Input
High: Open
Low: Closed
Front Cover B Interlock Switch
Finisher
012-303 DOCKING INTERLOCK Input

SWITCH
High: Docked
Low: Undocked
Senses the docking to Processor.
IOT Feed stop signal.
Finisher
012-304 STAPLE DOOR INTER- Input

LOCK SWITCH
High: Open
Low: Closed
Senses Front Cover C Interlock
open. IOT Feed Stop signal.
Finisher
012-306 COMPILER COVER

SAFETY SWITCH
Input
High: Closed
Low: Open
Senses Compiler Upper Chute
open. IOT Feed stop signal that
turns off 24V to Staple Motor.
Finisher
014-260 ROS READY
Input
High: Stop
Low: Regular Rotation
Checks the Polygon Motor
Run Polygon Motor High Speed
(014 - 051) simultaneously
015-200 ITT IMAGE AREA
Input
Checks IIT image area
IIT
Table 2 Output Component Control Codes
High: Bin not full

Finisher
Low: Bin full
inputting.
Description
Output CC Codes
012-290 BIN 10 FULL SENSOR Input
Input
ID
In_Out
Smart Help
Module_I
D
003-001 TRD ENABLE
Output
Processor
003-002 24 OK
Output
Turn on (force) the K1 Relay of the Processor

AC Drive PWBA
ID
Description
Finisher
1/05
6-106
Reissue
DocuColor 12/DCCS50
ID
Description
004-007 MAIN MOTOR
004-009 FUSER MOTOR
004-021 DRUM MOTOR
005-011

Module_I
D
In_Out
Smart Help
Output
The Main Motor rotates at a freProcessor

quency of 2000.8 Hz
The PR and IVT are turned on
simultaneously
IF you operate the Drum Motor and
the main Motor at the same time,
then start one of them, the other
Motor will shut down. (This is
because they are both using the
same Hard signal)
Output
Output
The fuser motor rotates with a frequency of 1495.886 Hz.

Note: also used with V-TRA
Processor
- The drum motor rotates with a

Processor
frequency of 1495.886 Hz.
- Drum Motor Gain sell, 2 (low)
- PR and IBT are turned on simultaneously
- If you operate the drum motor
and the main motor at the same
time, then stop one of them, the
other motor will slow down. (This is
because they are both using the
same hard signal)
SET GATE SOLENOID Output

OPEN
After 5 sec., turned OFF automatically
DADF
005-012 SET GATE SOLENOID Output

CLOSE
DADF
005-040 FEED MOTOR
Output
DADF
005-055 BELT MOTOR CW
Output
The DADF Belt Motor forwards
DADF
005-056 BELT MOTOR CCW
Output
Belt Motor (Normal rotation)

The DADF Belt Motor reverses
DADF
005-075 REGI GATE SOLENOID
Output
DADF
005-081 EXIT MOTOR
Output
On: Rotates
DADF
005-083 DOC READY
Output
Simultaneous Output item: (IISS

sheet abort)
DADF
005-084 DOC SET LED
Output
On: L
DADF
006-002 ITT EXPOSURE LEAP Output
Reissue
DocuColor 12/DCCS50
ID
Description
Smart Help
006-003 COOLING FAN LOW

SPEED
Output
ON: L
Cooling Fan: High
IIT
006-005 IIT SCAN MOTOR

(Scan)
Output
Moves the Carriage 50mm in the

scan direction and stops automatically
IIT
006-006 IIT SCAN MOTOR

(Return)
Output
IIT Scan Motor (Return)
IIT
006-007 FUSER CUT
Output
On: Active
IIT
006-013 COOLING FAN HIGH

SPEED
Output
On: L
IIT
006-086 IIT IMAGE AREA
Output
On: Active
IIT
006-091 EXCHANGE TO ADF
Output
On: Active
Simultaneous on item
IIT
007-078 HCF FEED CLUTCH
Output
Engages the HCF Nudger Roll to

the Feed Motor.
HCF
007-079 HCF ELEVATE MOTOR Output
Unidirectional Motor to move the

HCF
HFC Paper Tray in the up direction
only (motor is not engaged in the
down direction).
007-080 HCF FEED MOTOR
Output
Unipolar 200 step / rev stepper

motor with a maximum 800 PPS.
One revolution = 200 steps = 152
mm paper travel.
HCF
008-006 #1 NUDGER ROLL

SOLENOID
Output
ON time is 2000 msec
Processor
008-007 #1 FEED MOTOR CCW Output
Motor reverse. Tray lift up (upper

limit detection stop)
ON time: 5500 msec
Processor
008-008 #1 FEED MOTOR CW
Output
Motor normal rotation: Feed Roll

rotation
Processor
008-009 #1 TAKE AWAY FEED

CLUTCH
Output
On drives connection
Processor
008-011
Output
Processor
Motor reverse: Tray lift up (upper

Does not turn on if the tray is not
set
ON time: 6000 msec
Processor
#2 NUDGER ROLL
SOLENOID
After 180 sec., Turns OFF automat- IIT

ically
1/05
6-107
Module_I
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In_Out
General Procedures
ID

Module_I
D
ID
Description

rotation
Processor
009-011
CARTRIDGE MOTOR K Output
Output
Processor
Output
Processor

set.
ON time: 6000 msec
Processor
Description
In_Out
Smart Help
Output

CLUTCH
SOLENOID
Output
Motor normal rotation: Feed roll

rotation
Processor

CLUTCH
Output
Processor

SOLENOID
Output
Processor

set
ON time: 6000 msec
Processor
Output

rotation
Processor

CLUTCH
Output
Processor
008-025 TAKE AWAY MOTOR
Output
On (rotation)
Processor
008-030 Tray 5 NUDGER ROLL Output

SOLENOID
Processor
008-037 TRAY 5 FEED CLUTCH Output
Processor
008-049 TRAY 5 LIFTER

MOTOR CCW (up)
Output
Processor
008-042 TRAY 5 LIFTER

MOTOR CW (down)
Output
Lower limit detection stop ON time: Processor

300 msec
Tray 5 Lift Motor CCW
008-043 MAIN MOTOR 2
Output
On: Port (L)
Processor
008-054 REGI MOTOR
Output
On: Port (L)
Processor
General Procedures
1/05
6-108
In_Out
Module_I
D
Smart Help
Automatically turns OFF after 10

Processor
sec.
Cannot run with Cartridge Motors Y
(009-012), M (009-013), or C (009014)
009-012 CARTRIDGE MOTOR Y Output

sec.
Cannot run with Cartridge Motors
M (009-013), C (009-014) or K
(009-011).
Processor
009-013 CARTRIDGE MOTOR

M
Output

Processor
sec.
(009-012), C (009-014) or K (009011).
009-014 CARTRIDGE MOTOR

C
Output

Processor
sec.
(009-012), C (009-013) or K (009011).
009-018 ROTARY LOCK MECH Output

LATCH
Latch - High: Rotary Lock SEL

RETN
Low: Rotary Lock SEL SUCF
Release - High: Rotary Lock SEL
RETN
Processor
009-021 DEVE MOTOR

CLUTCH
Output
On (High): Latch
Off (Low): Release
Processor
009-025 IBT ROLL CONTACT
Output
Run simultaneously with Main

Processor
Motor (004-007)
Automatically turns OFF after the
Roll Retract Home Position Sensor
detects the Contact Position (On:
Low, Off: High)
009-026 IBT ROLL RETRACT
Output

Processor
Motor (004-007)
Automatically turns OFF after the
Roll Retract Home Position Sensor
detects the Retract Position (On:
Low, Off: High)
009-031 DISPENSE MOTOR K
Output
Start after moving the Rotary to the Processor

K color and dispensing the toner.
NOTE: To drive the rotary, Move the
rotary to the K color in dC920
(Developer Unit Check).
Reissue
DocuColor 12/DCCS50
ID

Module_I
D
Description
In_Out
Smart Help
009-032 DISPENSE MOTOR Y
Output

Y color and dispensing the Toner.
NOTE: To drive the rotary, move the
rotary to the Y color in dC920
(Developer Unit Check)
Automatically turns off after 2 sec.
Cannot run with Dispense Motor M
(009-033), C (009-034) or K (009031).
009-033 DISPENSE MOTOR M Output

Cannot run with Dispense Motor Y
(009-032), C (009-034) or K (009031).
009-034 DISPENSE MOTOR C
Output

Cannot run with Dispense Motor Y
(009-032), C (009-033) or K (009031).
009-040 ADC LED
Output
On: L
Processor
009-050 ERASE LAMP
Output
On: Turns on the lamp.
Processor
009-057 2ND BELT TRANSFER Output

ROLL

ROLL CONTACT
Reissue
DocuColor 12/DCCS50
ID
Run simultaneously with Drum

Processor
Motor (004-021) and 2nd BTR CL
ON - Contact (009-058)
DC ON: 2.2kV - Discharge (can be
changed in NVM 771-033)
Processor
Motor (004-007)
Automatically turns off after the 2nd
BTR Home Position sensor detects
the Contact On Position, On: Low
Cannot run with 2nd BTR CL On Retract (009-059)
1/05
6-109
Description
In_Out
Module_I
D
Smart Help

ROLL RETRACT

Processor
Motor (004-021) and Main Motor
(004-007)
Automatically turns off after the 2nd
BTR Home Position Sensor detects
the Retract Position, On: Low
Cannot run with 2nd BTR CL On Contact (009-058)
009-066 IBT CLEANER CONTACT
Output

Processor
Motor (004-007)
Automatically turns off after the IBT
Cleaner Contact Home Position
Sensor detects the contact position.
ON: Low, OFF: High
009-067 IBT CLEANER

RETRACT
Output

Processor
Motor (004-007)
Automatically turns off after the IBT
Cleaner Contact Home Position
Sensor detects the contact position.
Cannot run with IBT Cleaner Contact (009-066).
009-068 PRE CLEAN

COROTRON dC
Output

Processor
Motor (004-021)
DC ON: PWM Output value = NVM
(0-255) - Discharge (variable value)
/ NVM 774-031 = 1 oclock output
value = 0 / NVM 774-031 = 2
oclock output value = 96.
NVM 774-033 / NVM 774-031 = 3
oclock output value = 130 NVM
774-029
009-070 CHARGE COROTRON Output

WIRE
Run Simultaneously with Drum

Motor (004-021)
Processor
009-074 SAW COROTRON dC
Output
ON: 3 KV - Discharge. (can be

changed in NVM 771-034)
Processor
009-076 DEVE BIAS dC
Output
ON: PWM Output Value - 573

fixed - Apply
Processor
009-077 DEVE BIAS AC COLOR Output

Processor
fixed - Apply
Cannot be run with Deve Bias - AC
B/W (009-079)
009-079 DEVE BIAS AC BLACK Output

Processor
Cannot be run with Deve Bias - AC
Color (009-077)
General Procedures
ID
Description
In_Out
Smart Help

Module_I
D
ID
Description
Module_I
D
In_Out
Smart Help

RETRACT
Output
Turn on Exit Motor (010-040) simul- Processor

taneously.
ON: L
Automatically turns off after Pressure Roll Retract Sensor detects
the contact position.
Cannot run with Fuser Nip CL OFF
(010-023).
009-081 CHARGE COROTRON Output

GRID

Motor (004-021)
ON: PWM Output Value = 717
(NVM 774-005)
Processor
009-085 ROTARY MOT FAN
Output
ON: L
Processor
009-088 BLOWER
Output
ON: L
Processor
009-089 CC FAN
Output
ON: L
Processor
010-004 FUSER FAN-LOW

SPEED
Output
ON: Port H
Processor
NOTE: When you exit from the I/O
check, exit at high speed.
Cannot run with Fuser Fan High
Speed (010-018).
010-025 INVERT ROLL NIP

SOLENOID
Output
On (Roll Nip): L
Processor
Reverse: Keep the state.
ON time: 100 msec
Cannot run with Invert Nip Solenoid
Release (010-026).
010-005 INVERT GATE SOLENOID INVERT
Output
ON (INV): L
Reverse: Keep the state
ON time: 100 msec
Cannot run with Invert Gate Solenoid Exit (010-006)
Processor
010-026 INVERT ROLL

RELEASE SOLENOID
Output
On (Roll Nip): L
Processor
Reverse: Keep the state.
ON time: 100 msec
Cannot run with Invert Nip Solenoid
Release (010-025).
010-006 INVERT GATE SOLENOID EXIT
Output
On (Exit): L
Reverse: Keep the state
ON time: 100 msec
Cannot run with Invert Gate Solenoid Invert (010-005).
Processor

ROLL CONTACT
Output
010-018 FUSER FAN-HIGH

SPEED
Output
ON: L
Processor
NOTE: When you exit from the I/O
Cannot run with Fuser Fan Low
Speed (010-004)
ON: L
Processor
Automatically turns off after the
detects the Contact position.
Cannot run with External Heat Roll
Retract Motor - Retract (010-028)

ROLL RETRACT
Output
010-020 INVERT MOTOR CW
Output
Motor On: Port (L) [CW] normal

rotation (upward): Port (H) Motor
Speed = 350 mm/s
Cannot run with Invert Motor CW
ON: L
Processor
Automatically turns off after the
detects the Contact position.
Cannot run with External Heat Roll
Retract Motor - Retract (010-027)

ROLL LAMP
Output
ON: L
Processor
NOTE: The fuser temperature control will be halted during the Diag.
Component Control and Diag. subsystem check. The fuser temperature control continues in any other
Diag.
Processor
010-021 INVERT MOTOR CCW Output
Motor On: Port (L) [CCW] reverse Processor

rotation (downward): Port (L) Motor
Speed = 450 mm/s
Cannot run with Invert Motor CW

CONTACT
Turn on Exit Motor (010-040) simul- Processor

taneously.
ON: L
Automatically turns off after Pressure Roll Retract Sensor detects
the contact position.
Cannot run with Fuser Nip CL OFF
(010-024).
Output
General Procedures
1/05
6-110
Reissue
DocuColor 12/DCCS50
ID
Description
010-030 HEAT ROLL LAMP

LAMP

Module_I
D
In_Out
Smart Help
Output
ON: L
Processor
Diag.
Output
ON: L
Processor
Diag.
010-032 WEB MOTOR
Output
ON: H
010-033 OIL PUMP
Output
ON: H
Processor
010-040 EXIT MOTOR
Output
ON: L
Processor
010-047 1ST BELT TRANSFER Output

ROLL
Processor
010-050 DUPLEX OUT MOTOR Output
ON: Port (L)
Processor
010-060 FUSER INT FAN-LOW

SPEED
ON: H
NOTE: When you exit the I/O
Cannot run with Fuser INT Fan
High Speed (010-061)
Processor
Output
Processor
010-061 FUSER INT FAN-HIGH Output

SPEED
ON: L
Processor
NOTE: When you exit the I/O
check, exit at low speed.
Cannot run with Fuser INT Fan Low
Speed (010-060)
010-085 OCT MOTOR

REVERSE
Output
CCW (moves to the home position): Processor

Port (H) Home detected.
Stop ON time: 600 msec
Cannot run with OCT Motor Forward (010-086)
010-086 OCT MOTOR FOREWARD
Output
Reissue
DocuColor 12/DCCS50
CW (moves to the offset position):

Port (H) Offset detected.
Stop ON time: 600 msec
Cannot run with OCT Motor
Reverse (010-085)
Processor
1/05
6-111
Module_I
D
ID
Description
In_Out
Smart Help
011-005
MAILBOX DRIVE
MOTOR
Output
Starts / Stops the Paper Transport

Roll
Sorter
011-010
DECURLER STEPPING MOTOR SPEED

60
Output
Starts / Stops driving the Decurler

Transport Roll.
Speed: 60 mm / sec.
Sorter
011-011

130
Output

Transport Roll.
Speed: 130 mm / sec.
Sorter
011-012

220
Output

Transport Roll.
Sorter
011-013

350
Output

Transport Roll.
Sorter
011-081
OCT GATE SOLENOID Output

OCT-ON
Must have the OCT Gate Solenoid Sorter

Bin Tray On (011-082).
Switch the OCT Gate to the OCT
direction. Return: OCT direction.
Time: 150 msec
011-082
OCT GATE SOLENOID Output

BIN TRAY-ON
Switch the OCT Gate to the Bin

Tray direction.
Suction: Bin tray direction.
Cannot run with OCT Gate Solenoid OCT ON.
Sorter
011-083
BIN 2 GATE SOLENOID
Output
Switch the 2 Bin Gate to the Bin

Tray direction.
Cannot run with the 3 to 10 Bin
Gate Solenoids (011-084 through
011-091).
Sorter
011-084
BIN 3 GATE SOLENOID
Output

Tray direction.
Cannot run with the 2,4 to 10 Bin
Gate Solenoids (011-083, 011-085
through 011-091).
Sorter
011-085
BIN 4 GATE SOLENOID
Output

Sorter
Tray direction.
Cannot run with the 2, 3, 5 to 10 Bin
Gate Solenoids (011-083, 011-084,
011-086 through 011-091).
General Procedures

Module_I
D
ID
Description
Switch the 5 Bin Gate to the 5 Bin

Tray direction.
Cannot run with the 2 to 4, 6 to 10
Bin Gate Solenoids (011-083
through 011-085, 011-087 through
011-091).
Sorter
011-095
OCT OFFSET MOTOR Output

BACK

Tray direction.
011-091).
Sorter

Tray direction.
011-091).
Sorter
ID
Description
In_Out
Smart Help
011-086
BIN 5 GATE SOLENOID
Output
011-087
BIN 6 GATE SOLENOID
Output
011-088
011-089
011-090
011-091
011-093
BIN 7 GATE SOLENOID
Output
BIN 8 GATE SOLENOID
Output
BIN 9 GATE SOLENOID
Output
BIN 10 GATE SOLENOID
Output
OCT OFFSET MOTOR Output

FRONT
General Procedures
012-005 MBX DRIVE MOTOR
Switch the 8 Bin Gate to the 8 Bin Sorter

Tray direction.
Cannot run with the 2 to 7, 9, 10 Bin
011-088, 011-090, 011-091).
Tray direction.
Cannot run with the 2 to 8,10 Bin
011-089, 011-091).
Sorter
Switch the 10 Bin Gate to the 10

Bin Tray direction.
011-091).
Sorter
Moves the OCT to the front direction and stops at the OCT Offset
Position.
(CW) Moves the OCT to the front
direction and stops 20 msec after
the OCT Offset Position Sensor
detects it.
Sorter
1/05
6-112
In_Out
Output
Module_I
D
Smart Help
Moves the OCT to the rear direction Sorter

and stops at the OCT Offset Position.
(CCW) Moves the OCT to the front
Direction and stops 20 msec after
the OCT Offset Position Sensor
detects it.
Cannot run with Offset Position
Sensor ON.
Cannot run with OCT Offset Motor
Front.
Low: On
Drives MBX Drive Motor
Finisher
012-010 DEC MOTOR ON/OFF Output

60
Low: On
Finisher
Drives DEC Paper Transport Roll at
60mm/s (actually 130mm/s)
012-011
DEC MOTOR ON/OFF Output

130
Low: On
Finisher
130mm/s.

220
Low: On
Finisher
220mm/s.

350
Low: On
Finisher
130mm/s.
012-020 FINSHER TRANSPORT MOTOR
Output
Low: On
Drives Finisher Transport Motor.
012-024 EJECT MOTOR FORWARD
Output
Not measurable
Finisher
Drives Eject Roll forward.
Note: Not measurable in field due to
24V Clock.
012-025 EJECT MOTOR

REVERSE
Output
Not measurable
Finisher
Drives Eject Roll backward.
24V Clock.
012-026 EJECT CLAMP AND

OFFSET MOTOR UP/
DOWN
Output
High: On
Finisher
Drives Eject Roll up/down. (500ms)
012-027 EJECT CLAMP AND

OFFSET MOTOR F/R
Output
High: On
Drives Eject Roll to front/rear.
(500ms)
Finisher
Finisher
Reissue
DocuColor 12/DCCS50
ID
Description

Module_I
D
In_Out
Smart Help
012-030 END WALL MOTOR

OPEN
Output
High: On
Finisher
Drives End Wall to open it (300ms)
012-031 END WALL MOTOR

CLOSE
Output
High: On
Finisher
Drives End Wall to close it (300ms)
012-036 COMPILER TRAY

SOLENOID
Output
Low: On
Lowers Compiler Tray.
Finisher
High: On
No output is allowed if a response
is sensed from Tray Upper Limit
SNR before or while Stacker Tray
being driven upward. (500ms)
Finisher
High: On
No output is allowed if a response
is sensed from Tray Upper Limit
SNR before or while Stacker Tray
being driven downward.
Finisher
High: On
Drives Set Clamp. (300ms)
Finisher
012-040 STACKER MOTOR UP Output
012-041 STACKER MOTOR

DOWN
012-053 EJECT PADDLE

MOTOR
Output
Output
012-060 TAMPER MOTOR LOW Output

FRONT
Not measurable
Finisher
Drives Tamper to front at a low
speed. (560pps) (100 pulses)
24V Clock.
012-061 TAMPER MOTOR TOP Output

FRONT
Not measurable
Finisher
Drives Tamper to front at a high
24V Clock.
012-062 TAMPER MOTOR LOW Output

REAR
Not measurable
Finisher
Drives Tamper to rear at a low
24V Clock.
012-063 TAMPER MOTOR TOP Output

REAR
Not measurable
Finisher
Drives Tamper to rear at a high
24V Clock.
012-064 TAMPER MOTOR MID- Output

DLE FRONT
Not measurable
Finisher
Drives Tamper to front at a medium
24V Clock.
Reissue
DocuColor 12/DCCS50
ID
1/05
6-113
Description
In_Out
Module_I
D
Smart Help
012-065 TAMPER MOTOR MID- Output

DLE REAR
Not measurable
Finisher
Drives Tamper to rear at a medium
24V Clock.
012-070 FIN GATE SOLENOID- Output

MBX/SCT POSITION
Low: On
Switches Gate for MBX/SCT. (100
pulses)
Finisher
012-071 FIN GATE SOLENOID- Output

FINSHER POSITION
Low: On
Switches Gate for Finisher. (100
pulses)
Finisher
012-075 STAPLER MOTOR

CLOSE
Output
High: On
Does stapling. (Compiler cover
Safety ON) (Stops at Home or
times out in 500ms).
Finisher
012-076 STAPLE POSITION

MOTOR TOP FRONT
Output
Not measurable
Finisher
Drives Stapler Unit to front at a high
speed (2700pps). If End Wall Open
Sensor doesnt sense any, no output is allowed. (250 pulses).

MOTOR LOW FRONT
Output
Not measurable
Finisher
Drives Stapler Unit to front at a low
24V Clock

TOP REAR
Output
Not measurable
Finisher
Drives Stapler Unit to rear at a high
24V Clock

MOTOR LOW REAR
Output
Not measurable
Finisher
Drives Stapler Unit to rear at a low
24V Clock
012-081 MBX GATE SOLENOID CLOSE
Output
Low: On
Switches MBX Gate for SCT.
(150ms)
Finisher
General Procedures

Module_I
D
ID
Low: On
Switches MBX Gate for MBX.
(150ms)
Finisher
Output
Low: On
Switches 2Bin Gate for Bin 2
Finisher
012-084 3 BIN GATE SOLENOID
Output
Low: On
Finisher
Output
Low: On
Finisher
Output
Low: On
Finisher
Output
Low: On
Finisher
Output
Low: On
Finisher
Output
Low: On
Finisher
Output
Low: On
Finisher
Output
Low: On
Finisher
012-096 DEC PENETRATION

CHANGE
Output
Low: On
Finisher
Drives MBX Drive Motor, and
500ms after then switches Decurler
Penetration (from Release position
to Weak position or Weak to Strong
or Strong to Release). (Completes
at Cam position.
012-099 UNLOAD WHILE RUN

LED
Output
Low: On
Turns on per the Start instruction.
Turns off per the Stop instruction.
(250 pulses)
Finisher
014-050 POLYGON MOTOR

LOW SPEED
Output
Polygon Motor ON Signal ON: L

Polygon Speed Signal ON: L
Cannot run with Polygon Motor
High speed (014-051).
Processor
014-051 POLYGON MOTOR

HIGH SPEED
Output
ID
Description
In_Out
Smart Help
012-082 MBX GATE SOLENOID OPEN
Output
General Procedures
In_Out
Smart Help
Module_I
D
014-053 LASER DIODE A ON
Output
ON: Port (H)
Processor
014-054 LASER DIODE B ON
Output
ON: Port (H)
Processor
015-001 MEMORY READY
Output
Scan Start OK signal from IPS

Processor
(Done with IPS memory ready signal output check
Description
Processor
Polygon Motor ON Signal ON: L
Polygon Speed Signal ON: H
Cannot run with Polygon Motor Low
speed (014-050).
1/05
6-114
Reissue
DocuColor 12/DCCS50
dC351 NVM Initialize, Save/Restore
Table 1
Purpose
Code
Description
Save / Restore NVM
710-007
L-REGI Pulse Duplex 8.5x11
This option saves current NVM settings that were changed since the last service call or to
restore the saved NVM settings since the last service call.
710-008
L-REGI Pulse Duplex A4 S
710-009
L-REGI Pulse Duplex 8.5x13
715-028
DADF IPS Offset- FS
715-029
REGI ADJ revise VAL-FS
715-091
White Ref Adjustment Coefficient - Red
715-092
White Ref Adjustment Coefficient - Green
Dust Off Reset
715-093
White Ref Adjustment Coefficient - Blue
Turns all counters back to zero.
715-106
HOSEI SCAN
715-107
MB_SCAN
NVM Background Read
715-110
CCD Calibration Y Patch-R
This option will read/save all NVM locations found in dC131.
715-111
CCD Calibration Y Patch-G
715-112
CCD Calibration Y Patch-B
715-113
CCD Calibration M Patch-R
715-114
CCD Calibration M Patch-G
715-115
CCD Calibration M Patch-B
715-116
CCD Calibration C Patch-R
715-117
CCD Calibration C Patch-G
715-118
CCD Calibration C Patch-B
715-119
CCD Calibration K Patch-R
715-120
CCD Calibration C Patch-G
NOTE: Select Stop Background Read to stop a "Background Read" in progress.
715-121
CCD Calibration C Patch-B
NOTE: Table 1 list all NVM values read, saved or restored in NVM Background Processing dC351.
715-125
Platen / DADF Selection
715-132
REGI Revise VAL- SS
715-133
MAG Revise VAL- SS
720-003
LS OFFSET Tray 1
720-004
LS OFFSET Tray 2
720-005
LS OFFSET Tray 3
720-006
LS OFFSET Tray 4
720-007
LS OFFSET Tray 5
Machine Settings
This option saves the machine settings that were changed since the last service call or to
restore the machine settings since the last service call.
Procedure
1.
using the PWS.
2.
Select Adjustments on the Service Entry Screen.
3.
Select NVM Init, S/R. The "NVM Initialize Screen (dC301)" is displayed.
4.
Select the NVM Background Processing (dC351) Tab.
5.
Select Reset All HFSI to reset all HFSI counters to zero.
6.
Select Start Background Read to read the NVM settings to be saved/restored.
7.
8.
Once the Background Read has completed, select Save Current NVM Settings or
Restore NVM Settings.
Once the NVM Settings have been "Saved" or "Restored", select Save Machine Settings
or Restore Machine Settings.
Table 1
Code
Description
720-008
LS OFFSET Duplex
702-002
Tools mode information
720-018
ERASE LE
702-003
720-019
ERASE TE
702-004
720-020
ERASE SIDE
702-020
730-001
TIS Parameter
702-022
730-002
MUC Adj
702-057
Document Size 1
730-003
MUC Adj for OHP
702-122
730-004
MUL M Rate for Y-Y
702-130
730-005
MUL M Rate for M-Y
702-168
730-006
MUL M Rate for C-Y
710-004
DADF Lead REGI Time Simplex
730-007
MUL M Rate for Y-M
Reissue
DocuColor 12/DCCS50
1/05
6-115
General Procedures
Table 1
Table 1
Code
Description
Code
Description
730-008
MUL M Rate for M-M
773-276
VHS ADJ
730-009
MUL M Rate for C-M
773-381
VGS
730-010
MUL M Rate for Y-C
773-383
LDS
730-011
MUL M Rate for M-C
773-456
ALC 300L BIAS SET Y
730-012
MUL M Rate for C-C
773-476
ALC 300L BIAS Y
730-013
MUL M Rate for Y-B
773-477
ALC 300L BIAS M
730-014
MUL M Rate for M-B
773-478
ALC 300L BIAS C
730-015
MUL M Rate for C-B
773-479
ALC 300L BIAS K
730-016
MUL M Rate for Y-G
773-481
ALC 600 BIAS Y
730-017
MUL M Rate for M-G
773-482
ALC 600 BIAS M
730-018
MUL M Rate for C-G
773-483
ALC 600 BIAS C
730-019
MUL M Rate for Y-R
773-484
ALC 600 BIAS K
730-020
MUL M Rate for M-R
773-496
ALC_IO[Y]
730-021
MUL M Rate for C-R
773-497
ALC_IO[M]
730-025
HOSEI
773-498
ALC_IO[C]
730-026
MB
773-499
ALC_IO[K]
730-045
CBY
773-606
RADC Patch Y
730-046
CBM
773-607
RADC Patch M
730-047
CBC
773-608
RADC Patch C
730-048
CBK
773-609
RADC Patch K
730-049
X - Regi- Editor
774-018
Bottle Full Flag
730-050
Y - Regi- Editor
774-019
Bottle Near Full Counter
730-051
X - Mag- Editor
774-020
Bottle Goal
730-052
Sharpness Level
774-179
Drum Cycle Ini
760-002
Tray 5 Size Sensor analog smallest Value
775-085
Radc_TRC_CinB [Y]
760-003
Tray 5 Size Sensor Analog Greatest Value
775-086
Radc_TRC_CinB [M]
760-004
Tray 1 Paper Size
775-087
Radc_TRC_CinB [C]
761-043
Regi Motor On Timing (Panel A& B)
775-088
Radc_TRC_CinB [K]
761-048
Adjust Regi Motor On Timing (Duplex Mode)
775-279
Val LUT Manu Adj (Y)
773-102
HILITE FLAG
775-280
Val LUT Manu Adj (M)
773-115
TEMP 1S
775-281
Val LUT Manu Adj (C)
773-121
HUM VH/VM ADJ
775-282
Val LUT Manu Adj (K)
773-231
ADC Sensor Gain - mirror
775-415
P_LUT_B[Y]
773-253
ADC VCLEAN S AVE
775-416
P_LUT_B[M]
773-258
ADC VCLEAN D AVE
775-417
P_LUT_B[C]775-418
773-263
VALCS TARGET
775-418
P_LUT_B[K]
773-265
VALCS2 TARGET
775-815
TC_SET_Kari_Ave
773-266
RADC set Y
776-010
Trickle bottle near full
773-267
RADC Set M
776-011
Trickle Bottle Full
773-268
RADC Set C
776-012
NVM TRICKLE STS
773-269
RADC Set K
776-136
DEVE HOME SENSOR
General Procedures
1/05
6-116
Reissue
DocuColor 12/DCCS50
Table 1
dC361 NVM Save/Restore
Code
Description
Purpose
776-367
Toner Cartridge Status (K)
Restores the NVM data of the Main Processor after saving it to the PWS.
776-368
Toner Cartridge Status (Y)
776-369
Toner Cartridge Status (M)
Procedure
776-370
Toner Cartridge Status (C)
A. Saving NVM Data
776-371
Toner Cartridge Empty Detection (K)
1.
776-372
Toner Cartridge Empty Detection (Y)
using the PWS.
776-373
Toner Cartridge Empty Detection (M)
2.
776-374
Toner Cartridge Empty Detection (C)
3.
Select NVM Save/Restore (dC361). The NVM Save/Restore Screen is displayed.
776-375
Toner Cartridge Near Empty Threshold
4.
776-376
Toner Cartridge Empty Detection
Select the desired target module from Select All or Specify an Item from the Initialize
Area screen.
777-001
H/R Temperature 1
777-002
P/R Temperature 1
777-003
Ext. H/R Temperature 1
777-006
H/R Power Save Temperature
777-007
P/R Power Save Temperature
ii.
Select All will select all the modules of Initialize Area.
777-008
Ext. H/R Power Save Temperature
iii.
The NVM areas do not include the Dust Off target modules.
777-010
Heat Roll Ready Temperature
777-011
Pressure Roll Ready Temperature
777-012
Ext. Heat Roll Ready Temperature
777-051
Oil Pump On Time
777-055
PV after Oil Near Empty
777-056
PV from Oil Near Empty to Empty
B. Restoring NVM Data
777-057
OIL LIMIT PAP
1.
777-058
Limit Time after Oil Empty
using the PWS.
777-075
Threshold time Web Near Empty
2.
777-076
WEB EMP
This function performs PWB Replacement or NVM Initialization. Refer to dC301 NVM Initialization.
777-077
Web Status
3.
Select Adjustments in the Service Mode.
777-081
Environment temperature
4.
Select NVM Save/Restore. NVM Save/Restore Screen is displayed.
777-109
TH - Rotate woPPR-size Mix
5.
777-110
Rotate woPPR-size Mix
Select the desired target module from Select All or Specify an item from the Initialize
Area Screen.
777-135
TH TEMP Not RDY PPR 4C
6.
Select Start dC 361 Restore. The message confirming the start of restoring is displayed.
777-136
HR & PR Not Ready temperature start threshold B/W
7.
Select Yes.
777-137
HR & PR Not Ready temperature start threshold 4C HVY
777-138
HR & PR Not Ready temperature start threshold B/W HVY
8.
Restoring Completed is displayed after the restoring.
777-139
HR & PR Not Ready temperature start threshold 4C OHP
777-140
HR & PR Not Ready temperature start threshold B/W OHP
999-002
Output Configuration - Sorter / Mailbox
999-004
CRU Type
Reissue
DocuColor 12/DCCS50
a.
Module specification items are as described below. (Default: IISS)

i.
5.
When selecting the target module of IISS or PostIPS, initialize area by selecting
the desired target module and check that the selection is highlighted in blue.
Hold the Shift Key and click other desired target modules to make multiple
selections.
Select Start dC 361 Save.

NOTE: It may take several moments to save the NVM data.
6.
Select OK to start.
a.
a.
1/05
6-117
An error message will be displayed if the Storage Medium has a problem.

When restoring is not completed successfully, the message, ! The operation
requested was not completed successfully will be displayed.
General Procedures
dC351 NVM Initialize, Save/Restore, dC361 NVM
dC371 Configuration Page
h.
Purpose
Allows easy viewing and set-up of machine configuration.
6.
Procedure
1.
using the PWS.
2.
3.
Select NVM Init, S/R. "NVM Init, S/R" is the default screen.
4.
Select Configuration Page (dC371). The Configuration Page Screen is displayed.
5.
Make selections on the screen from the following categories:

a.
b.
c.
XC (NASG)
XE (ESG)
FX
Platen Only
Select Save to save the options or select Reset to reset the default settings back to original options prior to entering Configuration Page (dC371).
FX / AP
Machine Config
Digital Copier
Copier / Printer
Copier / Printer / Scanner
Printer with UI
Output Device(s)
Simple Catch Tray
Offset Catch Tray
Sorter
Mailbox
Finisher / Sorter
Finisher / Mailbox
Accessories
e.
Foreign Interface
g.
DADF
Market Place
d.
f.
Input Device
Accessory Connection
None
Auditron
Card Prepaid
Coin Kit
Tray 1 Paper Size
8.5" x 11"
A4
B5
A5
Feature Config
Edit Pad
High Capacity Feeder
General Procedures
dC371 Configuration Page
1/05
6-118
Reissue
DocuColor 12/DCCS50
dC391 Edit Pad
dC612 Color Test Pattern Print
Purpose
Purpose
This routine allows you to set custom colors easily for the Customer Color Palette. Once a color
is selected the Color Indices can be adjusted by percentage to obtain the custom color for a
specific color.
Prints the test pattern in the machine, to help identify Copy Quality problems.
NOTE: The numbered locations on the dC391Color Palette match the colored locations on the
Customer Color Palette.
NOTE: The Edit Pad feature must be selected on the dC371 Configuration Page to enable the
Edit Pad.
Procedure
1.
using the PWS.
2.
Select Diagnostics in the Service Entry Screen.
3.
Select Test Pattern (dc612).

a.
To print an Image Process System Test Pattern, select Image Process System:
Procedure
i.
Select the Pattern Number from the menu.
1.
using the PWS.
ii.
Select the Paper Tray.
iii.
Set the number of prints to output in the Print Count Box and select Start.
2.
3.
Select Edit Pad (dC391). The Edit Pad Screen is displayed.
i.
Image Output System
4.
Select the number on the Color Palette that corresponds to the Customer Color Palette.
ii.
Paper (Simplex/Duplex)
5.
Once the color is selected, Click and drag the slide bars in the Color Indices box to
obtain the Custom Colors or click the arrow right of the slide bar to increase and click the
left arrow to decrease.
iii.
Paper Tray/Size
iv.
Paper Type
v.
Screen Type
6.
Select Save to save the changes.
7.
Select Reset to restore the original settings prior to entering dC Edit Pad.
b.
To print the Image Output Test Pattern, select Image Output System.
vi.
Color Mode
vii.
Set the number of prints to output and select Start.
Test Patterns
For details on the test pattern generation location and output path, Table 1:
Table 1 Test Patterns
Pattern
Number
Reissue
DocuColor 12/DCCS50
1/05
6-119
Pattern Name
Description
Remarks
IIT Analog Gradation Ch1- 3C color gradation PG

6-RGB - 300 lines (3C)
with all CCD RGB Odd/
Even data
PreIPS (Image Processing)
IIT Analog Gradation Ch1, K-color gradation PG with PreIPS (Image Processing)
2-R - 300 lines (K)
CCD R Odd/Even data
IIT Analog Gradation Ch3, K-color gradation PG with PreIPS (Image Processing)
4-G - 300 lines (K)
CCD G Odd/Even data
IIT Analog Gradation Ch5, K-color gradation PG with PreIPS (Image Process6-B - 300 lines (K)
CCD B Odd/Even data
ing)
IIT Analog Gradation Ch1- K-color gradation PG with PreIPS (Image Processing)
R - 300 lines (K)
CCD R Odd data
R - 300 lines (K)
CCD R Even data
IIT Analog Gradation Ch3- K-color gradation PG with PreIPS (Image ProcessG - 300 lines (K)
CCD G Odd data
ing)
G - 300 lines (K)
CCD G Even data
General Procedures
dC391 Edit Pad , dC612 Color Test Pattern Print

Pattern
Number
Pattern Name
Description

Pattern
Number
Remarks
Pattern Name
Description
Remarks
B - 300 lines (K)
CCD B Odd data
28
MWAH PG 300 lines (3C) Solid L*, a*, b* - 300 lines PostIPS (Image Processing)
PG
10
IIT Analog Gradation Ch6- K-color gradation PG with PreIPS (Image ProcessB - 300 lines (K)
CCD B Even data
ing)
29
MAD PG - 300 lines (4C)
Solid M - 300 lines PG
PostIPS (Image Processing)
11
IIT digital FS gradation 300 lines (3C)
FS direction gradation PG PreIPS (Image Processing)
30
TRE PG - 300 lines (4C)
Solid YC - 300 lines PG
12
IIT digital SS gradation 300 lines (3C)
SS gradation PG
31
SFM PG (Post IPS) 300

lines (B/W)
Solid K 300 lines PG
13
IIT digital FS/SS gradation - 300 lines (3C)
FS/SS gradation PG
32
TBC PG(Post IPS)- 300

lines (4C)
Solid YMCK - 300 lines

PG
14
IIT shading data output 300 lines (3C)
Current shading correction PreIPS (Image Processing)

data is output. (PC with
dark center)
33
TBC horizontal stripe

YMCK (Post IPS) 300
lines (4C)
Horizontal stripe - Solid

YMCK - 300 lines PG
15
SID horizontal stripe

YMCK - 300 lines (4C)
Each Y.M.C.K developer:

PreIPS horizontal stripe
PG
34
TBC vertical stripe

YMCK(Post IPS) - 300
lines (4C)
Vertical stripes - Solid

YMCK - 300 lines PG
16
SID slant lines - 600 lines Each Y.M.C.K developer:

(4C)
PreIPS slant lines PG
35
Edit Bypass (Post IPS) 200R - 4C
17
SID grid: YMCK repeated Each Y.M.C.K developer:

- 600 lines(4C)
PreIPS grid PG
Output a normal copy

(bypassed the Editor) in
200R (4C).
18
First phase TRE PG1 300 lines (3C)
Half tone (AAH) PG
19
First phase TRE PG2 300 lines (3C)
Half tone (55H) PG
20
MEM SYS PG1 (MEM

SYS) - 300 lines (3C)
Solid RGB AAH - 300

lines PG
21
MEM SYS PG2 (MEM

SYS) - 300 lines (3C)
Solid RGB 55H: 300 lines PostIPS (Image Processing)

PG
22
CST horizontal stripe

YMCK (Post IPS) - 300
lines (4C)
Each Y.M.C.K developer:

PostIPS horizontal stripe
PG. (Pattern: Same as
number 15)
23
CST vertical stripe YMCK Each Y.M.C.K developer: PostIPS (Image Process(Post IPS) - 300 lines (4C) PostIPS vertical stripe PG ing)
24
64 gray-scale patch (Post 64 gray-scale patch PG

IPS) - 200R lines (4C)
25
YMCK overlaid grid - 600

lines-CST (4C)
26
Slant lines - 600 lines-CST Each Y.M.C.K developer:

(4C)
PostIPS horizontal stripe
PG (Pattern: Same as
number 16)
27
Grid YMCK repeated - 600 4C grid repeated PG

lines-CST (4C)
4C grid PG
General Procedures
NOTE: Set the test chart

on the platen and output
the PG.
36
Edit Bypass (Post IPS) 200R - 3C
Set the test chart on the

PostIPS (Image Processplaten and output the PG. ing)
the PG.
37
Edit Bypass (Post IPS) 200R - B/W

200R (B/W).

the PG.
38
Edit Bypass (Post IPS) 200R - Y

200R (Yellow).

the PG.
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Pattern
Number
39
Pattern Name
Description
Remarks
Edit Bypass (Post IPS) 200R - M

200R (Magenta).
Pattern
Number
46
Edit Bypass(Post IPS) 200R - C

200R (Cyan).
47
Edit Bypass(Post IPS) 200R - R

200R (Red).
48
Edit Bypass (Post IPS) 200R - G

200R (Green).
Edit Bypass (Post IPS) 200R - B

200R (Blue).
49
Normal copy (Post IPS)200R - 4C
Output a normal copy in

200R (4C).
Normal copy (Post IPS)200R - 3C

200R (3C).
50
DocuColor 12/DCCS50

200R (Yellow).
Normal copy (Post IPS)200R - M

200R (Magenta).
Normal copy (Post IPS)200R - C

200R (Cyan).
Normal copy (Post IPS)200R - R

200R (Red).

the PG.
51
Normal copy (Post IPS)200R - G

200R (Green).

the PG.
52
Normal copy (Post IPS)200R - B

200R (Blue).

the PG.

the PG.
Reissue
Normal copy (Post IPS)200R - Y

the PG.

the PG.
45

the PG.
44

200R (B/W).

the PG.

the PG.
43
Normal copy (Post IPS)200R - B/W

the PG.
42
Remarks

the PG.

the PG.
41
Description

the PG.

the PG.
40
Pattern Name
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53
ALL IPS PG(ANASimplified output - PWB

PostIPS (Image ProcessLOG+PRE+MEM+POST) PG (Analog, CMM and
ing)
PostIPS) in one sheet output
54
Color patch: 1st page
The upper color patch for

the Editor Pad is output.
General Procedures
dC701 Fuser Nip Measurement

Pattern
Number
Pattern Name
Description
55
Color patch: 2nd page
The middle color patch for PostIPS (Image Processing)

the Editor Pad is output.
56
Color patch: 3rd page
The bottom color patch for PostIPS (Image Processthe Editor Pad is output.
ing)
82
Grid (Measurement) - 600 20mm pitch/2dotline grid

Paper size: A3 or 17
84
Grid (Registration) - 600
85
Grid (45 degree) - 600
Remarks
IOT (Image output)
Scale/2dotline grid
IOT (Image Processing)
Paper size: A3A4L/A4S/
B4S/B5L/B5S/LetterL/LetterS
45 degree grid/2dotline
88
Color registration (Measurement) - 600
Cross mark/4dotline
89
Color registration (Visual

observation) - 600
Color registration visual

check pattern
Paper size: 17 or A3
97
Half tone - 4C
Any density pattern (Variable Cin% can be set).

98
Halftone - 3C

Purpose
Makes a copy for the Contact Arc Adjustment and measures the Fuser Nip Width with a simple
operation.
NOTE: For details, see Adjustments Section 4:ADJ 8.1.1 Fuser Nip Adjustment (dC701).
Procedure
1.
using the PWS.
2.
3.
Select Other Adjustments on the Adjustments Screen. Other Adjustments Screen is displayed.
4.
Select Fuser Nip Adjustments (dC701). Fuser Nip Adjustment Screen is displayed.
5.
Check that A4 LEF or Letter LEF paper has been loaded into Tray 5.
6.
Select Nip Adjustment Black Copy and press Start.
7.
The message execute is displayed.
8.
a.
Make a copy for measuring the nip width by using A4 LEF or Letter LEF.
b.
A error message screen will be displayed if there is no paper tray loaded with A4
LEF or Letter LEF.
The message Completed is displayed when the Nip Adjustment Black Copy is completed successfully.
a.
9.
When the Nip Adjustment Black Copy is not completed successfully, the message
Not completed successfully will be displayed.
Select Nip Adjustment Sequence.
99
Other Halftones

10. The message Executing in Progress is displayed at the same time the Nip Width Measurement begins.
100
16 grasslike SS
SS direction: 16 grayscale
11. The message Completed is displayed when the Nip Adjustment Sequence is completed successfully. The message Not completed successfully will be displayed when
the Nip Adjustment Sequence is not completed successfully.
101
ProCon
ProCon patch pattern/

16.3x19.3 mm patch
102
TED/STV - 600
TED/STV
Paper size: A4L
103
Wedge SS - 600
SS direction pattern/1
gray-scale
12. Measure the nip width of the output paper for Nip Adjustment Sequence.
General Procedures
dC612 Color Test Pattern Print, dC701 Fuser Nip Mea-
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dC740 Tray 5 Guide Adjustment
dC915 Machine Output
Purpose
Purpose
Checks whether the Tray 5 guide size (width) has been properly detected.
Displays Xerographic information on the Main Processor in an easily seen and understandable
format on the PWS.
NOTE: For details on adjustment, see ADJ 9.1.17 Tray 5 Guide Adjustment (dC740).
Procedure
1.
using the PWS.
2.
3.
Select Other Adjustments in the Adjustments screen.
4.
In the Other Adjustments Screen, select and execute the Tray 5 Guide Adjustment
(dC740).
5.
Run the guide detection.

a.
b.
c.
i.
Set the Tray 5 Guide at the minimum position.
ii.
In the Tray 5 Guide Adjustment Selection Screen, select Minimum Position

and press Start.
If the sensor output is within the range, the system displays OK.
iv.
If the sensor output is out of the range, the system displays NG.
XERO Related Data Display: Displays all the NVM data related to the Copy Quality as a
set.
2.
Displays the machine NVM data on the PWS UI.
Procedure
Displaying the dC915 XERO Data
Set at the minimum position.
iii.
1.
1.
using the PWS.
2.
3.
Select Machine Output on the Adjustments Screen. Machine Data Output Screen is
displayed.
4.
Select PWS Display for the Output Medium.
5.
Select Start. XERO Related Data Display Screen is displayed.
6.
Refer to XERO Related Chain Link Number List for the Output Items by the XERO
Related Data Display and the details of XERO Related NVM Data.
XERO Related Chain Link Number List
Set at the maximum position.

i.
Set the guide at the maximum position.
ii.
In the Tray 5 Guide Adjustment Selection Screen, select Maximum Position

and press Start.
Table 1 Xero-related NVM
iii.
If the sensor output is within the range, the system displays OK.
iv.
If the sensor output is out of the range, the system displays NG.
Guide test
i.
Set the guide at the position.
ii.
Select and run the Guide Test in the Tray 5 Guide Adjustment Selection
Screen.
iii.
The system displays the detected paper size group in the "Results" (Tray 5
Guide Adjustment Selections).
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ID (dec) NVM Number
Item
Max. (dec)
773-028
ADC Vpatch Fault flag
773-021
ADC Vclean Fault flag
775-010
Gray-scale ADC Vpatch Fault flag
775-011
Gray-scale ADC V clean Fault flag
773-022
VH/VM Fault flag
773-027
LD CONT Fault flag
773-099
HUM Fault flag
773-016
ADC V patch Fault counter: Y
65535
773-017
ADC V patch Fault counter: M
65535
10
773-018
ADC V patch Fault counter: C
65535
11
773-019
ADC V patch Fault counter: K
65535
12
773-011
ADC V clean Fault counter
65535
13
775-002
Gray-scale ADC V patch Fault counter: Y
65535
14
775-003
Gray-scale ADC V patch Fault counter: M
65535
15
775-004
Gray-scale ADC V patch Fault counter: C
65535
16
775-005
Gray-scale ADC V patch Fault counter: K
65535
17
775-001
Gray-scale ADC V clean Fault counter
65535
18
773-012
VH/VM Fault counter
65535
19
773-013
LD CONT Fault counter
65535
20
773-014
HUM Fault counter
65535
General Procedures
dC740 Tray 5 Guide Adjustment, dC915 Machine
ID (dec) NVM Number
Item
Max. (dec)
ID (dec) NVM Number
Item
Max. (dec)
21
Number of drum cycles: Sign (0: Positive/10:

Negative)
57
773-277
VM target
1023
58
773-396
Vadc target
1023
Number of drum cycles (Unit: 100cycle decrementing count)
65535
59
773-278
V hi-light control target
1023
Number of developer cycles: Y (Unit: Mot. ON

0.1 hour)
65535
60
773-388
VH measurement
1023
61
773-394
VM measurement
1023
62
773-397
Vadc measurement
1023
63
773-431
V hi-light control measurement
1023
64
773-401
VG setup
1023
65
773-421
LD setup
255
66
773-406
Vbias setup
1023
67
773-451
Hi-light setup: Y(300)
1023
22
23
24
25
26
773-357
773-356
773-342
773-343
773-344
773-345
Number of developer cycles: M (Unit: Mot. ON 65535

0.1 hour)
Number of developer cycles: C (Unit: Mot. ON
0.1 hour)
65535
Number of developer cycles: K (Unit: Mot. ON

0.1 hour)
65535
27
Number of transfer belt cycles (Unit: TBD)
65535
68
773-452
Hi-light setup: M(300)
1023
28
773-281
ADC target/gray-scale target1: Y
1023
69
773-453
Hi-light setup: C(300)
1023
29
773-282
ADC target/gray-scale target1: M
1023
70
773-454
Hi-light setup: K(300)
1023
30
773-283
ADC target/gray-scale target1: C
1023
71
773-461
Hi-light setup: Y(600)
1023
31
773-284
ADC target/gray-scale target1: K
1023
72
773-462
Hi-light setup: M(600)
1023
32
775-036
ADC gray-scale target2: Y
1023
73
773-463
Hi-light setup: C(600)
1023
33
775-037
ADC gray-scale target2: M
1023
74
773-464
Hi-light setup: K(600)
1023
34
775-038
ADC gray-scale target2: C
1023
75
775-741
TC Offset Out ID
65535
35
775-039
ADC gray-scale target2: K
1023
76
775-742
TC Ref OUT id
65535
36
773-606
ADC measurement: Y
1023
77
775-746
TC Ref OPEN OUT id
65535
37
773-607
ADC measurement: M
1023
78
775-743
TC OUT id - Y
65535
38
773-608
ADC measurement: C
1023
70
775-744
TC OUT id - M
65535
39
773-609
ADC measurement: K
1023
80
775-745
TC OUT id - C
65535
40
775-085
ADC gray-scale measurement1: Y
1023
81
775-750
TC SET ALL id
65535
41
775-086
ADC gray-scale measurement1: M
1023
82
775-747
TC SET OUT id - Y
65535
42
775-087
ADC gray-scale measurement1: C
1023
83
775-748
TC SET OUT id - M
65535
43
775-088
ADC gray-scale measurement1: K
1023
84
775-749
TC SET OUT id - C
65535
44
775-081
ADC gray-scale measurement2: Y
1023
85
775-751
TC OFFSET OUT Fail
65535
45
775-082
ADC gray-scale measurement2: M
1023
86
775-752
TC Ref OUT Fail
65535
46
775-083
ADC gray-scale measurement2: C
1023
87
775-756
TC Ref OPEN OUT Fail
65535
47
775-084
ADC gray-scale measurement2: K
1023
88
775-753
TC OUT Fail - Y
65535
48
773-251
ADC Vclean1_QA
1023
89
775-754
TC OUT Fail - M
65535
49
773-252
ADC Vclean1_QB
1023
90
775-755
TC OUT Fail - C
65535
50
773-256
ADC Vclean2_QA
1023
91
775-761
TC OFFSET OUT
65535
51
773-257
ADC Vclean2_QB
1023
92
775-762
TC Ref OUT
65535
52
773-231
ADC Gain
1023
93
775-763
TC Ref
65535
53
773-114
Humidity raw data (%)
1023
94
775-764
TC OUT Adj - Y
65535
54
773-115
Temperature raw data (degree (C))
1023
95
775-765
TC OUT Adj - M
65535
55
773-121
Set-up humidity (%)
1023
96
775-766
TC OUT Adj - C
65535
56
773-276
VH target
1023
97
775-784
TC SET - Y
65535
General Procedures
dC915 Machine Output
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dC918 IOT Highlight Setup

ID (dec) NVM Number
Item
Max. (dec)
Purpose
98
775-785
TC SET - M
65535
99
775-786
TC SET - C
65535
Sets the same Hi-Light density reproduction start points (for K, Y, M and C) and sets the
same Hi-Light densities for In-Board and Out-Board.
Sets the ESV/ADC control target values.
NOTE: For details on dC918 IOT Highlight Setup, see Adjustments Section 4: ADJ 9.1.5 IOT
Highlight Setup (dC918).
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General Procedures
dC915 Machine Output , dC918 IOT Highlight Setup
dC919 Color Balance Setup (IIT installed machine only)
dC920 Developer Unit Check
Purpose
Purpose
Takes a 4C copy in the Photo Mode and visually checks the Color Balance and then sets the
KYMC Color Balance NVM.
Rotates the Rotary Developer and sets it at the desired position.
Procedure
NOTE:
1.
Run this function only when requested by the customer for a Color Adjustment after the
Automatic Gray-Scale Correction has been performed (Tool mode).
2.
Before running this function the dC918 High Light Setup must have been performed properly.
NOTE: For details on dC919 Color Balance Setup, see Adjustments Section 4: ADJ 9.1.8
Color Balance Setup (dC919).
General Procedures
dC919 Color Balance Setup (IIT installed machine
1.
using the PWS.
2.
Select Diagnostics on the Service Entry Screen.
3.
Select System Test in the Fault Diagnostics Screen.
4.
Select Developer Unit Check (dc920).
5.
Select the Developer Unit to move. Select Start.
6.
After checking, move the Developer Unit to the Home Position.
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dC922 TRC Control/Toner Density Adjustment
dC923 PROCON PG
Purpose
Purpose
Measures the Gray-Scale Patch with the ADC Sensor and creates the TRC Correction
LUT in the IOT. If the result is not within the range, the system displays the Tone up/down
result.
Outputs the PRCON PG (ProCon pattern), measures the ADC Patch density by the ADC
Sensor and displays the result on the PWS Screen.
The PRCON PG should be used only for individual Adjust/Recover.
Displays the density of the 2 patches for each color on the IBT Belt.
Procedure
NOTE: For details on dC922 TRC Control/Toner Density Adjustment, see Adjustments
Section 4: ADJ 9.1.6 TRC Control/Toner Density Adjustment (dC922).
1.
using the PWS.
2.
3.
Select the MAX Setup (dC929) Tab.
4.
Select ProCon PG (dC923) in the Max Setup (dC929) Screen.
5.
Select a Tray from the Tray Drop Down List (paper: 11x17/A3 or 8.5x11/A4L) and click
Start.
6.
The ProCon PG is printed. (normal paper, full color, 300-lines, LUT off)
The system generates an ADC Patch for each color and updates the NVM value
after measuring the density.
The system checks the RADC Patch.
If OK, click Close to return to the Max Setup Screen.

NOTE: It is not necessary to run this routine to perform Max Setup. This routine can be
used as a quick check of the ADC Patch status.
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General Procedures
dC922 TRC Control/Toner Density Adjustment,
dC924 TRC Adjust / dC939 TRC Check PG
dC929 Max Setup
NOTE: NOT TO BE USED AT THIS TIME.
Purpose
The system displays the following Setup functions which you can use to set the image quality.
Purpose
To manually fine adjust the low/medium/high densities (TRC) for each color.
NOTE: Although it appears that the densities can be adjusted independently for different
screen types, this is not the case. An adjustment for one screen type will affect all of the
screens (300, 150C, 200R, and 600). Also, there is quite a bit of overlap among the low,
medium, and high densities. For these reasons, it is recommended that dC924/939 not be
used.
1.
dC945 IIT Calibration (See dC945 IIT Calibration) (IIT installed machine only)
2.
dC934 ADC/AGC Setup (See dC934 ADC/AGC Setup)
3.
dC933 VH/VM Setup (See dC933 VH/VM Setup)
4.
dC918 IOT Highlight Setup (See dC918 IOT Highlight Setup)
5.
dC922 TRC Control/Toner Density Adjustment (See dC922 TRC Control/Toner Density
Adjustment)
6.
dC924 TRC Adjustment/939TRC Check (See dC924 TRC Adjust / dC939 TRC Check
PG)
7.
dC919 Color Balance Setup (See dC919 Color Balance Setup (IIT installed machine
only)) (IIT installed machine only)
8.
dC923 PROCON PG (See dC923 PROCON PG).
NOTE: For the execution sequence of the Max Setup Functions, see Adjustments Section 4:
ADJ 9.1.1 Max Setup (dC929).
NOTE: If a 3-510 fault occurs while performing Max Setup, ensure that Automatic Tray switching for Trays 1 - 4 is enabled in Customer Tools
General Procedures
dC924 TRC Adjust / dC939 TRC Check PG, dC929 Max
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dC933 VH/VM Setup
dC934 ADC/AGC Setup
Purpose
Purpose
Sets the VG, LD light amount, Development Bias and ASG Bias output value by determining:
Automatically adjusts the ADC Sensor Gain.
The VG value wherein the Drum surface potential becomes the target VH in two different
VGs.
Adjusts the ADC Sensor Gain and automatically sets the gain so that the Vclean within
the range is obtained.
The LD light that is the target VM in three different LD light amounts.
The ASG Bias to correct the high light unit.
At the same time, measures the Vclean irregularity (Vclean P-P) for one belt circumference.
NOTE: For details on dC933 VH/VM Setup, see Adjustments Section 4: ADJ 9.1.4 VH/VM
Setup (dC933).
Reissue
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NOTE: For details on dC934 ADC/AGC Setup, see Adjustment Section 4: ADJ 9.1.3 ADC/
AGC Setup (dC934).
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General Procedures
dC933 VH/VM Setup, dC934 ADC/AGC Setup
dC945 IIT Calibration

Purpose
Functional details:
Computes and sets the White Reference Correction Coefficient.
Corrects the IIT Sensitivity Dispersion.
NOTE: For details on dC945 IIT Calibration, see Adjustments Section 4: ADJ 9.1.2 IIT Calibration (dC945).
General Procedures
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How to Enter/Exit the UI (IOT) Diagnostics Mode
UI (IOT) Diagnostic Modes
Procedure
The UI (IOT) Diagnostic supports the following modes. These selections are displayed on the
UI Customer Support Engineer Tools Screen.
1.
Power ON the machine.
2.
While holding down the 0" Button, press Start. A screen will display, asking you to Enter
your Access Number.
3.
Using the Keypad, Enter 6789.
4.
Press Confirm when finished. If you make a mistake, press C". The Customer Support
5.
6.
Select one of the following options on the screen:
NVM Initialize
NVM Read/Write
Component Control
Print
Subsystem Check
Max Setup
NVM Reset / NVM Initialization (dC301 UI Diagnostics)
NVM Read / Write (dC131 NVM UI Diagnostics)
Component Control (dC330 UI Diagnostics)
Print (dC612 Test Pattern UI Diagnostics)
Subsystem Check
To exit the UI (IOT) Diagnostics Mode, select Done.
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1.
Fuser Nip Measurement (dC701 UI Diagnostics)
2.
Developer Unit Check (dC920 UI Diagnostics)
Max Setup (UI Diagnostics)

1.
ADC/AGC Setup (dC934 UI Diagnostics)
2.
VH/VM Setup (dC933 UI Diagnostics)
3.
IOT Highlight Setup (dC918 UI Diagnostics)
4.
TRC Setup/Toner Concentration Adjustment (dC922 UI Diagnostics)

a.
TRC Control
b.
Toner Concentration Adjustment
c.
TRC Adjustment (dC924 UI Diagnostics)
5.
Color Balance Setup (dC919 UI Diagnostics) (IIT installed machine only)
6.
IIT Calibration (dC945 UI Diagnostics) (IIT installed machine only)

a.
White Reference Adjustment
b.
CCD Calibration
General Procedures
How to Enter/Exit the UI (IOT) Diagnostics, UI (IOT)
NVM Reset / NVM Initialization (dC301 UI Diagnostics)
NVM Read / Write (dC131 NVM UI Diagnostics)
Purpose
Purpose
Initializes NVM for each subsystem and Initializes NVM for the entire system.
Accesses NVM Read/Write Data by specifying the Chain-Link Number.
NOTE: Functional comparison between the UI Diagnostics and the PWS Diagnostics.
UI Diag.:
UI Diag.:
1.
1.
No dust-off function.
No module specification. All direct code specification.
Procedure
Procedure
1.
1.
Enter the UI Diagnostics Mode. Refer to How to Enter/Exit the UI (IOT) Diagnostics.
2.
In the Diagnostics Setup Screen, select NVM Read/Write.
3.
See the dC131 Code List and enter the Chain-Link Number. Selecting the Enter Number Button allows you to enter the number from the Ten-key Pad. for the Read/Write
dC131 NVM List.
To perform NVM Reset or NVM Initialization, refer to dC301 NVM Initialization.
CAUTION
Enter a correct number. (Make sure you have entered a correct number before you execute the
function. If you enter an invalid number, a secondary problem will occur.)
4.
Select the Start Button.
5.
Enter a new value from the ten-key pad. Select Start.
6.
After the operation, return to the Diagnostics Setup Screen by selecting Close on the
UI Screen.
The Screen shows the current NVM Value.
General Procedures
NVM Reset / NVM Initialization (dC301 UI Diagnos-
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Component Control (dC330 UI Diagnostics)
Purpose
Purpose
Checks the Input/Output of each component by specifying the Chain-Link Number.
Provides a Print Pattern for Setup and Diagnostics, performing a faster and more efficient
service.
NOTE: Functional comparison between the UI Diagnostics and the PWS Diagnostics:
1.
UI Diag.: No module specification. All direct code specification.
2.
Counter:
a.
3.
4.
UI Diag. restrictions:
Input/Output display - Input: The count is increased every time the High/Low Level
changes. The maximum count is 256. After reaching the maximum count, the
counter starts from 0.
1.
Paper type cannot be specified (Normal paper - Fixed)
2.
Tray cannot be specified (Normal paper - Fixed)
3.
Duplex cannot be specified (Normal paper - Fixed)
Number of simultaneous executions:
4.
Half-tone Cin%=20% fixed
a.
5.
You cannot select a pattern with the Color Test Pattern. You must enter a number from
the Code Table.
12 (Same as PWS). If the number exceeds 12, the oldest code is stopped.
Other message:
a.
A warning message is displayed on the UI when the following occurs:
Procedure
Number of simultaneous executions exceeded 12 and you pressed Start.
1.
You stopped a code that is not being executed or displayed the status.
2.
Select Print in the Diagnostics Setup Screen.
You specified a cycle for the code that cannot be cycled.
3.
The combination of a code that has already been executed and the new code is
illegal.
Select a Test Pattern to output in the Test Pattern Print List and set the following on the
screen:
a.
Category: IOT (Image output) or IPS (Image process)
You specified an undefined code.
b.
Pattern No: 1-30(IOT), 1-56(IPS)
You stopped the code from being executed.
c.
Mode: 4C, 3C, K, Y, M, C, R, G, B
Procedure
4.
1.
5.
After the operation completes, select Close and return to the Diagnostics Setup Screen.
2.
Select Component Control in the Diagnostics Setup Screen.
Test Pattern Print List (UI Diagnostic Mode)
3.
Select the Input Number Button on the UI Screen.
4.
See the dC330 Code List (Input), (Output), and enter an appropriate Chain-Link No.
Table 1 Test Patterns (UI Diagnostic Mode)
NOTE: Selecting the Input Number Button allows you to enter a number from the tenkey pad.
PG NO
ASIC name
Pattern name
Description
ANALOG
IIT Analog Gradation

Ch1 - 6-RGB, 300
lines (3C)
3C gradation PG PreIPS (Image process)

Reading all CCD
RGB Odd/Even data.
ANALOG

Ch1,2-R, 300 lines
(K)
3C gradation PG PreIPS (Image proReading all CCD

cess)
RGB Odd/Even data.
ANALOG

Ch3,4-G, 300 lines
(K)
K-color gradation PG PreIPS (Image process)

- Reading CCD G
Odd/Even data.
ANALOG
IIT Analog Gradation K-color gradation PG PreIPS (Image process)

Ch5,6-B, 300 lines (K) - Reading CCD B
Odd/Even data.
ANALOG

Ch1-R, 300 lines (K)
K-color gradation PG PreIPS (Image pro- Reading CCD R

cess)
Odd data.
ANALOG

Ch2-R, 300 lines (K)
K-color gradation PG PreIPS (Image pro- Reading CCD R

cess)
Even data.
CAUTION
5.
6.
To stop the operation, select the Stop Button.
7.
After the operation, all Input/Output tasks being executed will stop.The system returns to
the Diagnostics Setup Screen.
The Status Screen shows Low/High (Input) or ON/Off (Output).
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Remarks
General Procedures
Component Control (dC330 UI Diagnostics), Print
PG NO
ASIC name
Pattern name
Description
PG NO
ASIC name
Pattern name
Description
ANALOG

Ch3-G, 300 lines (K)

- Reading CCD G
Odd data.
23
CST
CST vertical stripes:

YMCK(POST
IPS)300 lines (4C)
PostIPS vertical stripe PostIPS (Image proPG for each Y.M.C.K cess)
developer.
ANALOG

Ch4-G, 300 lines (K)
K-color gradation PG PreIPS (Image pro- Reading CCD G

cess)
Even data.
24
CST
64 gray-scale patch
(POST IPS)200R
lines (4C)
64 gray-scale patch
PG
PostIPS (Image process)
ANALOG

Ch5-B, 300 lines (K)

- Reading CCD B
Odd data.
25
CST
YMCK overlaid grid:

600 lines-CST (4C)
4C grid PG
26
CST
10
ANALOG

Ch6-B, 300 lines (K)

- Reading CCD B
Even data.
Slant line: 600 linesCST (4C)
11
IIC
IIT DIGITAL FS gra- FS direction gradation PreIPS (Image prodation, 300 lines (3C) PG
cess)
PostIPS horizontal
stripe PG for each
Y.M.C.K developer.
(Pattern: Same as
No. 16)
27
CST
12
IIC
IIT DIGITAL SS gra- SS gradation PG

dation, 300 lines (3C)
PreIPS (Image process)
Grid: Repeated for

4C grid repeated PG
YMCK, 600 lines-CST
(4C)
13
IIC
IIT DIGITAL FS/SS

gradation, 300 lines
(3C)
FS/SS gradation PG
28
MWAH
MWAH PG300 lines

(3C)
Solid L*, a*, b*300

lines PG
29
MAD
14
IIC
IIT shading data output, 300 lines (3C)
Outputs the current

shading correction
data. (PG with dark
center).
MAD PG300 lines

(4C)
Solid M 300 lines PG PostIPS (Image process)
30
TRE
TRE PG300 lines

(4C)
Solid YC 300 lines

PG
31
SFM
PreIPS horizontal
stripe PG for each
Y.M.C.K developer
SFM PG (POST
IPS)300 lines (B/W)
Solid K 300 lines PG
SID horizontal
stripes: YMCK, 300
lines (4C)
32
TBC
TBC PG (POST
IPS)300 lines (4C)
Solid YMCK 300 lines PostIPS (Image process)

PG
15
SID
Remarks
Remarks
16
SID
SID slant lines, 600

lines (4C)
PreIPS slant line PG

for each Y.M.C.K
developer
33
TBC
TBC horizontal
Horizontal stripe PostIPS (Image prostripes: YMCK (POST solid: YMCK 300 lines cess)
IPS) 300 lines (4C)
PG
17
SID
SID grid: Repeated

for YMCK, 600 lines
(4C)
PreIPS grid PG for

each Y.M.C.K developer
34
TBC
TBC vertical stripes:

YMCK(POST
IPS)300 lines (4C)
18
TRE
1st phase TRE PG1,

300 lines (3C)
Half-tone (AAH)PG
35
TBC
19
TRE
1st phase TRE PG2,

300 lines (3C)
Half-tone (55H)PG
20
CMM
MEM SYS PG1(MEM Solid RGB AAH 300

SYS)300 lines (3C)
lines PG
EDIT BYPASS (POST Outputs a normal

IPS), 200R, 4C
copy (bypassing the
Editor): 200R (4C)
Note: Place the test
chart on the platen
and output the PG.
21
CMM
MEM SYS PG2(MEM Solid RGB 55H 300

SYS)300 lines (3C)
lines PG
36
TBC
22
CST
CST horizontal
PostIPS horizontal
stripes: YMCK(POST stripe PG for each
IPS)300 lines (4C)
Y.M.C.K developer.
(Pattern: Same as
No. 15)

IPS), 200R, 3C
copy (bypassing the
Editor): 200R (3C)
chart on the platen
and output the PG.
General Procedures
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Vertical stripes Solid: YMCK 300

lines PG
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DocuColor 12/DCCS50

PG NO
ASIC name
Pattern name
37
TBC

IPS), 200R, B/W
copy (bypassing the
Editor): 200R (B/W)
chart on the platen
and output the PG.
38
TBC
EDIT BYPASS(POST Outputs a normal

PostIPS (Image proIPS), 200R, Y
copy (bypassing the cess)
Editor): 200R (Yellow)
chart on the platen
and output the PG.
39
40
41
TBC
TBC
TBC
Description

Remarks
PG NO
ASIC name
Pattern name
Description
Remarks
44
TBC
Normal copy (POST

IPS), 200R, 4C
Output a normal
copy: 200R (4C)
chart on the platen
and output the PG.
45
TBC
Normal copy (POST

IPS), 200R, 3C
Output a normal
copy: 200R (3C)
chart on the platen
and output the PG.
46
TBC
Normal copy (POST

IPS), 200R, B/W
Output a normal
copy: 200R (B/W)
chart on the platen
and output the PG.
47
TBC
Normal copy (POST

IPS), 200R, Y
Output a normal
copy: 200R (Yellow)
chart on the platen
and output the PG.

IPS), 200R, M
copy (bypassing the
Editor): 200R
(Magenta)
chart on the platen
and output the PG.

IPS), 200R, C
copy (bypassing the
Editor): 200R (Cyan)
chart on the platen
and output the PG.
48
TBC
Normal copy (POST

IPS), 200R, M

IPS), 200R, R
copy (bypassing the
Editor): 200R (Red)
chart on the platen
and output the PG.
Output a normal
copy: 200R
(Magenta)
chart on the platen
and output the PG.
49
TBC
Normal copy (POST

IPS), 200R, C
Output a normal
copy: 200R (Cyan)
chart on the platen
and output the PG.
50
TBC
Normal copy (POST

IPS), 200R, R
Output a normal
copy: 200R (Red)
chart on the platen
and output the PG.
51
TBC
Normal copy (POST

IPS), 200R, G
Output a normal
copy: 200R (Green)
chart on the platen
and output the PG.
52
TBC
Normal copy (POST

IPS), 200R, B
Output a normal
copy: 200R (Blue)
chart on the platen
and output the PG.
42
TBC

PostIPS (Image proIPS), 200R, G
copy (bypassing the cess)
Editor): 200R (Green)
chart on the platen
and output the PG.
43
TBC

IPS), 200R, B
copy (bypassing the
Editor): 200R (Blue)
chart on the platen
and output the PG.
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General Procedures

Description
PG NO
ASIC name
Pattern name
53
TBC
ALL IPS PG(ANAIntegrated the PWB

PostIPS (Image proLOG+PRE+MEM+PO PGs of Analog, CMM cess)
ST)
and PostIPS into one
simplified output.
54
TBC
Color patch: 1st page Outputs the top color PostIPS (Image process)
patch for the Editor
Pad.
55
TBC
Color patch: 2nd

page
56
TBC
Color patch: 3rd page Outputs the lower

color patch for the
Editor Pad.
HALFTONE
Grid (Measurement),
600
20mm pitch/2dotline IOT (Image output)

grid
HALFTONE
Grid (Registration),
600
Scale/2dotline grid
Paper size:A3A4L/
A4S/B4S/B5L/B5S/
LetterL/LetterS
Outputs the middle

color patch for the
Editor Pad.
Remarks
PG NO
ASIC name
Pattern name
12
HALFTONE
16 gray-scale SS, 300 16 GRAY-SCALES IN IOT (Image output)

THE SS DIRECTION
Paper size: A3
13
HALFTONE
ProCon, 300
ProCon patch pattern/16.3 X 19.3mm

patch
Paper size: A3
IOT (Image output)
14
HALFTONE
TED/STV, 300
TED/STV
Paper size: A4
IOT (Image output)
15
HALFTONE
Wedge SS, 300
SS direction pattern/1 IOT (Image output)

gray-scale width:
12dots
Paper size: A3
16
HALFTONE
Half-tone, 200R
Any density pattern

IOT (Image output)
17
HALFTONE
16 gray-scale SS,
200R
16 GRAY-SCALES IN IOT (Image output)

THE SS DIRECTION
Paper size: A3
18
HALFTONE
ProCon, 200R

patch
Paper size: A3S
IOT (Image output)
IOT (Image output)
IOT (Image output)
Description
Remarks
HALFTONE
Grid 45 degree, 600
45 degree grid/
IOT (Image output)
2dotline
19
HALFTONE
TED/STV, 200R
HALFTONE
Color registration
(Measurement), 600
Cross mark/4dotline IOT (Image output)

TED/STV
Paper size: A4L
20
HALFTONE
Wedge SS, 200R
HALFTONE
Color registration
(Visual check), 600
Color registration IOT (Image output)

visual check pattern

gray-scale width:
12dots
Paper size: A3S
HALFTONE
Half-tone, 600
Any density pattern

IOT (Image output)
21
HALFTONE
Half-tone, 200C
HALFTONE
16 gray-scale SS, 600 16 gray-scales in the

SS direction
Paper size: A3
IOT (Image output)
Any density pattern

Paper size: A3S or
17S
22
HALFTONE
16 gray-scale SS,
200C
ProCon, 600

patch
Paper size: A3
IOT (Image output)

THE SS DIRECTION
Paper size: A3S
23
HALFTONE
ProCon, 200C
IOT (Image output)
IOT (Image output)

patch
Paper size: A3S
24
HALFTONE
TED/STV, 200C
TED/STV
Paper size: A4L
IOT (Image output)
25
HALFTONE
Wedge SS, 200C

gray-scale width:
12dots
Paper size: A3S
HALFTONE
HALFTONE
TED/STV, 600
TED/STV
Paper size: A4L
10
HALFTONE
Wedge SS, 600

gray-scale width:
12dots
Paper size: A3
11
HALFTONE
Half-tone, 300
Any density pattern

IOT (Image output)
General Procedures
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IOT (Image output)
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Fuser Nip Measurement (dC701 UI Diagnostics)

PG NO
ASIC name
Pattern name
Description
Remarks
Purpose
26
HALFTONE
Half-tone, 150C
Any density pattern

Paper size: A3S or
17S
IOT (Image output)
Creates a special copy and measures the Fuser Nip pressure.
27
HALFTONE
16 gray-scale SS,
150C

THE SS DIRECTION
Paper size: A3S
ProCon, 150C

patch
Paper size: A3S
IOT (Image output)
IOT (Image output)
28
HALFTONE
NOTE:
The External Heat Roll is not latched while this function is running.
Measurement must be done after the P/R is warm. If the P/R is not warm, copy 40 or 50
pages first.
UI Diag.:
29
HALFTONE
TED/STV, 150C
TED/STV
Paper size: A4L
30
HALFTONE
Wedge SS, 150C

gray-scale width:
12dots
Paper size: A3S
1.
Measurement copy is limited only to 1 page.
2.
dC701 Jam: Close first and re-run the function.
NOTE: Paper used varies depending on the market.
XE: A4L
NASG: Letter, 8.5x11 LEF
Procedure
1.
2.
Select Subsystem Check in the Diagnostics Setup Screen.
3.
Select Fuser Nip Measurement in the Subsystem Screen.
4.
Select the following instructions on the screen:
5.
a.
Set the A4L (8.5 X 11 LEF) in the Tray 5 and select Start.
b.
Set the measurement copy in the Tray 5 and select Start.
Measure the In/Out Nip Width on the measurement copy. (Use the scale.)
a.
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DocuColor 12/DCCS50
Normal value
i.
In: 10.3 0.3mm
ii.
Out: 10.3 0.3mm
6.
If the measurement value differs, adjust the value. See ADJ 8.1.1 Adjusting the Fuser Nip
Pressure. Repeat Steps 4-5.
7.
If the correct value is obtained, select Close and return to the Diagnostics Setup Screen.
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General Procedures
Print (dC612 Test Pattern UI Diagnostics), Fuser
Developer Unit Check (dC920 UI Diagnostics)
Max Setup (UI Diagnostics)
Purpose
Purpose
Specifies the K/Y/M/C Home Positions and rotates the Rotary Developer to the Home Position.
The Max Set Up in the UI Diagnostics does not have all the functions of the PWS Diagnostics. If you need to adjust the following, do so using the PWS Diagnostics:
NOTE: For the execution sequence of the Max Setup Functions, see Adjustments Section 4:
ADJ 9.1.1 Max Setup (dC929).
UI Diag.:
1.
You cannot select and execute the function.
2.
When the developer moves to the Home Position correctly, the system turns on the Yellow Indicator and then, at every Start, the developer moves to the Magenta, Cyan and
Black Home Positions. If you select the End Button, the developer automatically moves
back to the Home Position.
1.
The following describes the Max Setup flow.

a.
dC945 IIT Calibration (IIT installed machine only)
b.
c.
dC922 TRC Setup/Toner Density Adjustment
Procedure
d.
dC924 TRC Adjustment
1.
e.
dC939 TRC Check PG
2.
Select Subsystem Check in the Diagnostics Setup Screen.
f.
dC934 ADC/AGC Setup
3.
Select Developer Unit Check in the Subsystem Check Screen. The indicator arrow is
located at the HomePosition.
g.
dC933 VH/VM Setup
h.
dC919 Color Balance Setup (IIT installed machine only)
2.
NOTE: The Rotary Developer Unit moves to the Home Position.

4.
5.
Every time you select the Start Button, the Developer Unit moves as follows:
YellowN MagentaN CyanN BlackN Home
6.
When the Developer Unit Check ends, select Close. The system returns to the Diagnostics Setup Screen.
Functions that the UI Diag. supports:

a.
b.
dC934 ADC/AGC Setup
c.
dC933 VH/VM Setup
d.
e.
dC922 TRC Setup/Toner Density Adjustment
f.
dC924 TRC Adjust
g.
dC919 Color Balance Setup
NOTE: Execute 2f and 2g above only if a fault has occurred after the setup.
3.
General Procedures
Developer Unit Check (dC920 UI Diagnostics), Max
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Functions that the UI Diag. does not support:

a.
dC939 TRC Check PG
b.
dC923 ProCon PG
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IIT Calibration (dC945 UI Diagnostics) (IIT installed

machine only)
ADC/AGC Setup (dC934 UI Diagnostics)
Purpose
Automatically adjusts and sets the ADC Sensor Gain so that the Vclean within the range is
obtained. At the same time, the Vclean Irregularity (Vclean RD) for the belt circumference is
measured.
Purpose
Sets the Correction Coefficient that corrects the dispersion of the B-CCD Sensor Color
Sensitivity caused by dispersion in the Blue Filter's Spectral Distribution.
Calculates the IIT Correction Coefficient and IPS Correction Coefficient.
Sets the IIT Density Target Value for Automatic Gray-Scale Correction.
UI Diag.:
1.
UI Diag.:
1.
The White Reference function in the PWS-Diagnostics is not provided in the UI-Diagnostics.
NOTE: This section only describes the calibration in the UI-Diagnostics. For details, see
Adjustments Section 4: ADJ 9.1.2 IIT Calibration (dC945).
Procedure
No Target Value displays.
NOTE: This section only describes the ADC/AGC Setup in the UI-Diagnostics. For details on
PWS-Diagnostics, see Adjustment Section 4: ADJ 9.1.3 ADC/AGC Setup (dC934).
Procedure
1.
2.
Select Max SetupADC/AGC Setup.
3.
Select Start.
1.
4.
The system displays the Set Value on the UI.
2.
Select Max Setup IIT Calibration.
5.
Select Close and return to the Max Setup Screen.
3.
Place the Color Test Pattern on the Platen Glass.
4.
Select Start.
5.
The system displays the Coefficient and the results display on the UI.
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General Procedures
IIT Calibration (dC945 UI Diagnostics) (IIT installed
VH/VM Setup (dC933 UI Diagnostics)
IOT Highlight Setup (dC918 UI Diagnostics)
Purpose
Purpose
Sets the VG/LD Light Amount, Development Bias and the ASG Bias Output.
Sets the Hi-Light Density Reproduction Start Points for K/Y/M/C and Uniform Hi-Light Density for In-board/Out-board.
From any 2 VGs, set the VG Value so that the Drum Surface Potential becomes the
Target VH.
From any 3 Light Amounts, set the LD Light Amount that is the Target VM.
UI Diag.:
1.
No Target Value displays.
Visually check the PG Copy, adjust the "IOT Reproduction Start Points for K/Y/M/C Colors (300/600) using the ASG Bias.
Adjust the IOT IN/OUT Density Difference for K/Y/M/C colors (common to 300 and 600
lines) using the ASG Bias (EOS side).
Measure the ASG Bias and Highlight Potential after In/Out Adjustment, and set the
Target Control Value.
NOTE: This section only describes the Setup in the UI-Diagnostics. For details on PWS-Diagnostics, see dC933 VH/VM Setup.
Procedure
1.
No Target Value displays
1.
2.
Tray 2 fixed
2.
Select Max SetupVH/VM Setup.
3.
Select Start.
NOTE: This section only describes the Setup in the UI-Diagnostics. For details, see dC918 IOT
Highlight Setup.
4.
The system displays the results on the UI.
5.
UI Diag.:
Procedure
1.
2.
Select Max SetupIOT Highlight Setup.
3.
Check and adjust the In/Out Density Difference.

NOTE: If the paper is A3 or A4L, select 300.
a.
Select PG Print 300/600. Select Start. The system prints the checking PG.
b.
Visually check the In/Out Density Differences for all 4 colors. If there is NO difference, proceed to Step 4. If there is difference, perform the following steps:
Select In/Out on the Screen. Select the Color (Y, M, C, K) to be adjusted. Change
the value by using the +/- Button.
NOTE: To darken the density for Out, decrease the value.
4.
5.
General Procedures
VH/VM Setup (dC933 UI Diagnostics), IOT Highlight
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Repeat Steps 3-a through 3-b until there is no density difference.
Check and adjust the Hi-Light Density Start Point.

a.
Select the PG Print 300 or 600 (A4L). The system prints a 300 or 600 line PG.
b.
Visually check the 300 or 600 line PG if Cin 8.6% (for each K, Y, M and C) has
been reproduced and Cin 7.1% is NOT reproduced.
c.
Select the mode 300 or 600 to adjust. Select a color (Y, M, C, K) to be adjusted.
Change the value by using the +/- Button.
d.
Check the Highlight as described in 4-b. Repeat Steps 4-a through 4-c until the
High Light is satisfactory.
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TRC Setup/Toner Concentration Adjustment (dC922 UI

Diagnostics)
TRC Adjustment (dC924 UI Diagnostics)
Purpose
Checks the PG Output with the PG Test Print Pattern. Manually fine-adjusts the density (low/
middle/high) for each color.
Purpose
The system displays the control function buttons (TRC Control, TRC Adjustment,) for the TRC
Setup.
UI Diag.:
1.
No target value display
2.
Tray2 fixed
NOTE: This section only describes the Adjustment in the UI-Diagnostics. For details, see
dC924 TRC Adjust / dC939 TRC Check PG.
Preparation
Visually check the PG with all OK colors in dC924 TRC Setup. Check the density (low/middle/
high) and perform the following steps as needed:
NOTE: This section only describes the Setup in the UI-Diagnostics. For details see dC922
TRC Setup/Toner Density Adjustment.
Procedure
Procedure
1.
1.
2.
2.
Select the following:
3.
4.
The system displays the measurement value and displays the results on the UI.
5.
If the evaluation of each color is OK, select Close twice and return to the Max Setup
Screen.
Select the Toner Density Adjustment.
7.
Select an NG Color (Y, M, C, K) in Step 5. Select the Start Button.
8.
Run Step 8 in all NG items.
9.
Select Close to return to the TRC Setup/Toner Density Adjustment Screen.

Max SetupTRC Setup/Toner Concentration AdjustmentTRC Adjustment.
Max SetupTRC Setup/Toner Concentration AdjustmentTRC Control
6.
3.
Select a Color to adjust and the Density (Low, Mid, High). Change the Value with the
up/down button. (up: Darker density/down: Lighter density)
4.
Perform Step 3 in all modes that need an adjustment.
5.
Select Close twice to return to the Max Setup Screen.
10. Select the TRC Control and check if there is no NG.

If there is an NG, repeat Steps 2-10.
11. Select Close twice to return to the Max Setup Screen.
12. Visually check the low/middle/high density of the PG with all OK colors. Adjust the
density if needed, refer to; TRC Adjustment (dC924 UI Diagnostics).
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General Procedures
TRC Setup/Toner Concentration Adjustment
Color Balance Setup (dC919 UI Diagnostics) (IIT installed

machine only)
Purpose
To correct the YMCK Color Balance.
Take a 4C copy in the Photo Mode. Visually check the copy. Reset the YMCK Color Balance Value.
NOTE: Run this function at the customers request, after the automatic gray-scale is corrected.
NOTE: The Hi-Light Setup must be performed before running this function.
NOTE: This section only describes the setup in the UI-Diagnostics. For details, see IOT Highlight Setup (dC918 UI Diagnostics).
Procedure
1.
2.
Max SetupColor Balance Setup.
3.
Place Test Pattern (82E10810) on the Platen Glass. Select the Start Button.
Take a PG Print in the following mode:
a.
APS, 100%, Normal paper, LUTON
NOTE: If each color has no defects in density, go to Step 4.

If there are defects in color density, adjust the color balance for colors with defects using
the UI.
4.
Select Close to return to the Max Setup Screen.
General Procedures
Color Balance Setup (dC919 UI Diagnostics) (IIT in-
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General Information
Installation Space Requirements
Product Codes
Installation Space Requirements without Accessories

(Figure 1)
Table 1 Product Codes
Product
USA
(60Hz)
Canada
(60Hz)
Latin
Latin
America America
(110V)
(220V)
Xerox
Europe
(220V)
DocuColor 12 Digital Copier/Printer
FU2
FU2
FU2
FU3
FU3
DocuColor 12 LP
FU0
FU0
FU0
FU1
FU1
Wing (Left/Right)
GC1
GC1
GC1
GC1
GC1
Convenience Stapler Kit
KM6
KM6
KM6
KM6
KM6
Off-Set Catch Tray
GF6
GF6
GF6
GF6
GF6
FT4
FT4
FT4
FT4
FT4
Sorter/Mailbox
FY8
FY8
FY8
FY8
FY8
Finisher
RV8
RV8
RV8
RV8
RV8
IDFE
MFY
MFY
MFY
MFY
MFY
Cobra L (1 Byte)
GL2
GL2
GL2
GL2
GL2
Cobra Memory Upgrade Kit
HY6
HY6
HY6
HY6
HY6
Cobra Token Ring Kit
LY7
LY7
LY7
LY7
LY7
BNC Transceiver Kit
HY8
HY8
HY8
HY8
HY8
Mobility Kit
MC4
MC4
MC4
MC4
MC4
DocuColor 12 Edit Pad
GC0
GC0
GC0
GC0
GC0
DocuColor 12 Edit Pad w/o DADF
VM0
VM0
VM0
VM0
VM0
Electronic Pre Collation (EPC) Kit
FKP
FKP
FKP
FKP
FKP
EPC Enablement Kit
FGT
FGT
FGT
FGT
FGT
DocuColor 12 Foreign Interface
GL1
GL1
GL1
GL1
GL1
Figure 1 Installation Space Requirements without Accessories

Table 1 Installation Space Requirements without Accessories
Fixed Space Requirements
Dimensions
Movable Space Requirements
in.
mm
in.
mm
21
533
21
533
24
610
100
23
585
23
585
D w/o IDFE
91.5
2324
71.5
1816 *
D w/ IDFE
95.5
2426
75.5 **
1918 **
68.5
1740
68.5
1740
Measured from the rear of processor if IDFE is not present.

106.5 in. (2705mm) if installed in hallway.
* 86.5 in. (2200mm) if installed in hallway.
**90.5 in. (2300mm) if installed in hallway.
Reissue
DocuColor 12/DCCS50
1/05
6-143
General Procedures
General Information, Installation Space Require-
Installation Space Requirements with Edit Pad (Right Side)
Installation Space Requirements with HCF
(Figure 2)
Figure 3 Installation Space Requirements with HCF

Figure 2 Installation Space Requirements with Edit Pad (Right Side)
Table 3 Installation Space Requirements with HCF

Table 2 Installation Space Requirements with Edit Pad

Dimensions
Dimensions
in.
mm
in.
mm
51
1300
51
1300
24
610
100
23
585
23
585
D w/o IDFE
91.5
2324
71.5 *
1816 *
D w/ IDFE
95.5
2426
75.5 **
1918 **
98.5
2500
98.5
2500
in.
mm
in.
mm
21
533
21
533
24
610
100
55
1400
55
1400
D w/o IDFE
91.5
2324
71.5 *
1816 *
D w/ IDFE
95.5
2426
75.5 **
1918 **
100.5
2555
100.5
2555
** 90.5 in. (2300mm) if installed in hallway.
Installation Space Requirements with HCF and Edit Pad (Right Side)
(Figure 4)
General Procedures
1/05
6-144
Reissue
DocuColor 12/DCCS50
Figure 4 Installation Space Requirements with HCF and Edit Pad (Right Side)
Figure 5 Installation Space Requirements with HCF and Sorter/Mailbox
Table 4 Installation Space Requirements with HCF and Edit Pad
Table 5 Installation Space Requirements with HCF and Sorter/Mailbox

Dimensions
in.
mm
in.
mm
51
1300
51
1300
24
610
100
55
1400
55
D w/o IDFE
91.5
2324
D w/ IDFE
95.5
130.5

Dimensions
in.
mm
in.
mm
51
1300
51
1300
24
610
100
1400
65.5
1665
65.5
1665
71.5 *
1816 *
D w/o IDFE
91.5
2324
71.5 *
1816 *
2426
75.5 **
1918 **
D w/ IDFE
95.5
2426
75.5 **
1918 **
3315
130.5
3315
141
3580
141
3580
Installation Space Requirements with HCF and Sorter/Mailbox
Installation Space Requirements with HCF, Sorter/Mailbox and Edit

Pad (Left Side)
(Figure 5)
(Figure 6)
Reissue
DocuColor 12/DCCS50
1/05
6-145
General Procedures
Figure 6 Space Requirements with HCF, Sorter/Mailbox and Edit Pad (Left Side)
Figure 7 Installation Space Requirements with Sorter/Mailbox
Table 6 Space Requirements with HCF, Sorter/Mailbox and Edit Pad
Table 7 Installation Space Requirements with Sorter/Mailbox

Dimensions
in.
mm
in.
mm
86
2185
86
2185
24
610
100
65.5
1665
65.5
D w/o IDFE
91.5
2324
D w/ IDFE
95.5
176

Dimensions
in.
mm
in.
mm
21
533
21
533
24
610
100
1665
65.5
1665
65.5
1665
71.5 *
1816 *
D w/o IDFE
91.5
2324
71.5 *
1816 *
2426
75.5 **
1918 **
D w/ IDFE
95.5
2426
75.5 **
1918 **
4470
176
4470
111
2819
111
2819
Installation Space Requirements with Sorter/Mailbox
Installation Space Requirements with Sorter/Mailbox and Edit Pad

(Left Side)
(Figure 7)
(Figure 8)
General Procedures
1/05
6-146
Reissue
DocuColor 12/DCCS50
Figure 8 Installation Space Requirements with Sorter/Mailbox and Edit Pad (Left Side)
Figure 9 Installation Space Requirements without Accessories (LP Only)
Table 8 Installation Space Requirements with Sorter/Mailbox and Edit Pad
Table 9 Installation Space Requirements without Accessories (LP Only

Dimensions
in.
mm
in.
mm
86.5
2185
86
2185
24
610
100
65.5
1665
65.5
D w/o IDFE
91.5
2324
D w/ IDFE
95.5
176

Dimensions
in.
mm
in.
mm
21
533
21
533
24
610
100
1665
23
585
23
585
71.5 *
1816 *
95.5
2324
71.5
1918
2426
75.5 **
1918 **
68.5
1740
68.5
1740
4470
176
4470
Measured from the rear of Integrated Digital Front End.


Installation Space Requirements with HCF

(Figure 10)
Installation Space Requirements without Accessories

(Figure 9)
Reissue
DocuColor 12/DCCS50
1/05
6-147
General Procedures
Electrical Specifications
Input Service Requirements
The requirements for input power in each market are shown below:
Table 1 Line Requirements
Specification
NASG
ESG
Voltage
115VAC 10% *
line - to - neutral
220-240VAC 10%
line - to - neutral
Frequency
60 Hz
50 Hz
Phase
Single phase, 2-wire

plus earth ground
Single phase, 2-wire

plus earth ground
Service **
C/P
LP
Figure 10 Installation Space Requirements with HCF
Dimensions
15 Amps
15 Amps
15 Amps
NOTE: * For Mexico only, the machine must be functional at 10% above the rated voltage input
of the power supply.
Table 10 Installation Space Requirements with HCF

20 Amps
NOTE: ** Dedicated service line is recommended, but not required. System plugs into standard office outlets with a single power cord.
Current/ Power Requirements
in.
mm
in.
mm
51
1300
51
1300
24
610
100
23
585
23
585
95.5
2426
75.5
1918
98.5
2500
98.5
2500
Current and Power specifications for each market are as follows:

Table 2 Power Consumption
Specification
Max Power Consumption
C/P
LP
Measured from the rear of Integrated Digital Front End.
Avg. Warm-up Current

C/P
LP
Avg. Standby Current

C/P
LP
NASG
(@ 115VAC)
2.112 kVA
1.584 kVA
1.584KVA
(@ 115VAC)
12.5A (1.6 kVA)
(@ 240VAC)
8.0A (1.6kVA)
11.0A (1.265 kVA)

(@ 115VAC)
7.0A (0.8 kVA)
5.3A (0.6 kVA)
Avg. Run Current (4-color) (@ 115VAC)

C/P
10.0A (1.2 kVA)
LP
Current Rating
C/P
LP
General Procedures
Installation Space Requirements, Product Specifica-
1/05
6-148
ESG
(@ 220VAC)
2.2 kVA
6.3A (1.265 kVA)

(@ 240VAC)
3.8A (0.8 kVA)
3.0A (0.6 kVA)
(@ 240VAC)
5.7A (1.2 kVA)
7.5A (0.9 kVA)
4.5A (0.9 kVA)
16 Amps
10 Amps
12 Amps
10 Amps
Reissue
DocuColor 12/DCCS50
201% through 400%: 1.5%
Other Electrical Specifications
1.
Leakage protection
Copy Speed
First copy out time
2.
3.
Internal earth leakage breaker
Electrical Noise
Black/White: 7.9 sec. 8.511 (A4) LEF
Full Color: 18 sec. 8.511 (A4) LEF
VCCI Class 1 compliance
Ground
First copy out time with EPC option - Collated mode
Class 3
Black/White 10 sec. - 8.511 (A4) LEF
Environmental Specifications
Full Color: 22 sec. - 8.511 (A4) LEF
Heat Output
Tray 5 or Transparency mode
Table 3
1.8 copies/min.
Continuous copy in copies/min.
Model
avg. BTU/hr.
(operating)
avg. BTU/hr.
(standby)
C/P
4080
2720
LP
3755
1230
Table 5 Copies per Minute

Paper
Size
Copy Mode
B/W
4 Color
1117 (A3)
25
6.2
8.514 (B4)
28.8
6.2
Table 4 Audible Noise
8.511 (A4) LEF
50
12.5
Continuous Noise
Impulse Noise (db)
8.511 (A4) SEF
28.8
6.2
Stand by
48.3
Copy Cycle
67.1
62.2
Audible Noise
Ozone Generation
Maximum 0.02 ppm
Temperature
50F (10C) to 95F (35C)
Relative Humidity
15% TO 85% (Non-condensing)
Altitude
0-10,000 ft. (3050M) (Above 2,000 meters requires adjustment by a CSE)
Levelness
Maximum level difference - 5mm or less (front to back)
Maximum level difference - 10mm or less (right to left)
Image Loss
Lead Edge: 31mm or the optional setting of 4mm
Sides: 31mm
Trail Edge: 31mm
Copy Paper Capability

Paper Trays
Tray 1
16 lb. (64 G/m2) through 24 lb. (90 G/m2)
Tray 2, 3, 4
Tray 5
System Capability
Warm-up Time
100V: 8 minutes 45 seconds or less (20(C) 68(F), 60%)
Magnification
25% to 400% in 1% increments
25% through 200%: 1%
Reissue
DocuColor 12/DCCS50
1/05
6-149
General Procedures
Paper Cassette Sizes Available

Table 6 Paper Cassette Sizes - NASG and ESG
NASG
ESG
810 LEF
A4 LEF
A4 LEF
215279 LEF
8.511 LEF
A3 SEF
A3 SEF
215279 SEF
8.511 SEF
B4 ISO SEF
912 SEF
215315 SEF
8.513 SEF
215330 SEF
8.514 SEF
215356 SEF
A4 SEF
A4 SEF
1117 SEF
279432 SEF
Paper Cassette/receiving Tray Capacity
Cassette 500 sheets
Paper Tray Bypass 100 sheets (20 lb./80gsm)
Receiving tray 100 Sheets
General Procedures
1/05
6-150
Reissue
DocuColor 12/DCCS50
DADF Product Specifications
Size Sensing (NASG)

Table 7 Size Sensing - (NASG)
DADF Physical Characteristics

Dimensions (DADF)
Document Size
Sensed Size
1117 4mm
1117 (280432)
912 SEF 4mm
912 (229305)
Dimensions
8.514 SEF 4mm
8.514 (216356)
Width
24"
640mm
8.513 SEF 4mm
8.513 (216331)
Depth
20.5"
535mm
8.512.4 SEF 4mm
8.512.4 (216315)
Height
9"
130mm
8.511 SEF 4mm
8.511 (216280)
Weight: DADF only
31lb.
14kg
8.511 LEF 4mm
118.5 (280216)
Machine with DADF
549 lb.
249kg
810 SEF 4mm
810 (204254)
810 LEF 4mm
108 (254204)
DADF Electrical Specifications
8.55.5 SEF 4mm
5.58.5 (140216)
FREQUENCY
8.55.5 LEF 4mm
8.55.5 (216140)
Table 9 DADF Dimensions and Weights
Table 8 Size Sensing - (ESG)
50/60Hz 2%
Supplied by machine
POWER CONSUMPTION
Document Size
Sensed Size
A3 4mm
A3 (297420)
B4 SEF 4mm
B4 (257364)
DADF System Capability
A4 SEF 4mm
A4 (210297)
DOCUMENT SIZE
A4 LEF 4mm
A4 (297210)
B5 SEF 4mm
B5 (182257)
Maximum 1117 (A3)
B5 LEF 4mm
B5 (257182)
Minimum 5.58.5 (A5)
A5 SEF 4mm
A5 (148210)
DOCUMENT TRAY
A5 LEF 4mm
A5 (210148)
B6 SEF 4mm
B6 (128182)
B6 LEF 4mm
B6 (182128)
A6 SEF 4mm
A6 (105148)
A6 LEF 4mm
A6 (148105)
REGISTRATION
B7 SEF 4mm
B7 (91128)
B7 LEF 4mm
B7 (12891)
Lead edge 2.5
A7 SEF 4mm
A7 (74105)
Side edge 3
A7 LEF 4mm
A7 (10574)
Skew 2.5
B8 SEF 4mm
B8 (6491)
B8 LEF 4mm
B8 (9164)
A8 SEF 4mm
A7 (5274)
A8 LEF 4mm
A7 (7452)
B9 SEF 4mm
B9 (4564)
B9 LEF 4mm
B9 (6445)
DocuColor 12/DCCS50
Metric
INPUT VOLTAGE
Size Sensing (ESG)
Reissue
US
120 Watts
Capacity 50 documents
SIZE MIXED MODE
1/05
6-151
In this mode sizes from 5.58.5 (A5) to 1117 (A3) can be mixed.
General Procedures
DADF SIZE SENSING (NASG)
Table 12 Sorter/Mailbox Dimensions and Weights

Dimensions
Table 10 DADF Size Sensing - (NASG)

Document Size
Sensed Size
US
Metric
Depth
29"
744mm
Height
46"
1170mm
Weight:
Sorter/Mailbox Only
110lb.
50kg
1117
1117 (280432)
1114.9 SEF
1117 (280432)
8.514 SEF
8.514 (216356)
8.513 SEF
8.514 (216356)
Sorter/Mailbox Electrical Specifications
8.512.4 SEF
--
FREQUENCY
8.511 SEF
8.511 (216280)
8.511 LEF
118.5 (280216)
810 SEF
811 (216280)
810 LEF
118.5 (280216)
8.55.5 SEF
5.58.5 (140216)
8.55.5 LEF
8.55.5 (216140)
A4 SEF
A4 (210297)
A4 LEF
A4 (297210)
Sorter/Mailbox System Capability
50/60Hz 2%
INPUT VOLTAGE
Supplied by machine
POWER CONSUMPTION
70 Watts
COPY SORT SIZE

DADF SIZE SENSING (ESG)
Table 11 DADF Size Sensing - (ESG)
Maximum 1218
Minimum A6 Postcard-OCT
TRAY CAPACITIES
Sensed Size
ESG
Document Size
Copy Output Tray 400 Copies-OCT
1114.9 SEF
1117 (280432)
8.514 SEF
8.514 (216356)
8.513 SEF
8.514 (216356)
Sorter/Mailbox 60-105 gsm
8.512.4 SEF
--
Offset Catch Tray 60-250 gsm
A3
A3 (297420)
B4 SEF
B4 (257364)
Finisher Product Specifications
A4 SEF
A4 (210297)
A4 LEF
A4 (297210)
B5 SEF
B5 (182257)
B5 LEF
B5 (257182)
Dimensions
A5 SEF
A5 (148210)
A5 LEF
A5 (210148)
Width
29.9"
760mm
Depth
25.9"
660mm
Height
41.7"
1060mm
Weight:
Finisher Only
132lb.
60kg
BASIC WEIGHT RANGE
Finisher Physical Characteristics

Dimensions (Finisher)
Table 13 Finisher Dimensions and Weights
Sorter/Mailbox Product Specifications

Sorter/Mailbox Physical Characteristics
US
Metric
Dimensions (Sorter)
Finisher Electrical Specifications
Table 12 Sorter/Mailbox Dimensions and Weights

Dimensions
Width
General Procedures
US
23.5"
FREQUENCY
Metric
599mm
1/05
6-152
50/60Hz 2%
Reissue
DocuColor 12/DCCS50
INPUT VOLTAGE
Table 14 Magnification Accuracy
Supplied by machine
POWER CONSUMPTION
70 Watts
UI display
magnification (%)
Actual magnification Actual magnification

(%)
(Reference)
282
282.8
A6A3
400
400.0
Finisher System Capability
NOTE: Variable magnification (25~400%) for every 1%.
COPY SORT SIZE

2.
Maximum 1218
Minimum A6 Postcard-OCT
a.
25%~400% (every 1%)
Magnification Precision
TRAY CAPACITIES
Variable magnification
1.
Copy Output Tray 400 Copies-OCT
BASIC WEIGHT RANGE
Longitudinal magnification precision

a.
Fixed magnification: 100%0.5%
b.
Free magnification: 25% ~200%:1.0%

201% ~400%:1.5%
Finisher 60-105 gsm
Offset Catch Tray 60-250 gsm
2.
Magnification
1.
Lateral magnification precision

a.
Fixed magnification: 100%0.5%
b.
Variable magnification: 25% ~200%: 1.0%
Fixed Magnification
a.
201% ~400%:1.5%
The key operator tool provides 7 types of fixed magnification.
Copy Speed (CPM)
From these, 6 types can be selected from the table below.
1.
One type can be set for every 1%. (m in the table: Factory default)
Tray 1-4
a.
CPM (Regular paper (64gsm~less than 105gsm)/No1~No4 trays)
Table 14 Magnification Accuracy

UI display
magnification (%)
Actual magnification Actual magnification

(%)
(Reference)
25
25.0
35
35.4
A3A6
50
50.0
A3A5
64
64.7
11X178.5X11
70
70.7
A3A4, B4B5
78
78.0
8.5X148.5X11
81
81.6
B4A4, B5A5
86
86.6
A4B5, A3B4
97
97.3
A48.5X11
115
115.0
B5A4, B4A3
122
122.4
A4B4, A5B5
127
127.3
8.5X13A3
129
129.4
8.5X1111X17
141
141.4
A4A3, B5B4
154
154.5
5.5X8.58.5X14
180
180.0
8.5X13A2
200
200.0
A5A3
220
220.0
5.5X8.511X17
Reissue
DocuColor 12/DCCS50
Regular paper (Continuous copy - Unit: sheets/minute)
Table 15 Copy Speed

Black/White
Black/White
Full color
Full color
Simplex
Duplex
Simplex
Duplex
A3
25
25
6.2
6.2
B4
28.8
28.8
6.2
6.2
A4 LEF
50
50
12.5
12.5
A4 SEF
28.8
28.8
6.2
6.2
b.
Thick paper (Continuous copy - Unit: sheets/minute)

CPM - Simplex Mode (Thick paper (105~128gsm))
Table 16 Thick paper Copy Speed
1/05
6-153
Black/White
Full color
A3
5.8
3.5
B4
5.8
3.5
A4 LEF
5.8
3.5
A4 SEF
5.8
3.5
General Procedures
2.
Tray 5 (Continuous copy - Unit: sheets/minute)
a.
Maximum: 297X432mm (A3,11X17)
CPM - Tray 5
b.
Minimum: No limitation
2.
Table 17 Tray 5 Copy Speed
Document size/weight through the DADF:

a.
Maximum: 297X432mm (A3,11X17)
Black/White
Full color
Weight
b.
Minimum: 148.5mmX210mm (A5S, 5.83X8.27)
Regular paper A4 L/Letter L
25
6.2
64~105gsm
c.
Weight (DADF): 38gsm~128gsm (Duplex: 50gsm~110gsm)
Regular paper A3
20
6.2
64~105gsm
Document Size Detection
OHPA4 L/Letter L
20
2.4
1.
OHPA3
Thick paper A4 L/Letter L
5.8
3.5
105~162gsm
Thick paper A3
5.8
3.5
105~162gsm
Extra thick paper A4 L/Letter L 3.3
2.4
163~250gsm
Extra thick paper A3
3.3
2.4
163~250gsm
Postcard
3.3
2.4
Document scanning
Table 20 Document Size Detection
Machine can detect the

following sizes of originals.
Platen
Document
orientation
Document
size (mm)
NASG
ESG
NASG
ESG
Postcard SEF
100X148
(Post Card)
(101X152)
ALT
Copy Speed (DPM)
A6 SEF
105X148
ALT
1.
B6 SEF
128X182
B6 LEF
182X128
A5 SEF
148X210
A5 LEF
210X148
5.5X8.5 SEF
140X215.9
A3OHP - Feed 1 sheet at a time. No CPM specification.

Auto Feed (Duplex) (Continuous copy - Unit: sheets/minute)
Table 18 Duplex Copy Speed
DADF
Paper size
AE off/ACS off
AE ON/ACS Off
AE either on/off. ACS

must be on.
Black/White
A4 LEF
40
40
40
5.5X8.5 LEF
215.9X140
Black/White
B4
25.7
23.6
19
B5 SEF
215.9X279.4 X
Black/White
A3
22
20
16.6
B5 LEF
279.4X215.9 X
Full color
A4 LEF
12.5
12.5
12.5
8.5X13 SEF
215.9X330.2 -
Full color
B4
6.2
6.2
6.2
8.5X14 SEF
215.9X355.6 X
Full color
A3
6.2
6.2
6.2
B4 SEF
257X364
8th Opening
SEF
267X388
A3 SEF
297X420
11X17 SEF
297.4X431.8 X
2.
Auto Feed (Simplex) (Continuous copy - Unit: sheets/minute)

Table 19 Auto Feed Copy Speed
Paper size
AE off/ACS off
AE ON/ACS Off
AE either on/off. ACS

must be on.
Black/White
A4 LEF
40
40
23.6
Mix Mode only
Black/White
B4
25
14
14
Default is A6S, Postcard S is selectable.
Black/White
A3
20
12.5
12.5
Default is Postcard S; A6 S is selectable.
Full color
A4 LEF
12.5
9.3
9.4
Full color
B4
6.2
6.2
Full color
A3
6.2
6.2
Document Size/Weight (DADF)

1.
NOTE:
Image Loss
1.
Lead edge: 31mm
2.
Bottom edge: 31mm
3.
Side edge: 31mm
Document sizes using Platen:
General Procedures
1/05
6-154
Reissue
DocuColor 12/DCCS50
Copy (Print) Paper

1.
2.
Tray (B5~A3, Letter)
Table 24 Tray Settings
a.
NO1 Tray: 64~105gsm
b.
NO2~4 Tray: 64~128gsm (105~128gsm paper: Select Thick Paper 1.)
Tray 5: 64~250gsm
Table 21 Paper Part Numbers
NASG Market
ESG Market
For B/W
4024DP (20#)
80 gsm Premier
3R91720,
3R91721
For Color
Color Xpressions
93 (24# bond)
3R5464,
3R5465
Colortech Plus
(90gsm)
3R94641 (A4),
3R94642 (A3)
Tray 1
Refer to: Table 22
Tray 2-4
Adjustable Tray
Tray 5
Adjustable Tray
HCF (option)
Adjustable Tray (8.5x11 or A4 only)
Set Paper Guides at new paper position and select the loaded
paper size using the User Interface.
Paper size setting is performed automatically at setting the guide
for the regular sized paper.
NOTE: Tray 5 paper sizes are selected from the Control Panel.
Table 25 Tray 5 Paper Sizes
Paper Cassette Type

Paper sizes and orientation loadable in each tray are as follows:
Tray 5
Paper Size / Orientation
Table 22 Paper Size Specifications
NASG ESG
Tray 1
Postcard SEF
NASG spec
(8.5x11) LEF
(Post Card) LEF (101X152)
ALT
ESG spec
A4 LEF
(Post Card) LEF (101X152)
ALT
A6 SEF
105X148
ALT
A6 LEF
105X148
ALT
B6 SEF
128X182
B6 LEF
182X128
A5 SEF
148X210
A5 LEF
210X148
5.5X8.5 SEF
140X215.9
5.5X8.5 LEF
215.9X140
B5 SEF
215.9X279.4 X
B5 LEF
279.4X215.9 X
A4 SEF
210x297
A4 LEF
297x210
8x10 SEF
8x10 SEF
8x11 SEF
215.9x279.4 X
8x11 LEF
279.4x215.9 X
8.5X13 SEF
215.9X330.2 -
8.5X14 SEF
215.9X355.6 X
8.5X14 SEF
215.9X355.6 X
B4 SEF
257X364
A5 SEF, A4 LEF, Letter (8.5x11) LEF paper load is possible if

paper guide position is changed and the size is input in NVM R/W
(dC131) or in Configuration Page (dC371).
Table 23 Paper Size Specifications

Tray 2,3 and 4
NASG spec.
ESG spec.
Common specification among NASG and

ESG. A3SEF, B4SEF, A4SEF, A4LEF, B5SEF,
B5LEF, Letter (8.5x11) SEF, Letter (8.5x11)
LEF, Legal (8.5x14) SEF, 11x17 SEF, 8th
Opening SEF, Suryu-kai LEF, Legal (8.5x13)
SEF, 8x10 LEF
12x18 SEF can be loaded in special Tray 5.

12x18 SEF can be loaded in Trays 2,3 or 4 if modified by the CSE
per ADJ 9.1.19 (Tray 2, 3, and 4 for 12 x 18 Paper).
For the irregular sized paper, tray can be used if paper guide position is changed and the size is input using the User Interface.
Reissue
DocuColor 12/DCCS50
1/05
6-155
100X148
General Procedures
Table 25 Tray 5 Paper Sizes

Table 27 Platen Registration
Tray 5
Paper Size / Orientation

NASG ESG
8th Opening
SEF
267X388
A3 SEF
297X420
11X17 SEF
297.4X431.8 X
12X18 SEF
SRA3:12.6x17.7 320x450
SEF
DADF
DADF single unit
3.0
2.1 (Side1)
2.1 (Side2)
2.5 (Side1)
2.5 (Side2)
Lead skew (200mm) 2.0

(mm)
1.6 (Side1)
1.6 (Side2)
2.0 (Side1)
2.2 (Side2)
1.5 (Side1)
1.5 (Side2)
Size skew (400mm) 4.0

(mm)
3.2 (Side1)
3.2 (Side2)
4.0 (Side1)
4.0 (Side2)
Linearity (Longitudi- 1.0 (Side1)

nal: 400mm) (mm)
1.0 (Side2)
1.0 (Side1)
1.0 (Side2)
1.0 (Side1)
1.0 (Side2)
Linearity (Lateral/
1.0 (Side1)
Skew: 280mm) (mm) 1.0 (Side2)
1.0 (Side1)
1.0 (Side2)
1.0(Side1)
1.0 (Side2)
2.0 (Side1)
2.0 (Side2)
2.0 (Side1)
2.0 (Side2)
2.0 (Side1)
2.0 (Side2)
Parallelism (400mm) 1.3 (Side1)

1.3 (Side2)
(mm)
1.3 (Side1)
1.3 (Side2)
1.3 (Side1)
1.3 (Side2)
Perpendicularity
(400mm) (mm)
Others: Non-standard size (Enter the size from the Control Panel).
Range
1.
Main scanning direction: 148~297mm (Default: 257mm)
2.
Subscanning direction: 203~432mm (Default: 257mm)
Tray/Cassette Capacity
1.
Tray 5 (Platen) Tray (Platen)

Side registration
(mm)
Tray 1: 500 sheets (4024DP20lb)
2.
Tray 2~4: 550 sheets (4024DP20lb)
3.
Tray 5: 100 sheets (15mm stack) (4024DP20lb)
4.
HCF: 2000 sheets (4024DP20lb)
Document Input Tray, Tray/Exit Tray Capacity (DADF) (Unit: sheet)

Both Input tray and exit tray have the same capacity, as follows:
Table 26
A4 or less
B4
A3
Thin paper (38~49gsm)
50
50
50
Regular paper (50~100gsm)
50
50
50
Thick paper (101~128gsm)
40
40
40
Output Tray (Bin) Capacity (Unit: sheet)

1.
Exit Tray: 200 Sheets
2.
OCT (Offset Catch Tray): 500 sheets
3.
Sorter/Mailbox Bin: 100 sheets/Bin (No. of bins: 10 Bins)
Lateral magnification% (100%)
0.5%/280mm
0.5%/280mm
0.5%/280mm
0.5%/280mm
0.5%/280mm
0.5%/280mm
Lateral magnification% (25~200%)
1.0%/280mm
1.0%/280mm
1.0%/280mm
1.0%/280mm
1.0%/280mm
1.0%/280mm
Lateral magnification% (201~400%)
2.0%/280mm
2.0%/280mm
2.0%/280mm
2.0%/280mm
2.0%/280mm
2.0%/280mm
Longitudinal magnifi- 0.5%/200mm

cation (Top half)%
0.5%/200mm
(100%)
0.5%/200mm
0.5%/200mm
0.5%/200mm
0.5%/200mm

cation (Bottom
0.5%/200mm
half)% (100%)
0.5%/200mm
0.5%/200mm
0.5%/200mm
0.5%/200mm

cation% (100%)
0.5%/400mm
0.5%/400mm
0.5%/400mm
0.5%/400mm
0.5%/400mm

cation%
0.5%/280mm
(25%~200%)
0.5%/280mm
0.5%/280mm
0.5%/280mm
0.5%/280mm

cation%
2.0%/280mm
(201%~400%)
2.0%/280mm
2.0%/280mm
2.0%/280mm
Copy Consistency
Table 27 Platen Registration
Lead edge registration (mm)
Tray 5 (Platen) Tray (Platen)
DADF
DADF single unit
2.2
2.5 (Side1)
2.5 (Side2)
1.5 (Side1)
1.5 (Side2)
General Procedures
1.6 (Side1)
1.6 (Side2)
1/05
6-156
Reissue
DocuColor 12/DCCS50
Common Tools
Product Tools and Test Patterns

Table 1 Common Tools
Table 1 Tools and Test Patterns
Description
Part Number
Description
Part Number
Screw Driver (-) 3 x 50
600T40205
Color Test Pattern
82E13120
Screw Driver (+) 6 x 100
600T1989
Black & White Test Pattern
82E8220
Screw Driver (+) NO.1
499T356
0.3 Density Gray Test Pattern
82P207
Stubby Driver (+) (-)
600T40210
HVPS test probe
600T1653
Screw Driver (=) 100MM
499T355
HVPS test probe adapter
600T1996
Spanner and Wrench 5.5 x 5.5
600T40501
Corotron wire installation tool
600T1990
Spanner and Wrench 7x 7
600T40502
Corotron cleaning wand (20 per kit)
600K39410
Hex Key Set
600T02002
Copy Paper Carrying Case
600T1999
Box Driver 5.5MM
600T1988
Copy Paper Zip Lock Bag
600T2000
Side Cutting Nipper
600T40903
Xerox Color Xpressions 24# 11 17
3R5465
Round Nose Pliers
600T40901
Colourtech 90 GSM A3
3R94642
Digital Multi-meter Set
600T2020
Service and Machine NVM Log
700P97436
Interlock Cheater
600T91616
Serial Cable
600T2058
Silver Scale 150MM
600T41503
Parallel Cable
600T2065
CE Tool Case
600T1901
PWS Powercord Adapter (for convenience outlet)
600T2018
Magnetic Screw Pick-up Tool
600T41911
Miniature Test Probe
600T02177
Scriber Tool
600T41913
Magnetic pickup
600T41911
Loupe
600T42008
Flash Light
600T1824
Brush
600T41901
Tester Lead Wire (red)
600T 9583
Tester Lead Wire (black)
600T2030
Reissue
DocuColor 12/DCCS50
1/05
6-157
General Procedures
Common Tools, Product Tools and Test Patterns
Cleaning Materials
Machine Consumables
Table 1 Cleaning Materials

NASG Part
Number
ESG Part
Number
Cleaning fluid
(8oz., Formula A)
43P48
8R90034
Film remover (8 oz.)
43P45
8R90176
Lens/mirror cleaner
43P81
8R90178
Lint-free (white) cleaning

cloth
19P3025
19P3025
Description
Lint-free Optics cleaning cloth 499T90417
499T90417
Cleaning towels
35P3191
600S4372
Drop cloth
35P1737
35P1737
Cotton Swab
35P2162
35P2162
Table 1 Machine Consumables

Description
NASG
Part #
ESG
Part #
Weight
Capacity
Remarks
(Nominal Life)
Developer - Black
5R616
5R90241
490g
Replace when
an error occurs.
Developer - Cyan
5R617
5R90242
490g
Replace when
an error occurs.
Developer - Magenta
5R618
5R90243
490g
Replace when
an error occurs.
Developer -Yellow
5R619
5R90244
490g
Replace when
an error occurs.
Toner Cartridge - Black
6R945
6R90280
490g (full)
Toner:284g 5,000 images
140g (empty) Carrier:66.3g (Note 1)
Toner Cartridge - Cyan
6R946
6R90281
490g (full)
Toner CartridgeMagenta
6R947
6R90282
490g (full)
Toner Cartridge - Yellow 6R948
6R90283
490g (full)
Xerographic Module
(Copy/Print Cartridge)
T&M Drum
13R558
13R560
1,900g
40,000 (Note 2)
Xerographic Module
(Copy/Print Cartridge)
FSMA Drum
13R557
13R559
1,900g
40,000 (Note 2)
Fuser Oil Cartridge,

CRU
8R7975
8R7982
450g (full)
300cc/CRU
150g (empty)
40,000 prints
Toner Waste Bottle
8R7976
8R7983
1,600g (full)
250 (empty)
40,000 prints
Waste Carrier Bottle
8R7977
8R7984
1,000g (full)
160g (empty)
40,000 prints
Fuser Web Assembly,

CRU
8R7980
8R7985
950g
40,000 prints
NOTE:
1.
2.
General Procedures
Cleaning Materials, Machine Consumables
1/05
6-158
Toner Life
Y, M, C: 5,000 images when documents with a 5% image density are copied in full
color mode using A4 paper.
K: 5,000 images when documents with a 5% image density are copied in black mode
using A4 paper.
C.C assembly life is 50,000 prints.
Reissue
DocuColor 12/DCCS50
Change Tag Introduction
Processor (P) Tags
Important modifications to the copier are identified by a tag number which is recorded on a tag
matrix label attached to the inside of the Front Fuser Cover, or inside the Front Door. This section describes all of the tags associated with the copier, as well as multinational applicability,
classification codes, and permanent or temporary modification information.
Processor Tags
Classification Codes
A tag number may be required to identify differences between parts that cannot be interchanged, or differences in diagnostic, repair, installation, or adjustment procedures.
TAG:
P1
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:
FU3: 310512043x FU1: 310512691x

NAME:
A tag number may also be required to identify the presence of optional hardware, special nonvolatile memory programming, or whether mandatory modifications have been installed. Each
tag number is given a classification code to identify the type of change that the tag has made.
The classification codes and their descriptions are listed in the table below.
FU2: 040199 FU0: 025021
IBT Cleaner Assy.
PURPOSE:
KIT NUMBER:
N/A
REFERENCE:
PL 7.1
Table 1
Classification Code
Description
Mandatory tag.
Tag not installed in the field.
Optional tag.
Repair Tag.
TAG:
P2
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:
FU2: 040199 FU0: 025021

FU3: 310512153x FU1: 310512691x
NAME:
Rotary PWB/Plate Assy.
PURPOSE:
Countermeasure for Rotary PWB short circuit problem
KIT NUMBER:
N/A
REFERENCE:
PL 6.1
TAG:
P3
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:
FU2: 040321 FU0: 025022

FU3: 310512332x FU1: 310512707x
NAME:
Aligner Baffle Assy.
PURPOSE:
Reissue
DocuColor 12/DCCS50
Duplex Aligner performance improvement
KIT NUMBER:
N/A
REFERENCE:
PL 2.18
1/05
6-159
General Procedures
Change Tag Introduction, Processor (P) Tags
TAG:
P4
TAG:
P7
CLASS:
CLASS:
USE:
ALL
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
N/R
MFG SERIAL NUMBERS:
BR PWB
PURPOSE:
Cut-in: Oil Roll Assembly deleted from BI first M/C:

FU2: 040051 FU0: 025010
This Tag indicates presence of Omron BR PWB (before cut-in of XCD PWB)
FU3: 310512016x FU1: 310512684x
KIT NUMBER:
N/A
Cut-in: Deletion of Drive Assy:
REFERENCE:
PL 3.5
FU2: 040329 FU0:025037

FU3: 310512332x FU1: 310512707x
Cut-in: Tag 7 marked (Harness change):
FU2: 040321 FU0:025022
FU3: 310512332x FU1: 310512707x
TAG:
P5
CLASS:
USE:
ALL
NAME:
IBT Oil Roll Assembly and Drives removal.
PURPOSE:
MFG SERIAL NUMBERS:
FU2: 040920 FU0: 025093
IBT redesign
KIT NUMBER:
N/A
REFERENCE:
N/A
FU3: 310512545 FU1: 310512719

NAME:
ROS Assembly
PURPOSE:
Updated Assy to correct 1mm banding problem
KIT NUMBER:
N/A
REFERENCE:
PL 4.1
TAG:
P8
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:
Cut-in: New Welding cutin:

FU2: 040199 FU3: 3105123123x,
TAG:
P6
CLASS:
USE:
ALL
Cut-in: Tag 8 marked:

FU2: 040321 FU3: 3105123332x
NAME:
MFG SERIAL NUMBERS:

NAME:
Cut-in FU2:040321, FU0:025022, FU3:310512332x,

FU1:310512707x
IOT CPU PWB
PURPOSE:
IIT Brace Kit
PURPOSE:
The purpose of this kit is to install a new Brace in the IIT Assembly
KIT NUMBER:
605K91041
REFERENCE:
PL 3.1
New pull up resistor on the IOT CPU PWB allows use of all WCS-approved
PWBs for downloading of IOT Software.
KIT NUMBER:
N/A
REFERENCE:
PL 9.2
General Procedures
Mail Box / Sorter Tags, Mail Box / Sorter Tags
1/05
6-160
Reissue
DocuColor 12/DCCS50
TAG:
P9
TAG:
P12
CLASS:
CLASS:
USE:
ALL
USE:
ALL
MFG SERIAL NUMBERS:
Cut-in: Temporary change:
MFG SERIAL NUMBERS:
FU2: 040199 FU0: 025022
FU2: 040823 FU0: 025093

FU3: 310512545x FU1: 310512719x
FU3: 310512179x FU1: 310512691x
NAME:
Wick Assembly Kit
Cut-in: Permanent change:
PURPOSE:
FU2:040321, FU0:025022, FU3:310512332,

FU1:310512702x
KIT NUMBER:
NASG - 600K78063
REFERENCE:
PL 8.7
Wick Assembly change for image disturbance correction

ESG - 600K78073
Cut-in: Tag 9 marked:

FU2: 040479 FU0: 025052
FU3: 310512394x FU1:310512707x
NAME:
Exit/Fuser Nip Drive Assembly
PURPOSE:
To repair Exit Drive short circuit due to excessive cable length
KIT NUMBER:
REFERENCE:
N/A
TAG:
P13
PL 1.6
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:
FU2: 040694 FU0: 25093

FU3: 310512538x FU1: 310512719x
NAME:
TAG:
P10
CLASS:
USE:
ALL
VSEL Extension PWB
PURPOSE:
MFG SERIAL NUMBERS:
PWB Update
KIT NUMBER:
N/A
REFERENCE:
PL 9.2
FU2: 040547 FU0:025052

FU3: 310512438x FU1:310512707x
NAME:
IOT CPU S/W V4.43.1h CD-ROM
PURPOSE:
IOT CPU S/W upgrade with alternate UI language support
KIT NUMBER:
133K21302
REFERENCE:
TAG:
P14
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:
FU2: 041304 FU3: 310512662x

FU1: 310512729x FU0:025138
NAME:
ATC Sensor Kit
PURPOSE:
The kit adds ATC Sensor and revised IOT Drive PWB, to detect TC from the
Developer Roll surface.
TAG:
P11
CLASS:
KIT NUMBER:
606K91040
USE:
ALL
REFERENCE:
PL 9.2
MFG SERIAL NUMBERS:
FU2: 040592 FU0:025052

FU3: 310512438x FU1: 310512707x
NAME:
Support weld for Fuser Exit ON Jam
PURPOSE:
KIT NUMBER:
Support weld for Fuser Exit ON Jam

605K91060
REFERENCE:
Reissue
DocuColor 12/DCCS50
1/05
6-161
General Procedures
TAG:
P15
TAG:
P18
CLASS:
CLASS:
USE:
ALL
USE:
MFG SERIAL NUMBERS:

NAME:
FU2: 041442 FU3: 310512781x
MFG SERIAL NUMBERS:
FU1: 310512734x FU0: 025138
NAME:
Cyan Toner Leak Fix
PURPOSE:
PURPOSE:
Change to Rotary Motor switching frequency to eliminate high frequency sound

complaints
Eliminate gap in Cyan Oil Seal, to prevent Cyan Toner leakage

KIT NUMBER:
600K82900
REFERENCE:
REFERENCE:
PL 6.1
TAG:
P16
TAG:
P19
CLASS:
CLASS:
USE:
ALL
USE:
ALL
KIT NUMBER:
600K82870
MFG SERIAL NUMBERS:
FU2: 041304 FU3: 310512662x
MFG SERIAL NUMBERS:
IOT Software Retrofit Kit
PURPOSE:
Software Upgrade to V6.00.2
FU2: 041496 FU0: 025138

FU3: 310512785x FU1: 310512734x
FU1: 310512729x FU0: 025138

NAME:
N/A
Rotary Motor Noise Kit
NAME:
DADF Software Upgrade to V2.2
PURPOSE:
The purpose of this kit is to install new DADF Software
KIT NUMBER:
605K07201
KIT NUMBER:
635K07220 (XC)
REFERENCE:
TAG P6 is a prerequisite for this Kit.
REFERENCE:
TAG P16 is a prerequisite for this Kit.
TAG:
P17
TAG:
P20
CLASS:
CLASS:
USE:
ALL
USE:
ALL
MFG SERIAL NUMBERS:
FU2: 041496 FU0: 025138
MFG SERIAL NUMBERS:
FU3: 310512785x FU1: 310512734x
NAME:
NAME:
Film Seal Assy Mandatory Retrofit Kit
PURPOSE:
Install thicker Film Seal to prevent toner splatter
KIT NUMBER:
605K91090
REFERENCE:
PL 7.1, PL 7.8
General Procedures
Roll Assy Field Retrofit Kit
PURPOSE:
Exchange IBT Drive Roll to improve banding (105mm pitch, etc.) occurring in
A-zone.
KIT NUMBER:
600K82710
REFERENCE:
PL 7.1
1/05
6-162
Reissue
DocuColor 12/DCCS50
TAG:
P21
TAG:
P24
CLASS:
CLASS:
USE:
ALL
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
FU2: 041496 FU0: 025138
MFG SERIAL NUMBERS:
FU3: 310512785x FU1: 310512734x
NAME:
Pickup Roll for Fuser Assy improvement
PURPOSE:
UI PWB with Edit Function
PURPOSE:
UI PWB with Edit function added to all machines; PWB removed from Edit Pad
Kit
To improve life of Oil Metering System
KIT NUMBER:
600K83630
KIT NUMBER:
600K83650
REFERENCE:
PL 8.9
REFERENCE:
Kit purpose is to add updated PWB to pre-Tag 24 cutin machines when

installing new Edit Pad kit
TAG:
P22
CLASS:
USE:
MFG SERIAL NUMBERS:
NAME:
IOT Software Retrofit Kit
PURPOSE:
IOT S/W upgrade to V6.20.2h
KIT NUMBER:
630K11450
TAG:
P23
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:
FU2: 041496 FU0: 025138
Exit Roll
PURPOSE:
To reduce corrugation marks
KIT NUMBER:
N/A
REFERENCE:
PL 2.26
P25
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:
FU2: 041496, FU0: 025138

FU3: 310512785x FU1: 310512734x
NAME:
PURPOSE:
FU3: 310512785x FU1: 310512734x

NAME:
TAG:
Repair miswiring of AC outlet
KIT NUMBER:
N/A
REFERENCE:
This Tag cancelled; replaced by TAG P28
TAG:
P26
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:
FU2: 046765, FU0: 025138

FU3: 310868820x FU1: 31051273x
NAME:
Distributor Field Repair Kit
PURPOSE:
To repair DCD (debris centered deletions problem) and prevent damage to Dispenser seals.
KIT NUMBER:
600K83451
REFERENCE:
PL 6.5
NOTE: Certain machines received the change during manufacturing, but were not tagged. The
serial number for these machines are as follows:
Reissue
DocuColor 12/DCCS50
FU2: 044535 - 046764
FU3: 310868415x - 310868819x
1/05
6-163
General Procedures
TAG:
P27
TAG:
P30
CLASS:
CLASS:
USE:
ESG only
MFG SERIAL NUMBERS:

NAME:
XCD PWB (Mitcheldean Production Only)
PURPOSE:
ESG-specific XCD PWB
KIT NUMBER:
N/A
REFERENCE:
PL 3.5
TAG:
P28
CLASS:
USE:
ALL
N/A
S/W V 7.06 for Finisher upgrade
PURPOSE:
Finisher upgrade to S/W V 7.06
KIT NUMBER:
635K7230
TAG:
P31
CLASS:
USE:
ESG Only
NAME:
EU Safety/EMI fix
FU2: 043894 FU0: 025138
PURPOSE:
FU3: 31086831x FU1: 310512734x
REFERENCE:
Fuser modifications to accommodate new EMI requirements

PL 9.6
Incorrect AC Inlet and Outlet connector wiring
PURPOSE:
To correct the AC wiring problem on the AC Power Inlet and Outlet connectors
KIT NUMBER:
605K9740
REFERENCE:
Kit number is for RITS tracking purposes
TAG:
P29
CLASS:
P32
CLASS:
USE:
ALL
FU2: 054790 FU0: 310868312x
FU3: 310869570x FU1: 310512734x
NAME:
N/A
Magnification Distortion Kit
PURPOSE:
TAG:
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:

NAME:
NAME:
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:

NAME:
MFG SERIAL NUMBERS:

213 7078999
Kit provides new Half Tone PWB to alleviate interval distortion
KIT NUMBER:
600K84300
REFERENCE:
PL 9.2
General Procedures
New ROS and Half Tone PWB design (42.37 MHz)
PURPOSE:
KIT NUMBER:
600K86000
REFERENCE:
PL 4.1, PL 9.2
1/05
6-164
Reissue
DocuColor 12/DCCS50
TAG:
P33
TAG:
P36
CLASS:
CLASS:
USE:
ALL
USE:
ALL
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
NAME:
NAME:
Toner Spray Kit
PURPOSE:
Reduce trail edge toner spray and banding that occurs 150 mm from trail edge
KIT NUMBER:
600K85871
Sorter/Mailbox Crease Reduction Kit
PURPOSE:
KIT NUMBER:
600K83420
REFERENCE:
REFERENCE:
TAG S2
TAG:
P34
TAG:
P37
CLASS:
CLASS:
USE:
ALL
USE:
MFG SERIAL NUMBERS:
MFG SERIAL NUMBERS:
NAME:
NAME:
PURPOSE:
To reduce the appearance of 6.6 mm pitch banding
KIT NUMBER:
600K86080
PURPOSE:
FU2:58493 - 059335 FU0:025257 - 025357
Countermeasure for oil leak from Oil Pan
REFERENCE:
REFERENCE:
TAG:
P38
CLASS:
USE:
ALL
ALL
MFG SERIAL NUMBERS:
TAG:
P35
CLASS:
USE:
MFG SERIAL NUMBERS:
NAME:
NAME:
PURPOSE:
PURPOSE:
KIT NUMBER:
To reduce banding that occurs 60 mm from the trail edge

600K86090
FU2:58884
EPC Enablement
Harnessing changes to allow installation of EPC option
KIT NUMBER:
498K2440
REFERENCE:
PL 20.1
REFERENCE:
Reissue
DocuColor 12/DCCS50
1/05
6-165
General Procedures
TAG:
P39
CLASS:
USE:
ALL
Mail Box / Sorter Tags
MFG SERIAL NUMBERS:
TAG:
S1
NAME:
CLASS:
USE:
ALL
V11.5x Software update
PURPOSE:
Updates software to enable EPC and increased imageable area.
KIT NUMBER:
630K12210
REFERENCE:
MFG SERIAL NUMBERS:

NAME:
PURPOSE:
Adds Tag Matrix to the Mail Box/Sorter and firmware upgrade
KIT NUMBER:
TAG:
P40
CLASS:
USE:
ESG ONLY
TAG:
S2
MFG SERIAL NUMBERS:
CLASS:
NAME:
USE:
ALL
ESS PS Removal
PURPOSE:
Component not required in DC12 - DCCS50 Only
KIT NUMBER:
N/A
REFERENCE:
830564
S/W and Tag Matrix

635K780
MFG SERIAL NUMBERS:

NAME:
Sorter/Mailbox Crease Reduction Kit
PURPOSE:
TAG:
P41
CLASS:
USE:
ALL
NAME:
VOID
KIT NUMBER:
600K83420
REFERENCE:
TAG P36
REFERENCE:
TAG:
P42
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
3-380 Fault Countermeasures
PURPOSE:
KIT NUMBER:
Mfg. change to prevent short circuits

N/A
REFERENCE:
General Procedures
1/05
6-166
Reissue
DocuColor 12/DCCS50
High Capacity Feeder (HCF) Tags

TAG:
HCF1
CLASS:
USE:
ALL
HCF4
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
FT4 685969
FT4:688798
HCF Control PWB w/ V2.5 software
PURPOSE:
MFG SERIAL NUMBERS:

NAME:
TAG:
New software to fix 8-190 and 8-192 faults
REFERENCE:
PL 15.16
HCF Control PWB w/V2.4 S/W update
PURPOSE:
V2.4 software fixes 8-190 and 8-192 HCF Take Away Roll Sensor On Jam
faults
KIT NUMBER:
N/A
REFERENCE:
PL 15.16
TAG:
HCF5
CLASS:
USE:
MFG SERIAL NUMBERS:
TAG:
HCF2
CLASS:
USE:
ALL
Lift Motor Fix
PURPOSE:
REFERENCE:
MFG SERIAL NUMBERS:

NAME:
NAME:
FT4 687185
Drive Belt Tensioner
PURPOSE:
Feed Head modification
KIT NUMBER:
N/A
REFERENCE:
PL 15.10
TAG:
HCF6
CLASS:
USE:
All
MFG SERIAL NUMBERS:

NAME:
TAG:
HCF3
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
Low torque HCF kit
PURPOSE:
Paper feeder modified to reduce mis-feeds
KIT NUMBER:
604K22210
REFERENCE:
PL 15.10
FT4 687185
Skew Kit
PURPOSE:
KIT NUMBER:
Resolve skewed feeding problem

600K89040
REFERENCE:
Reissue
DocuColor 12/DCCS50
1/05
6-167
General Procedures
High Capacity Feeder (HCF) Tags, Integrated Digi-
Integrated Digital Front End (IDFE) Tags

TAG:
IDFE 1
CLASS:
USE:
ALL
USE:
NASG (US), NASG (Canada), AO, ESG.
MFG SERIAL NUMBERS:
GL2 - 385719
DCCS 50 Controller/Software
PURPOSE:
Software roll from version 1.02 to 1.07 (System Software installation CD-ROM
v1.1)
Manufacturing Cut-in S/N GL2 383925 and above
EME fixes/UL Label
PURPOSE:
IDFE 5
CLASS:
NAME:
MFG SERIAL NUMBERS:

NAME:
TAG:
KIT NUMBER:
701P33191 Software Upgrade Kit, 701P33197 Software Upgrade Kit

Instructions
Support of Manufacturing Standard Configuration
KIT NUMBER:
TAG:
IDFE 2
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
Manufacturing Firmware Upgrades for U33 and U34
PURPOSE:
Print and Image Quality fixes
TAG:
IDFE 6
CLASS:
USE:
ALL
KIT NUMBER:
MFG SERIAL NUMBERS:
TAG:
IDFE 3
NAME:
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
GL2 386198 - QC47 350216
Electromagnetic Compliance
PURPOSE:
Comply with EMC limits, addition of Ethernet grounding, filter array to power
connector, copper fingers and tape to DDI Connector Plate
EE Seal Noise Fix
PURPOSE:
EE Seal added to DB 15 to solve IOT noise problem
KIT NUMBER:
TAG:
IDFE 4
TAG:
IDFE 7
CLASS:
CLASS:
USE:
ALL
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
DCCS 50 Controller/Software
PURPOSE:
KIT NUMBER:
Launch Software Version 1.0

software is available by ordering Customer Support Pack 701P31194
MFG SERIAL NUMBERS:

NAME:
GL2 386533
Maintenance release V1.2
PURPOSE:
Software to support TAG IDFE 8, and fix reported field problems
KIT NUMBER:
REFERENCE:
General Procedures
Integrated Digital Front End (IDFE) Tags,
1/05
6-168
Reissue
DocuColor 12/DCCS50
TAG:
IDFE 8
TAG:
IDFE 11
CLASS:
CLASS:
USE:
ALL
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
GL2 387285
New hardware configuration
PURPOSE:
Hardware update to obsolete components
REFERENCE:
MFG SERIAL NUMBERS:

NAME:
GL2 393154
S/W release V2.1
PURPOSE:
Fixes reported field problems
KIT NUMBER:
REFERENCE:
TAG:
IDFE 9
CLASS:
TAG:
IDFE 12
USE:
ALL
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
GL2 387895
S/W release V2.0
PURPOSE:
MFG SERIAL NUMBERS:
New software to support Finisher option
GL2 395206
NAME:
Centreware S/W release V3.1
KIT NUMBER:
PURPOSE:
Features enhancement
REFERENCE:
KIT NUMBER:
REFERENCE:
TAG:
IDFE 10
CLASS:
TAG:
IDFE 13
USE:
ALL
CLASS:
USE:
ALL
MFG SERIAL NUMBERS:

NAME:
GL2 392943
Video Board PWB
PURPOSE:
KIT NUMBER:
Hardware change to eliminate system crashes

606K7490
REFERENCE:
Reissue
DocuColor 12/DCCS50
MFG SERIAL NUMBERS:

NAME:
New hardware configuration
PURPOSE:
Hardware update to obsolete components
REFERENCE:
1/05
6-169
General Procedures
General Procedures
1/05
6-170
Reissue
DocuColor 12/DCCS50
7 Wiring Data
Plug/Jacks
Wiring Connector List ......................................................................................................
Plug/Jack IndexP/JP/JP/J ..............................................................................................
Plug/Jack Locator Diagrams ...........................................................................................
7-3
7-3
7-9
Wirenets
AC Power Wirenets .......................................................................................................
18VAC Wirenet ...............................................................................................................
3.3VDC/3.3V RET/3.5VDC/3.5V RET Wirenets..............................................................
+5VDC Wirenets .............................................................................................................
DC COM (+5V RET) Wirenets .......................................................................................
+12/-12VDC Wirenet .......................................................................................................
DC COM (+12/-12V RET) Wirenet ..................................................................................
13.3VDC Wirenet ............................................................................................................
DC COM (13.V RET) Wirenet ........................................................................................
+24VDC Wirenets ...........................................................................................................
DC COM (24V RET) Wirenets .......................................................................................
BSDs ...............................................................................................................................
Chain 01..........................................................................................................................
Chain 02..........................................................................................................................
Chain 03..........................................................................................................................
Chain 04..........................................................................................................................
Chain 05..........................................................................................................................
Chain 06..........................................................................................................................
Chain 07..........................................................................................................................
Chain 08..........................................................................................................................
Chain 09..........................................................................................................................
Chain 10..........................................................................................................................
Chain 11..........................................................................................................................
Chain 16..........................................................................................................................
Reissue
DocuColor 12/DCCS50
7-41
7-42
7-44
7-48
7-57
7-65
7-66
7-67
7-68
7-69
7-76
7-81
7-83
7-91
7-97
7-107
7-109
7-117
7-125
7-141
7-155
7-179
7-199
7-211
1/05
7-1
Wiring Data
Wiring Data
1/05
7-2
Reissue
DocuColor 12/DCCS50
Wiring Connector List
Plug/Jack IndexP/JP/JP/J
Table 1 Plug/Jack Index connector list
How to use the Wiring Connector List
P/J No.
Illustration No.
Item No.
1.
P/J1
7.2.22 Distribution PWB/IOT LVPS
11
P/J2
7.2.25 B3H LVPS/SSR/Transformer (AP)
11
P/J3
7.2.4 IPS
15
P/J4
12
J5
7.2.3 IIT
P5
7.2.4 IPS
14
P10
7.2.21 AC Drive PWB/Tray PWB/SSR
12
P/J11A
P/J11B
P12
P/J13
P/J14
15
P/J15
20
P/J16
19
P/J17
18
P/J18
17
P/J19
J20
7.2.25
P20
10
P/J21
P/J22
P/J23
P/J24
P/J25
P/J31
7.2.4 IPS
12
P/J33
7.2.4 IPS
10
P/J34
7.2.4 IPS
11
P/J35
7.2.4 IPS
P/J41
P/J42
P/J43
P/J44
P/J45
10
P/J53
7.2.23 Power Chassis
12
P/J54
13
P/J55
10
P/J56
11
P/J57
14
P/J58
2.
To find the location of a connector, refer to the Figure and Item Number of the Plug/Jack
Location Drawings section, by referring to Figure and Item Number of the Wiring Connector List.
The Plug/Jack and P/J in the Index are identified by following method:
a.
J250 represents Jack 250.
b.
P250 represents Plug 250
c.
Numerals without P or J represent both Jack and Plug
d.
CN1 represents Connector 1.
Refer to Figure 1 for an example of a Plug/Jack Index connector list entry.
Figure x
Item number in the

Illustration that shows
the specific location of
a Plug/Jack.
P/J Number
Figure number of the Illustration showing the area of the

Finisher where the Plug/Jack
can be located.
Figure 1 Plug/Jack Index connector list example
Reissue
DocuColor 12/DCCS50
1/05
7-3
Wiring Data
Wiring Connector List, Plug/Jack Index
P/J No.
Illustration No.
Item No.
P/J No.
Illustration No.
Item No.
P/J59
P/J119
7.2.5 Toner Cartridge
15
P/J70
7.2.30 w/Tag P31 (ESG only)
P/J120
16
J71
P/J121
7.2.15 Tray Feeder
16
J72
P/J122
7.2.2 Front Upper
15
J73
P/J123
7.2.15 Tray Feeder
15
J74
P/J124
7.2.15 Tray Feeder
14
P/J76
P/J125
7.2.15 Tray Feeder
13
P/J81
7.2.18 Main Switch/Deve.Bias HVPS/CC/PDD HVPS
19
P/J127
7.2.15 Tray Feeder
17
P/J81
P/J128
7.2.15 Tray Feeder
P/J82
14
P/J129
7.2.15 Tray Feeder
P/J82
P/J130
7.2.15 Tray Feeder
P/J83
10
P/J131
7.2.14 Tray 1-4 Sensor
P/J84
7.2.10 Registration
P/J132
P/J84
7.2.25
P/J134
P/J91
18
P/J136
P/J92
15
P/J139
7.2.8 IBT
P/J93
7.2.8 IBT
P/J140
7.2.8 IBT
P/J95
7.2.20 Rear Upper
23
P/J141
7.2.2 Front Upper
10
P/J96
7.2.10 Registration
P/J142
7.2.2 Front Upper
16
P/J98
7.2.24 Tray 2-4 Take Away Drive/Transformer
P/J144
7.2.17 Tray 5
P/J98
P/J145
7.2.17 Tray 5
10
P/J99
P/J146
7.2.17 Tray 5
P/J99
P/J147
7.2.17 Tray 5
P/J100
13
P/J148
7.2.17 Tray 5
11
P/J101A
P/J149
7.2.16 Inverter Unit
P/J101B
P/J150
P/J101C
P/J151
P/J101D
P/J152
10
P/J101E
P/J153
7.2.9 Drawer
P/J101F
P/J154
7.2.9 Drawer
P/J105
14
P/J157
7.2.11 2nd BTR
P/J109
7.2.17 Tray 5
13
P/J158
7.2.11 2nd BTR
P/J110
7.2.20 Rear Upper
P/J159
7.2.9 Drawer
P/J111
7.2.8 IBT
P/J160
7.2.10 Registration
P/J112
7.2.20 Rear Upper
11
P/J161
7.2.10 Registration
P/J113
7.2.2 Front Upper
P/J162
7.2.10 Registration
P/J114
7.2.2 Front Upper
P/J163
7.2.10 Registration
P/J115
7.2.20 Rear Upper
29
P/J164
P/J116
P/J167
7.2.12 Fuser Unit (Front)
16
P/J117
13
P/J168
P/J118
14
P/J169
7.2.13 Fuser Unit (Rear)
Wiring Data
Plug/Jack Index
1/05
7-4
Reissue
DocuColor 12/DCCS50
P/J No.
Illustration No.
Item No.
P/J No.
Illustration No.
Item No.
P/J170
P/J254
7.2.17 Tray 5
P/J171
20
P/J255
7.2.20 Rear Upper
15
P/J172
21
P/J256
7.2.20 Rear Upper
19
P/J173
15
P/J257
7.2.20 Rear Upper
10
P/J174
17
P/J260
7.2.20 Rear Upper
P/J175
19
P/J261
7.2.20 Rear Upper
P/J176
13
P/J262
7.2.20 Rear Upper
36
P/J191
P/J264
P/J192
P/J266
P/J193
P/J268
P/J194
12
P/J272
12
P/J195
14
P/J273
P/J196
11
P/J274
P/J198
P/J275
7.2.17 Tray 5
P/J199
18
P/J276
7.2.15 Tray Feeder
P/J201
7.2.20 Rear Upper
P/J280
21
P/J202
7.2.20 Rear Upper
26
P/J281
7.2.20 Rear Upper
35
P/J203
7.2.20 Rear Upper
P/J282
7.2.19 IOT Driver PWB/IOT CPU PWB
15
P/J204
7.2.20 Rear Upper
32
P/J283
7.2.2 Front Upper
11
P/J209A
11
P/J284
7.2.2 Front Upper
12
P/J209B
12
P/J289
7.2.2 Front Upper
14
P/J210A
P/J341
7.2.6 ROS/Half Tone PWB
P/J210B
10
P/J342
P/J211A
P/J345
P/J211B
P/J347
P/J212A
J387
7.2.7 VSEL Base TTL PWB (AP)
P/J212B
P387
10
P/J213
P/J388
P/J214
P/J389
P/J215
P/J391
P/J216
J393
P/J217
P393
P/J218
7.2.10 Registration
P/J395
P/J220
7.2.9 Drawer
J396
17
P/J222
7.2.20 Rear Upper
18
P396
P/J223
7.2.17 Tray 5
12
P/J397
P/J224
7.2.15 Tray Feeder
P/J398
P/J233
P/J399
11
P/J251
7.2.20 Rear Upper
P/J400
20
P/J252
7.2.20 Rear Upper
30
P401
21
P/J253
P402
22
Reissue
DocuColor 12/DCCS50
1/05
7-5
Wiring Data
Plug/Jack Index
P/J No.
Illustration No.
Item No.
P/J No.
Illustration No.
Item No.
P/J403
P491
7.2.1 Control Panel
14
P/J404
P/J492(CN4)
7.2.1 Control Panel
P/J405
23
P/J493
7.2.1 Control Panel
13
P/J406
P/J500
7.2.3 IIT
P/J411
12
P/J508
P/J412A
16
P/J509
P/J412B
16
P/J510
7.2.4 IPS
P/J413A
P512
7.2.4 IPS
P/J413B
P/J513
7.2.4 IPS
25
P/J414A
P/J514
7.2.4 IPS
26
P/J414B
P/J515
7.2.4 IPS
18
P/J415A
14
P516
7.2.4 IPS
21
P/J415B
14
P/J517
7.2.4 IPS
13
P/J416A
11
P518
7.2.4 IPS
27
P/J416B
11
P/J519
7.2.4 IPS
19
P/J417A
19
P/J520
7.2.3 IIT
10
P/J417B
19
P/J521
7.2.3 IIT
14
P/J418A
10
P/J522
7.2.3 IIT
11
P/J418B
10
P/J523
7.2.3 IIT
13
P/J419A
P/J524
7.2.3 IIT
12
P/J419B
P/J530
7.2.3 IIT
P/J420A
18
P/J531
7.2.3 IIT
P/J420B
18
P/J532
7.2.3 IIT
P/J421A
17
P/J533
7.2.3 IIT
P/J421B
17
P/J534
7.2.3 IIT
P/J422A
13
P/J535
7.2.3 IIT
P/J422B
13
P536
7.2.4 IPS
17
P/J431
18
P/J537
7.2.3 IIT
P/J432
17
P/J540
7.2.3 IIT
18
P/J433A
20
P/J541
7.2.3 IIT
P/J433B
20
P/J542
7.2.3 IIT
16
P/J434
19
J543A
7.2.3 IIT
17
P/J440
10
J543B
7.2.3 IIT
17
P/J441
P543A
7.2.26 DADF-1
10
P/J482A (CN1)
7.2.1 Control Panel
P543B
7.2.26 DADF-1
10
P/J482A
7.2.1 Control Panel
10
P/J544
7.2.3 IIT
15
P/J482B(CN2)
7.2.1 Control Panel
P/J550
7.2.27 DADF-2
P/J482B
7.2.1 Control Panel
11
P/J550
7.2.28 Mail Box Sorter
26
P/J484
7.2.1 Control Panel
P/J551
7.2.27 DADF-2
P/J486
7.2.1 Control Panel
P/J551
P/J490
7.2.1 Control Panel
12
P/J552
Wiring Data
Plug/Jack Index
1/05
7-6
Reissue
DocuColor 12/DCCS50
P/J No.
Illustration No.
Item No.
P/J No.
Illustration No.
Item No.
P/J553
P/J585
7.2.26 DADF-1
P/J554
P/J586
7.2.26 DADF-1
11
P/J555
11
P/J587
7.2.26 DADF-1
P/J556
12
P/J588
7.2.27 DADF-2
P/J557
13
P/J589
7.2.27 DADF-2
P/J558
P/J590
7.2.27 DADF-2
P/J559
P/J591
7.2.26 DADF-1
P/J560
7.2.4 IPS
23
P/J592
7.2.27 DADF-2
P/J560
33
J594
7.2.20 Rear Upper
37
P/J561
7.2.4 IPS
P/J594
7.2.27 DADF-2
P/J561
32
P/J595
7.2.27 DADF-2
10
P/J562
7.2.4 IPS
24
P/J596
7.2.27 DADF-2
12
P/J562
31
P/J597
7.2.27 DADF-2
P/J563
7.2.4 IPS
22
P/J598
7.2.27 DADF-2
11
P/J563
20
P/J599
7.2.27 DADF-2
P/J564
7.2.4 IPS
20
P/J651
7.2.29 Decurler
10
P/J564
29
P/J652
7.2.29 Decurler
P/J565
18
P/J653
7.2.29 Decurler
P/J566
28
P/J654
7.2.29 Decurler
11
P/J567
27
P/J656
7.2.29 Decurler
P567
7.2.4 IPS
16
P/J658
7.2.29 Decurler
P/J569
16
P658
7.2.4 IPS
P/J570
7.2.4 IPS
P/J659
7.2.29 Decurler
P/J570
14
P/J660
7.2.29 Decurler
12
J571
11
P/J661
7.2.29 Decurler
J571
17
P/J664
7.2.29 Decurler
P571
7.2.4 IPS
28
P/J665
7.2.29 Decurler
P571
7.2.29 Decurler
J700A
7.2.20 Rear Upper
31
P/J572
10
P700B
J572
7.2.4 IPS
30
J701A
7.2.9 Drawer
P572
10
P701A
7.2.20 Rear Upper
22
P/J573
J701B
7.2.9 Drawer
P573
7.2.4 IPS
P701B
7.2.20 Rear Upper
21
P573
7.2.4 IPS
J701C
7.2.9 Drawer
P575
7.2.4 IPS
29
P701C
7.2.20 Rear Upper
20
P578
7.2.4 IPS
J702A
7.2.8 IBT
P/J580
7.2.26 DADF-1
P702A
7.2.20 Rear Upper
P/J581
7.2.26 DADF-1
J702B
7.2.8 IBT
P/J582
7.2.26 DADF-1
P702B
7.2.20 Rear Upper
P/J583
7.2.26 DADF-1
J703A
7.2.17 Tray 5
P/J584
7.2.26 DADF-1
P703A
7.2.17 Tray 5
Reissue
DocuColor 12/DCCS50
1/05
7-7
Wiring Data
Plug/Jack Index
P/J No.
Illustration No.
Item No.
P/J No.
Illustration No.
Item No.
J703B
7.2.17 Tray 5
P/J803B
25
P703B
7.2.17 Tray 5
P/J804
22
P/J704
7.2.2 Front Upper
P/J805
P/J710
P/J805
21
P/J711
7.2.20 Rear Upper
38
P/J806
22
P/J712
7.2.2 Front Upper
P/J807
24
P/J713
7.2.20 Rear Upper
24
P/J818
30
P/J714
7.2.2 Front Upper
P/J819
P/J715
7.2.15 Tray Feeder
12
P/J823
P/J716
7.2.9 Drawer
P/J880
19
P/J717
7.2.20 Rear Upper
27
P/J880A
19
P/J718
7.2.10 Registration
J880
24
P/J719
7.2.10 Registration
J880A
24
P/J720
P880
15
P/J722
7.2.9 Drawer
J880B
24
P/J723
7.2.2 Front Upper
13
P880B
7.2.28
15
P/J724
P/J892
7.2.20 Rear Upper
14
P/J725
7.2.20 Rear Upper
34
P899
P/J726
7.2.20 Rear Upper
33
J900
16
P/J728
P903
7.2.20 Rear Upper
12
P/J729
P905
7.2.20 Rear Upper
13
P/J730
P906
11
P/J731
7.2.20 Rear Upper
17
P/J1100
P/J732
7.2.20 Rear Upper
16
P/J1150
7.2.20 Rear Upper
28
P/J734
P/J2010
7.2.20 Rear Upper
J765
7.2.26 DADF-1
P/J2020
7.2.20 Rear Upper
25
P769
7.2.26 DADF-1
P/J2030
7.2.20 Rear Upper
P/J791
7.2.15 Tray Feeder
18
CN1
7.2.1 Control Panel
P/J792
7.2.15 Tray Feeder
11
CN2
7.2.1 Control Panel
15
P/J793
7.2.15 Tray Feeder
CN3
7.2.1 Control Panel
P/J794
7.2.15 Tray Feeder
CN5
7.2.1 Control Panel
P/J795
CN6
7.2.1 Control Panel
P/J796
7.2.15 Tray Feeder
10
DP J2
P799
DS J2
P/J800
F51
23
P/J801A
26
F52
22
P/J801B
26
F53
P/J802A
23
F54
P/J802B
23
F55
P/J803
25
F56
P/J803A
25
FS1
7.2.2 Front Upper
Wiring Data
Plug/Jack Index
1/05
7-8
Reissue
DocuColor 12/DCCS50
Plug/Jack Locator Diagrams

P/J No.
Illustration No.
Item No.
FS2
7.2.2 Front Upper
FS3
7.2.2 Front Upper
FS4
7.2.2 Front Upper
FS11
FS12
FS50
FS51
FS52
FS60
FS61
FS62
FS63
FS800
7.2.15 Tray Feeder
FS801
7.2.15 Tray Feeder
JC
13
JD
16
SJ10
27
SJ51
7.2.17 Tray 5
SJ52
7.2.17 Tray 5
SJ801
23
SP71
SP72
TIJ1
TPJ1
TSJ1
Reissue
DocuColor 12/DCCS50
1/05
7-9
Wiring Data
Plug/Jack Index, Plug/Jack Locator Diagrams
Figure 1 - 7.2.1 Control Panel

Wiring Data
1/05
7-10
Reissue
DocuColor 12/DCCS50
Figure 2 - 7.2.2 Front Upper

Reissue
DocuColor 12/DCCS50
1/05
7-11
Wiring Data
Figure 3 - 7.2.3 IIT

Wiring Data
1/05
7-12
Reissue
DocuColor 12/DCCS50
Figure 4 - 7.2.4 IPS
Reissue
DocuColor 12/DCCS50
1/05
7-13
Wiring Data
Figure 5 - 7.2.5 Toner Cartridge

Wiring Data
1/05
7-14
Reissue
DocuColor 12/DCCS50
Figure 6 - 7.2.6 ROS/Half Tone PWB

Reissue
DocuColor 12/DCCS50
1/05
7-15
Wiring Data
Figure 7 - 7.2.7 VSEL Base TTL PWB (AP)

Wiring Data
1/05
7-16
Reissue
DocuColor 12/DCCS50
Figure 8 - 7.2.8 IBT

Reissue
DocuColor 12/DCCS50
1/05
7-17
Wiring Data
Figure 9 - 7.2.9 Drawer

Wiring Data
1/05
7-18
Reissue
DocuColor 12/DCCS50
Figure 10 - 7.2.10 Registration

Reissue
DocuColor 12/DCCS50
1/05
7-19
Wiring Data
Figure 11 - 7.2.11 2nd BTR
Wiring Data
1/05
7-20
Reissue
DocuColor 12/DCCS50
Figure 12 - 7.2.12 Fuser Unit (Front)

Reissue
DocuColor 12/DCCS50
1/05
7-21
Wiring Data
Figure 13 - 7.2.13 Fuser Unit (Rear)

Wiring Data
1/05
7-22
Reissue
DocuColor 12/DCCS50
Figure 14 - 7.2.14 Tray 1-4 Sensor

Reissue
DocuColor 12/DCCS50
1/05
7-23
Wiring Data
Figure 15 - 7.2.15 Tray Feeder

Wiring Data
1/05
7-24
Reissue
DocuColor 12/DCCS50
Figure 16 - 7.2.16 Inverter Unit

Reissue
DocuColor 12/DCCS50
1/05
7-25
Wiring Data
Figure 17 - 7.2.17 Tray 5

Wiring Data
1/05
7-26
Reissue
DocuColor 12/DCCS50
Figure 18 - 7.2.18 Main Switch/Deve.Bias HVPS/CC/PDD HVPS

Reissue
DocuColor 12/DCCS50
1/05
7-27
Wiring Data
Figure 19 - 7.2.19 IOT Driver PWB/IOT CPU PWB

Wiring Data
1/05
7-28
Reissue
DocuColor 12/DCCS50
Figure 20 - 7.2.20 Rear Upper

Reissue
DocuColor 12/DCCS50
1/05
7-29
Wiring Data
Figure 21 - 7.2.21 AC Drive PWB/Tray PWB/SSR

Wiring Data
1/05
7-30
Reissue
DocuColor 12/DCCS50
Figure 22 - 7.2.22 Distribution PWB/IOT LVPS

Reissue
DocuColor 12/DCCS50
1/05
7-31
Wiring Data
Figure 23 - 7.2.23 Power Chassis

Wiring Data
1/05
7-32
Reissue
DocuColor 12/DCCS50
Figure 24 - 7.2.24 Tray 2-4 Take Away Drive/Transformer

Reissue
DocuColor 12/DCCS50
1/05
7-33
Wiring Data
Figure 25 - 7.2.25 B3H LVPS/SSR/Transformer (AP)

Wiring Data
1/05
7-34
Reissue
DocuColor 12/DCCS50
Figure 26 - 7.2.26 DADF-1

Reissue
DocuColor 12/DCCS50
1/05
7-35
Wiring Data
Figure 27 - 7.2.27 DADF-2

Wiring Data
1/05
7-36
Reissue
DocuColor 12/DCCS50
Figure 28 - 7.2.28 Mail Box Sorter

Reissue
DocuColor 12/DCCS50
1/05
7-37
Wiring Data
Figure 29 - 7.2.29 Decurler

Wiring Data
1/05
7-38
Reissue
DocuColor 12/DCCS50
Figure 30 - 7.2.30 Tag P 31 Components

Reissue
DocuColor 12/DCCS50
1/05
7-39
Wiring Data
Wiring Data
1/05
7-40
Reissue
DocuColor 12/DCCS50
AC Power Wirenets
Figure 1 Wirenet AC Power (Neutral)

Reissue
DocuColor 12/DCCS50
1/05
7-41
Wiring Data
AC Power Wirenets
Figure 2 Wirenet AC Power (HOT)
18VAC Wirenet
Wiring Data
AC Power Wirenets , 18VAC Wirenet
1/05
7-42
Reissue
DocuColor 12/DCCS50
Figure 1 Wirenet AC 18V
Reissue
DocuColor 12/DCCS50
1/05
7-43
Wiring Data
18VAC Wirenet
3.3VDC/3.3V RET/3.5VDC/3.5V RET Wirenets
Figure 1 Wirenet 3.3VDC

Wiring Data
1/05
7-44
Reissue
DocuColor 12/DCCS50
Figure 2 Wirenet DC COM (3.3V RET)
Reissue
DocuColor 12/DCCS50
1/05
7-45
Wiring Data
Wiring Data
1/05
7-46
Reissue
DocuColor 12/DCCS50
Figure 4 Wirenet DC COM (3.5V RET)
Reissue
DocuColor 12/DCCS50
1/05
7-47
Wiring Data
+5VDC Wirenets
Figure 1 Wirenet +5VDC-1

Wiring Data
+5VDC Wirenets
1/05
7-48
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-49
Wiring Data
+5VDC Wirenets
Figure 3 Wirenet +5VDC-2 (cont)
Wiring Data
+5VDC Wirenets
1/05
7-50
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-51
Wiring Data
+5VDC Wirenets
Figure 5 Wirenet +5VDC-3 (cont)
Wiring Data
+5VDC Wirenets
1/05
7-52
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-53
Wiring Data
+5VDC Wirenets
Wiring Data
+5VDC Wirenets
1/05
7-54
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-55
Wiring Data
+5VDC Wirenets
Wiring Data
+5VDC Wirenets
1/05
7-56
Reissue
DocuColor 12/DCCS50
DC COM (+5V RET) Wirenets
Figure 1 Wirenet DC COM (+5V RET) -1

Reissue
DocuColor 12/DCCS50
1/05
7-57
Wiring Data
Wiring Data
1/05
7-58
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-59
Wiring Data
Wiring Data
1/05
7-60
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-61
Wiring Data
Wiring Data
1/05
7-62
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-63
Wiring Data
Wiring Data
1/05
7-64
Reissue
DocuColor 12/DCCS50
+12/-12VDC Wirenet
Figure 1 Wirenet +12/-12VDC

Reissue
DocuColor 12/DCCS50
1/05
7-65
Wiring Data
+12/-12VDC Wirenet
DC COM (+12/-12V RET) Wirenet
Figure 1 Wirenet DC COM (+12/-12V RET)

Wiring Data
DC COM (+12/-12V RET) Wirenet
1/05
7-66
Reissue
DocuColor 12/DCCS50
13.3VDC Wirenet

Reissue
DocuColor 12/DCCS50
1/05
7-67
Wiring Data
13.3VDC Wirenet
DC COM (13.V RET) Wirenet
Figure 1 Wirenet DC COM (13.V RET)

Wiring Data
DC COM (13.V RET) Wirenet
1/05
7-68
Reissue
DocuColor 12/DCCS50
+24VDC Wirenets

Reissue
DocuColor 12/DCCS50
1/05
7-69
Wiring Data
+24VDC Wirenets
Wiring Data
+24VDC Wirenets
1/05
7-70
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-71
Wiring Data
+24VDC Wirenets
Wiring Data
+24VDC Wirenets
1/05
7-72
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-73
Wiring Data
+24VDC Wirenets
Wiring Data
+24VDC Wirenets
1/05
7-74
Reissue
DocuColor 12/DCCS50
Figure 7 IIT/IPS LVPS Wirenet +24VDC-7
Reissue
DocuColor 12/DCCS50
1/05
7-75
Wiring Data
+24VDC Wirenets
DC COM (24V RET) Wirenets
Figure 1 Wirenet DC COM (24V RET) -1

Wiring Data
1/05
7-76
Reissue
DocuColor 12/DCCS50
Reissue
DocuColor 12/DCCS50
1/05
7-77
Wiring Data
Wiring Data
1/05
7-78
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-79
Wiring Data
Wiring Data
1/05
7-80
Reissue
DocuColor 12/DCCS50
BSDs
Purpose
The Block Schematic Diagrams (BSDs), show the distribution of electrical and mechanical
power.
Each functional chain is represented by a BSD. A BSD is a functional flow diagram containing
electrical circuit information and mechanical inputs and outputs. The functional flow is from left
to right (inputs on the left, outputs on the right).
Reissue
DocuColor 12/DCCS50
1/05
7-81
Wiring Data
BSDs
Wiring Data
BSDs
1/05
7-82
Reissue
DocuColor 12/DCCS50
Chain 01
Figure 1 BSD 1.1 Main Power On (1 of 2)
Reissue
DocuColor 12/DCCS50
1/05
7-83
Wiring Data
Chain 01
Figure 2 BSD 1.1 Main Power On (2 of 2)

Wiring Data
Chain 01
1/05
7-84
Reissue
DocuColor 12/DCCS50
Figure 3 BSD 1.2 DC Power Generation (IOT LVPS) (1 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-85
Wiring Data
Chain 01
Figure 4 BSD 1.2 DC Power Generation (IOT LVPS) (2 of 2)

Wiring Data
Chain 01
1/05
7-86
Reissue
DocuColor 12/DCCS50
Figure 5 BSD 1.3 DC Power Generation (IIT LVPS) (1 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-87
Wiring Data
Chain 01
Figure 6 BSD 1.3 DC Power Generation (IIT LVPS) (2 of 2)

Wiring Data
Chain 01
1/05
7-88
Reissue
DocuColor 12/DCCS50
Figure 7 BSD 1.4 Power Interlock Switching

Reissue
DocuColor 12/DCCS50
1/05
7-89
Wiring Data
Chain 01
Figure 8 BSD 1.5 Monitoring

Wiring Data
Chain 01
1/05
7-90
Reissue
DocuColor 12/DCCS50
Chain 02
Figure 1 BSD 2.1 Control Panel Switches and LEDs (1 of 2)
Reissue
DocuColor 12/DCCS50
1/05
7-91
Wiring Data
Chain 02
Figure 2 BSD 2.1 Control Panel Switches and LEDs (2 of 2)

Wiring Data
Chain 02
1/05
7-92
Reissue
DocuColor 12/DCCS50
Figure 3 BSD 2.2 UI Display

Reissue
DocuColor 12/DCCS50
1/05
7-93
Wiring Data
Chain 02
Figure 4 BSD 2.3 Power Save Switch and LED

Wiring Data
Chain 02
1/05
7-94
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-95
Wiring Data
Chain 02
Wiring Data
Chain 02
1/05
7-96
Reissue
DocuColor 12/DCCS50
Chain 03
Figure 1 BSD 3.1 PWB Communications (UI)

Reissue
DocuColor 12/DCCS50
1/05
7-97
Wiring Data
Chain 03
Figure 2 BSD 3.2 PWB Communications (IPS) (1 of 2)

Wiring Data
Chain 03
1/05
7-98
Reissue
DocuColor 12/DCCS50
Figure 3 BSD 3.2 PWB Communications (IPS) (2 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-99
Wiring Data
Chain 03
Figure 4 BSD 3.3 PWB Communications (DADF)

Wiring Data
Chain 03
1/05
7-100
Reissue
DocuColor 12/DCCS50
Figure 5 BSD 3.4 PWB Communications (Mailbox)

Reissue
DocuColor 12/DCCS50
1/05
7-101
Wiring Data
Chain 03
Figure 6 BSD 3.5 PWB Communications (PWS)

Wiring Data
Chain 03
1/05
7-102
Reissue
DocuColor 12/DCCS50
Figure 7 BSD 3.6 Foreign Interface

Reissue
DocuColor 12/DCCS50
1/05
7-103
Wiring Data
Chain 03
Figure 8
Wiring Data
Chain 03
BSD 3.12 Monitoring (1 of 2)
1/05
7-104
Reissue
DocuColor 12/DCCS50
Figure 9 BSD 3.12 Monitoring (2 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-105
Wiring Data
Chain 03
Wiring Data
Chain 03
1/05
7-106
Reissue
DocuColor 12/DCCS50
Chain 04
Figure 1 BSD 4.1 Main and Drum Drive Control (1 of 2)

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DocuColor 12/DCCS50
1/05
7-107
Wiring Data
Chain 04
Figure 2 BSD 4.2 Main and Drum Drive Control (2 of 2)

Wiring Data
Chain 04
1/05
7-108
Reissue
DocuColor 12/DCCS50
Chain 05
Figure 1 BSD 5.1 Interlock Switching

Reissue
DocuColor 12/DCCS50
1/05
7-109
Wiring Data
Chain 05
Figure 2 BSD 5.2 Document Setting and Feeding

Wiring Data
Chain 05
1/05
7-110
Reissue
DocuColor 12/DCCS50
Figure 3 BSD 5.3 Document Transportation (1 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-111
Wiring Data
Chain 05
Figure 4 BSD 5.3 Document Transportation (2 of 2)

Wiring Data
Chain 05
1/05
7-112
Reissue
DocuColor 12/DCCS50
Figure 5 BSD 5.4 Document Transport Mechanism

Reissue
DocuColor 12/DCCS50
1/05
7-113
Wiring Data
Chain 05
Figure 6 BSD 5.5 Document Exit Transportation

Wiring Data
Chain 05
1/05
7-114
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-115
Wiring Data
Chain 05
Wiring Data
Chain 05
1/05
7-116
Reissue
DocuColor 12/DCCS50
Chain 06
Figure 1 BSD 6.1 Document Illumination

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DocuColor 12/DCCS50
1/05
7-117
Wiring Data
Chain 06
Figure 2 BSD 6.2 Image Input
Wiring Data
Chain 06
1/05
7-118
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DocuColor 12/DCCS50
Figure 3 BSD 6.3 Carriage Control

Reissue
DocuColor 12/DCCS50
1/05
7-119
Wiring Data
Chain 06
Figure 4 BSD 6.4 Video Data and Signal Control

Wiring Data
Chain 06
1/05
7-120
Reissue
DocuColor 12/DCCS50
Figure 5 BSD 6.5 Laser Control

Reissue
DocuColor 12/DCCS50
1/05
7-121
Wiring Data
Chain 06
Figure 6 BSD 6.6 Laser Scanning

Wiring Data
Chain 06
1/05
7-122
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-123
Wiring Data
Chain 06

Wiring Data
Chain 06
1/05
7-124
Reissue
DocuColor 12/DCCS50
Chain 07
Figure 1 BSD 7.1 Tray 2 Paper Size Sensing

Reissue
DocuColor 12/DCCS50
1/05
7-125
Wiring Data
Chain 07

Wiring Data
Chain 07
1/05
7-126
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-127
Wiring Data
Chain 07

Wiring Data
Chain 07
1/05
7-128
Reissue
DocuColor 12/DCCS50
Figure 5 Tray 1 BSD 7.5 Paper Stacking (1 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-129
Wiring Data
Chain 07
Figure 6 Tray 1 BSD 7.5 Paper Stacking (2 of 2)

Wiring Data
Chain 07
1/05
7-130
Reissue
DocuColor 12/DCCS50
Figure 7 BSD 7.6 Tray 2 Paper Stacking (1 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-131
Wiring Data
Chain 07

Wiring Data
Chain 07
1/05
7-132
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-133
Wiring Data
Chain 07

Wiring Data
Chain 07
1/05
7-134
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-135
Wiring Data
Chain 07

Wiring Data
Chain 07
1/05
7-136
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-137
Wiring Data
Chain 07

Wiring Data
Chain 07
1/05
7-138
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-139
Wiring Data
Chain 07

Wiring Data
Chain 07
1/05
7-140
Reissue
DocuColor 12/DCCS50
Chain 08
Figure 1 BSD 8.1 Tray 1 Paper Feed
Reissue
DocuColor 12/DCCS50
1/05
7-141
Wiring Data
Chain 08

Wiring Data
Chain 08
1/05
7-142
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-143
Wiring Data
Chain 08

Wiring Data
Chain 08
1/05
7-144
Reissue
DocuColor 12/DCCS50

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DocuColor 12/DCCS50
1/05
7-145
Wiring Data
Chain 08
Figure 6 BSD 8.6 Vertical Transportation

Wiring Data
Chain 08
1/05
7-146
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DocuColor 12/DCCS50
Figure 7 BSD 8.7 Vertical Transport Control

Reissue
DocuColor 12/DCCS50
1/05
7-147
Wiring Data
Chain 08
Figure 8 BSD 8.8 Registration (1 of 2)

Wiring Data
Chain 08
1/05
7-148
Reissue
DocuColor 12/DCCS50
Figure 9 BSD 8.8 Registration (2 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-149
Wiring Data
Chain 08
Figure 10 BSD 8.9 Registration Control Mechanism (1 of 2)

Wiring Data
Chain 08
1/05
7-150
Reissue
DocuColor 12/DCCS50
Figure 11 BSD 8.9 Registration Control Mechanism (2 of 2)

Reissue
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1/05
7-151
Wiring Data
Chain 08

Wiring Data
Chain 08
1/05
7-152
Reissue
DocuColor 12/DCCS50

Reissue
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1/05
7-153
Wiring Data
Chain 08
Figure 14 Monitoring (3 of 3)
Wiring Data
Chain 08
1/05
7-154
Reissue
DocuColor 12/DCCS50
Chain 09
Figure 1 BSD 9.1 Charging and Exposure (1 of 2)

Reissue
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1/05
7-155
Wiring Data
Chain 09
Figure 2 BSD 9.1 Charging and Exposure (2 of 2)

Wiring Data
Chain 09
1/05
7-156
Reissue
DocuColor 12/DCCS50
Figure 3 BSD 9.2 Developer Rotor Drive Control (1 of 2)

Reissue
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1/05
7-157
Wiring Data
Chain 09
Figure 4 BSD 9.2 Developer Rotor Drive Control (2 of 2)

Wiring Data
Chain 09
1/05
7-158
Reissue
DocuColor 12/DCCS50
Figure 5 BSD 9.3 Development

Reissue
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1/05
7-159
Wiring Data
Chain 09
Figure 6 BSD 9.4 Toner Loading (Black/Yellow) (1 of 2)

Wiring Data
Chain 09
1/05
7-160
Reissue
DocuColor 12/DCCS50
Figure 7 BSD 9.4 Toner Loading (Black/Yellow) (2 of 2)

Reissue
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1/05
7-161
Wiring Data
Chain 09
Figure 8 BSD 9.5 Toner Loading (Magenta/Cyan) (1 of 2)

Wiring Data
Chain 09
1/05
7-162
Reissue
DocuColor 12/DCCS50
Figure 9 BSD 9.5 Toner Loading (Magenta/Cyan) (2 of 2)

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1/05
7-163
Wiring Data
Chain 09
Figure 10 BSD 9.6 Toner Dispense Control

Wiring Data
Chain 09
1/05
7-164
Reissue
DocuColor 12/DCCS50
Figure 11 BSD 9.7 Toner Dispense Mechanism

Reissue
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1/05
7-165
Wiring Data
Chain 09
Figure 12 BSD 9.8 IBT Belt Drive and 1st Transfer (1 of 2)

Wiring Data
Chain 09
1/05
7-166
Reissue
DocuColor 12/DCCS50
Figure 13 BSD 9.8 IBT Belt Drive and 1st Transfer (2 of 2)

Reissue
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1/05
7-167
Wiring Data
Chain 09
Figure 14 BSD 9.9 2nd Transfer and IBT Cleaning (1 of 2)

Wiring Data
Chain 09
1/05
7-168
Reissue
DocuColor 12/DCCS50
Figure 15 BSD 9.9 2nd Transfer and IBT Cleaning (2 of 2)

Reissue
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1/05
7-169
Wiring Data
Chain 09
Figure 16 BSD 9.10 2nd BTR Contact/Retract Switching

Wiring Data
Chain 09
1/05
7-170
Reissue
DocuColor 12/DCCS50
Figure 17 BSD 9.11 2nd Belt Cleaner Contact/Retract Switching

Reissue
DocuColor 12/DCCS50
1/05
7-171
Wiring Data
Chain 09
Figure 18 BSD 9.12 Oil Winding

Wiring Data
Chain 09
1/05
7-172
Reissue
DocuColor 12/DCCS50
Figure 19 BSD 9.13 Drum Cleaning and Toner Reclaim (1 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-173
Wiring Data
Chain 09
Figure 20 BSD 9.13 Drum Cleaning and Toner Reclaim (2 of 2)

Wiring Data
Chain 09
1/05
7-174
Reissue
DocuColor 12/DCCS50
Figure 21 BSD 9.14 Fan Control (1 of 2)

Reissue
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1/05
7-175
Wiring Data
Chain 09
Figure 22 BSD 9.14 Fan Control (2 of 2)

Wiring Data
Chain 09
1/05
7-176
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-177
Wiring Data
Chain 09

Wiring Data
Chain 09
1/05
7-178
Reissue
DocuColor 12/DCCS50
Chain 10
Figure 1 BSD 10.1 Pre-Fusing and Fuser Air Control (1 of 2)

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1/05
7-179
Wiring Data
Chain 10
Figure 2 BSD 10.1 Pre-Fusing and Fuser Air Control (2 of 2)

Wiring Data
Chain 10
1/05
7-180
Reissue
DocuColor 12/DCCS50
Figure 3 BSD 10.2 Fusing Heat Control (1 of 2 w/o Tag P31)

Reissue
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1/05
7-181
Wiring Data
Chain 10
Figure 4 BSD 10.2 Fusing Heat Control (1 of 2 with Tag P31)

Wiring Data
Chain 10
1/05
7-182
Reissue
DocuColor 12/DCCS50
Figure 5 BSD 10.2 Fusing Heat Control (2 of 2)

Reissue
DocuColor 12/DCCS50
1/05
7-183
Wiring Data
Chain 10
Figure 6 BSD 10.3 External Heat Control

Wiring Data
Chain 10
1/05
7-184
Reissue
DocuColor 12/DCCS50
Figure 7 BSD 10.4 Fuser Drive Control

Reissue
DocuColor 12/DCCS50
1/05
7-185
Wiring Data
Chain 10
Figure 8 BSD 10.5 Fuser Oil Dispense and Web Winding Mechanism (1 of 2)
Wiring Data
Chain 10
1/05
7-186
Reissue
DocuColor 12/DCCS50
Figure 9 BSD 10.5 Fuser Oil Dispense and Web Winding Mechanism (2 of 2)
Reissue
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1/05
7-187
Wiring Data
Chain 10
Figure 10 BSD 10.6 External Heat Roll and Pressure Roll Nip Control
Wiring Data
Chain 10
1/05
7-188
Reissue
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Figure 11 BSD 10.7 Fuser Exit Transportation

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1/05
7-189
Wiring Data
Chain 10
Figure 12 BSD 10.8 Inverter Transportation

Wiring Data
Chain 10
1/05
7-190
Reissue
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Figure 13 BSD 10.9 Exit and Inverter Motor Drive

Reissue
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1/05
7-191
Wiring Data
Chain 10
Figure 14 BSD 10.10 Duplex Transportation

Wiring Data
Chain 10
1/05
7-192
Reissue
DocuColor 12/DCCS50
Figure 15 BSD 10.11 OCT Control

Reissue
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1/05
7-193
Wiring Data
Chain 10

Wiring Data
Chain 10
1/05
7-194
Reissue
DocuColor 12/DCCS50

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1/05
7-195
Wiring Data
Chain 10

Wiring Data
Chain 10
1/05
7-196
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-197
Wiring Data
Chain 10
Wiring Data
Chain 10
1/05
7-198
Reissue
DocuColor 12/DCCS50
Chain 11
Figure 1 BSD 11.1 Mail Box DC Power & Interlock Switching (1 of 2)

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1/05
7-199
Wiring Data
Chain 11
Figure 2 BSD 11.1 Mail Box DC Power & Interlock Switching (2 of 2)

Wiring Data
Chain 11
1/05
7-200
Reissue
DocuColor 12/DCCS50
Figure 3 BSD 11.2 Mail Box Drives (1 of 2)

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1/05
7-201
Wiring Data
Chain 11
Figure 4 BSD 11.2 Mail Box Drives (2 of 2)

Wiring Data
Chain 11
1/05
7-202
Reissue
DocuColor 12/DCCS50
Figure 5 BSD 11.3 Decurler Control

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1/05
7-203
Wiring Data
Chain 11
Figure 6 BSD 11.4 Mail Box Transportation

Wiring Data
Chain 11
1/05
7-204
Reissue
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Figure 7 BSD 11.5 Bin Tray Transportation

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1/05
7-205
Wiring Data
Chain 11
Figure 8 BSD 11.6 Bin Full Sensors

Wiring Data
Chain 11
1/05
7-206
Reissue
DocuColor 12/DCCS50
Figure 9 BSD 11.7 Mail Box OCT Control

Reissue
DocuColor 12/DCCS50
1/05
7-207
Wiring Data
Chain 11

Wiring Data
Chain 11
1/05
7-208
Reissue
DocuColor 12/DCCS50

Reissue
DocuColor 12/DCCS50
1/05
7-209
Wiring Data
Chain 11

Wiring Data
Chain 11
1/05
7-210
Reissue
DocuColor 12/DCCS50
Chain 16
Figure 1 BSD 16.1 Integrated Digital Front End

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1/05
7-211
Wiring Data
Chain 16
Wiring Data
Chain 16
1/05
7-212
Reissue
DocuColor 12/DCCS50
8A HCF
PL 15.10 Paper Feeder Assembly: Part 1 OF 6..............................................................

PL 15.16 Elevator Motor and Feed Motor .......................................................................
HCF Paper Faults

07-280 HCF Communication Fault RAP ........................................................................
07-289 HCF Broken Failure RAP ...................................................................................
07-308 Interlock Switch Open RAP ................................................................................
OF7-001 HCF Out of Paper RAP....................................................................................
8a-3
8a-3
8a-4
8a-5
HCF Handling Faults

08-190 HCF Take Away Roll Sensor On Jam RAP .......................................................
8-193 HCF (Tray 6) Pre Registration Sensor On Jam ....................................................
8-194 HCF (Tray 6) Registration Sensor On Jam ...........................................................
OF8-001 HCF Does not feed - No Fault Code RAP .......................................................
8a-7
8a-8
8a-9
8a-10
8a-10
8a-11
Plug/Jacks
Plug/Jack Index ...............................................................................................................
Plug/Jack Locator Diagram .............................................................................................
8a-45
8a-45
8a-46
Block Schematic Diagrams (BSDs)

HCF BSDs.......................................................................................................................
HCF Paper Supply

8-501 HCF Paper Size Mismatch RAP .........................................................................
8a-36
8a-37
8a-38
8a-39
8a-40
8a-41
8a-42
8a-43
8a-47
8a-13
Repairs
7. HCF
REP 2.7.5 HCF Assembly...............................................................................................
REP 2.7.6 HCF Elevator Motor .......................................................................................
REP 2.7.7 HCF Elevator Long/Short Cables ..................................................................
REP 2.7.8 HCF Brake .....................................................................................................
REP 2.7.9 HCF Control PWB..........................................................................................
8a-15
8a-16
8a-17
8a-19
8a-20
8. HCF
REP 2.8.26 HCF Feed Motor ..........................................................................................
REP 2.8.27 HCF Feeder Assembly ................................................................................
REP 2.8.35 HCF Front/Rear Spring................................................................................
REP 2.8.36 HCF Baffle Assembly...................................................................................
REP 2.8.37 HCF Feed Belt .............................................................................................
REP 2.8.38 HCF Feed/Nudger/Retard Rolls...................................................................
REP 2.8.39 HCF One-Way Feed/Gear Clutch ................................................................
REP 2.8.40 HCF Friction Clutch .....................................................................................
REP 2.8.41 HCF Feed Clutch .........................................................................................
REP 2.8.42 HCF TAR Sensor .........................................................................................
REP 2.8.43 HCF Tray Empty/Stack Height Sensors ......................................................
8a-21
8a-21
8a-22
8a-23
8a-24
8a-24
8a-25
8a-25
8a-26
8a-26
8a-27
Adjustments
ADJ 2.1 HCF Registration...............................................................................................
8a-29
Parts Lists
HIGH CAPACITY FEEDER
PL 15.1 Elevator Assembly: Part 1 OF 3 ........................................................................
Reissue
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8a-33
8a-34
8a-35
1/05
8a-1
1/05
8a-2
Reissue
DocuColor 12/DCCS50
07-280 HCF Communication Fault RAP
07-289 HCF Broken Failure RAP
Fault Code 07-280 indicate that an HCF communication fault has occurred.
The HCF Stack Height Sensor failed to change state within the specified time after the HCF
Tray started to lift.
Procedure
NOTE: Prior to switching off the machine, ensure all pending jobs are saved.
Go to Flag 1 on BSD 8.13. Check the wires for an open circuit or a short circuit to ground. If the
wires are good, replace the HCF Control PWB (PL 15.16). If the problem continues, replace
the IOT CPU PWB (PL 9.2).
Initial Actions
Ensure connector P/J841 on the HCF Control PWB is seated properly.
Refer to BSD 7.11 and 7.12 in the following procedure.
Procedure
Enter dC330, 007-186 HCF Stack Height Sensor and press Start. Pull the HCF Tray out.
The display changed from L to H.
Y
N
Check for +5VDC between pins 1 and 3 of P/J841 on the HCF Control PWB. +5VDC is
measured between pins 1 and 3 of P/J841.
Y
N
Check for +5VDC between pins 3 and 4 of J2 HCF Control PWB. +5VDC is measured between pins 3 and 4 of J2.
Y
N
Check for +5VDC between pins 20 and 9 of P/J44 Distribution PWB. +5VDC is
measured between pins 20 and 9 ofP/J44.
Y
N
Go to Wirenet +5 VDC-1 Figure 7.
Go to Flag 3 on BSD 8.13. Check the connector and wiring for an open circuit.
Replace the HCF Control PWB (PL 15.16).
Go to Flag 2 and Flag 4 on BSD 7.11. Check the connectors and wiring for an open circuit. If the connectors and wiring are OK, then replace the Stack Height Sensor (PL
15.12).
Enter dC330, 007-079 HCF Elevator Motor and press Start.
CAUTION
lower the paper from the feed position, pull out respective tray. If the tray is overdriven it will be
Ensure that the Elevator Motor energizes. The Elevator Motor energizes and then deenergizes within 30 seconds.
Y
N
Check for +24VDC between pins 2 and 1 of P/J845 HCF Control PWB. +24VDC is measured between pins 1 and 2 of P/J845 on the HCF Control PWB (This measurement
must be taken within 30 seconds after closing the tray.)
Y
N
Check for +24VDC between pins 1 and 2 of J2HCF Control PWB. +24VDC is measured between pins 1 and 2 of J2 on the HCF Control PWB.
A
Reissue
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8a-3
B
07-280 HCF Communication Fault RAP , 07-289
B
Y
07-308 Interlock Switch Open RAP
N
Check for +24VDC between pins 13 and 17 of P/J45 on the Distribution PWB.
+24VDC is measured between pins 13 and 17 of P/J45 on the Distribution
PWB.
Y
N
HCF Interlock is open.
Initial Actions
Ensure that the HCF is properly aligned and pushed tightly against the IOT.
Go to Flag 2 on BSD 8.13. Check the connectors and wiring.
Procedure
Go to Flag 1 on BSD 7.12. Check the connectors and wiring. If the connectors and wiring
are OK, then replace the HCF Elevator Motor Assembly (PL 15.16)
Enter dC330, 007-308 HCF Interlock Switch and press Start.

Move the HCF away from the machine. The displays changes.
Y
N
Check for +5VDC between pins NO and C of P/J-847 on the HCF Interlock Switch.
+5VDC is measured between pins NO and C of P/J-847on the HCF Interlock Switch.
Y
N
Check for +5VDC between pins 1 and 2 of P/J843 on the HCF Control PWB.
+5VDC is measured between pins 1 and 2 of P/J843.
Y
N
Check for +5VDC between pins 3 and 4 of J2 HCF Control PWB. +5VDC
is
measured between pins 3 and 4 of J2.
Y
N
Check for +5VDC between pins 20 and 9 of P/J44 Distribution PWB.
+5VDC is measured between pins 20 and 9 of P/J44.
Y
N
parts that are worn, broken, binding, or slipping:
Elevator Motor (PL 15.16)
HCF Stack Height Sensor (PL 15.12)
HCF Feeder Assembly (PL 15.10)
HCF Assembly (PL 15.1)
Wiring Harness
Go to Flag 3 on BSD8.13 and check the connector and wiring for an open
circuit.
Go to Flag 2 on BSD7.12 and check the connector and wiring for an open circuit.
Replace the HCF Interlock Switch (PL 15.1).
Ensure that there are no obstacles in the docking area of HCF or the machine.
07-289 HCF Broken Failure RAP , 07-308 Interlock
1/05
8a-4
Reissue
DocuColor 12/DCCS50
OF7-001 HCF Out of Paper RAP
The HCF Stack Height Sensor failed to change state within the specified time after the HCF
Tray started to lift.
NOTE: Prior to switching off the machine, ensure all pending jobs are saved.
Initial Actions
Ensure connector P/J841 on the HCF Control PWB is seated properly.
N
PWB.
Y
N

Go to Flag 1 on BSD 7.12. Check the connectors and wiring. If the connectors and wiring
are OK, then replace the HCF Elevator Motor Assembly PL 15.16.
Procedure
Enter dC330, 007-186 HCF Stack Height Sensor and press Start. Pull the HCF Tray out.
The display changed from L to H.
Y
N
Check for +5VDC between pins 1 and 3 of P/J841 on the HCF Control PWB. +5VDC is
Y
N
Check for +5VDC between pins 3 and 4 of J2 HCF Control PWB. +5VDC is measured between pins 3 and 4 of J2.
Y
N
Check for +5VDC between pins 20 and 9 of P/J44 Distribution PWB. +5VDC is
Y
N
Go to Wirenet +5 VDC-1 Figure7.
parts that are worn, broken, binding, or slipping:
Elevator Motor (PL 15.16)
HCF Stack Height Sensor (PL 15.12)
HCF Feeder Assembly (PL 15.10)
HCF Assembly (PL 15.1)
Wiring Harness
Go to Flag 3 and check the connector and wiring for an open circuit.
Go to Flag 2 and Flag 4 on BSD 7.11. Check the connectors and wiring. If the connectors
and wiring are OK, then replace the Stack Height Sensor (PL 15.12).
Enter dC330, 007-079 HCF Elevator Motor and press Start.
CAUTION
lower the paper from the feed position, pull out respective tray. If the tray is overdriven it will be
Ensure that the Elevator Motor energizes. The Elevator Motor energizes and then deenergizes within 30 seconds.
Y
N
Check for +24VDC between pins 2 and 1 of P/J845 HCF Control PWB. +24VDC is measured between pins 1 and 2 of P/J845 on the HCF Control PWB (This measurement
must be taken within 30 seconds after closing the tray.)
Y
N
Check for +24VDC between pins 1 and 2 of J2 HCF Control PWB. +24VDC
is
measured between pins 1 and 2 of J2 on the HCF Control PWB.
A
B
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8a-5
1/05
8a-6
Reissue
DocuColor 12/DCCS50
08-190 HCF Take Away Roll Sensor On Jam RAP
If the connectors and wiring are OK, then replace the HCF Feed Motor (PL 15.16).
The control logic detected that paper from the HCF was late to the HCF TAR sensor.
Enter dC330, 007-078 HCF Feed Clutch and press Start.

Check that the HCF Feed Clutch energizes. The HCF Feed Clutch energizes.
Y
N
Check for +24VDC at pins 1 and 3 of J-851 on the HCF Feed Clutch. 24VDC is measured at pins 1 and 3 of J-851 on the HCF Feed Clutch.
Y
N
+24VDC is measured between pins 11 and 10 of P/J841 on the HCF Control
PWB.
Y
N
Initial Actions
Check for obstructions in the paper path
Check to ensure that the Feed Belt is not overtensioned
Check for contamination on the HCF TAR Sensor lens
Ensure that connector P/J405 on the IOT CPU PWB is seated correctly
Procedure
Enter dC330, 007-100 HCF TAR Sensor and press Start.
Block the HCF TAR Sensor with paper. The Display changes from H to L.
Y
N
Y
N
good, replace the TAR Sensor (PL 15.11).
Go to Flag 2 on BSD 8.12. Check the connectors and wiring. repair or replace as
required (PL 15.11).
If the connectors and wiring are OK, then replace the HCF Feed Clutch (PL 15.13).
Check /replace the following components until the problem is resolved. Replace any components that are worn, broken, binding, loose or slipping.
Connect the meter from P/J841-5 on the HCF Control PWB to machine frame. Block the
TAR Sensor with a sheet of paper. The voltage at P/J841-5 goes from +5 VDC when
the sensor is unblocked, to less than +1.0 VDC when the sensor is blocked.
Y
N
There is +5 VDC between P/J841-4 and P/J841-6 on the HCF Control PWB.
Y
N
Go to Flag 3 on BSD 8.12 and check the harness for a short circuit. If the harness is good, replace the HCF Control PWB (PL 15.16.)
the harness is OK, replace the HCF TAR Sensor (PL 15.11). If the problem continues, replace the HCF Control PWB (PL 15.16).
Drive Roll (PL 15.12)
Feeder Housing (PL 15.14)
Feed/Nudger Roller (PL 15.14)
One Way Clutch (PL 15.14)
Gear Clutch (PL 15.14)
Paper Feeder Harness (PL 15.11)
HCF Mounting Bracket
Replace the HCF Control PWB (PL 15.16.)

Enter dC330, 007-080 HCF Feed Motor and press Start.
Check that the HCF Feed Motor energizes. The HCF Feed Motor energizes.
Y
N
Check for +24VDC between pins 1 and 2 of J2 on the HCF Control PWB. +24VDC
is
Y
N
PWB.
Y
N
Go to Wirenet +24 VDC-1 (Figure 29).
A
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8a-7
The control logic detected that paper from the HCF was late to the IOT Takeaway Sensor.

Y
N
Y
N
PWB.
Y
N
Initial Actions
Procedure
Cheat the L/H Cover Interlock Switch. Enter dC330 008-150 Take Away Sensor and press
Start. Block the Takeaway Sensor with a sheet of paper. The display changes from H to L.
Y
N
Y
N
Connect the meter from P/J420-B5 on the IOT Drive PWB to machine frame. Block the
Takeaway Sensor with a sheet of paper. The voltage at P/J420-B5 goes from +5 VDC
when the sensor is unblocked, to less than +1.0 VDC when the sensor is blocked.
Y
N
There is +5 VDC between P/J420-B6 and P/J420-B4 on the IOT Drive PWB.
Y
N
harness is OK, replace the Takeaway (D1-T/A) Sensor (PL 2.8). If the problem continues, replace the IOT Drive PWB (PL 9.2).

Y
N
is
Y
N
PWB.
Y
N
A
1/05
8a-8
Reissue
DocuColor 12/DCCS50
The control logic detected that paper from the HCF was late to the IOT Takeaway Sensor.

Y
N
Y
N
PWB.
Y
N
Initial Actions
Procedure
Cheat the L/H Cover Interlock Switch. Enter dC330 008-150 Take Away Sensor and press
Start. Block the Takeaway Sensor with a sheet of paper. The display changes from H to L.
Y
N
Y
N
Connect the meter from P/J420-B5 on the IOT Drive PWB to machine frame. Block the
Takeaway Sensor with a sheet of paper. The voltage at P/J420-B5 goes from +5 VDC
when the sensor is unblocked, to less than +1.0 VDC when the sensor is blocked.
Y
N
There is +5 VDC between P/J420-B6 and P/J420-B4 on the IOT Drive PWB.
Y
N
harness is OK, replace the Takeaway (D1-T/A) Sensor (PL 2.8). If the problem continues, replace the IOT Drive PWB (PL 9.2).

Y
N
is
Y
N
PWB.
Y
N
A
Reissue
DocuColor 12/DCCS50
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8a-9
8-193 HCF (Tray 6) Pre Registration Sensor On Jam
8-194 HCF (Tray 6) Registration Sensor On Jam
The Pre Registration Sensor did not actuate within the specified time after the feed started
from HCF (Tray 6).
The Registration Sensor did not actuate within 956 - 1056 msec after the feed started from
HCF (Tray 6).
Initial Actions
Initial Actions
Procedure
Procedure
Enter dC330 008-153 Pre Registration Sensor and press Start. The display is H.
Y
N
+5 VDC is measure between P/J419-13 on the IOT Drive and GND.
Y
N
Enter dC330 008-155 Registration Sensor and press Start. The display is H.
Y
N
+5 VDC is measure between P/J421-11 on the IOT Drive and GND.
Y
N
Y
N
There is +5 VDC between P/J419-14 and P/J419-12 on the IOT Drive PWB.
Y
N
Y
N
There is +5 VDC between P/J421-12 and P/J421-10 on the IOT Drive PWB.
Y
N
Y
N
Y
N
15.1)
Check for burrs on the Chute and Upper Chute in the Pre Registration Assembly (PL 15.2)
8-193 HCF (Tray 6) Pre Registration Sensor On Jam,
1/05
8a-10
Reissue
DocuColor 12/DCCS50
OF8-001 HCF Does not feed - No Fault Code RAP

The HCF will not feed paper and does not display a Fault Code.
Initial Actions
Ensure that the machine Software is at 6.00.2h or higher.
Check the following NVM locations: 761-070 = 608 and 761-071 = 601
Procedure
Go to 08-190 HCF Take Away Roll Sensor On Jam RAP .
Reissue
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8a-11
1/05
8a-12
Reissue
DocuColor 12/DCCS50
8-501 HCF Paper Size Mismatch RAP

An incorrect paper size was selected for HCF Tray.
Initial Actions
Ensure HCF Rear Paper Guide is installed correctly.
Ensure HCF Tray paper size selected matches the paper size loaded in HFC Tray.
Ensure that the HCF Paper Tray Size Switch is not obstructed.
Ensure HCF Tray paper size selected matches the Paper Guide size selection.
Ensure connector P/J405 on the IOT CPU PWB is seated properly.
Procedure
Set the HCF Rear Paper Guide to the A4 position. Enter dC330 007-187 HCF Paper Size
Switch and press Start.
Pull out the HCF Paper Tray. The Display changes.
Y
N
Check for +5VDC at pins NO and C of P/J-849 at the HCF Paper Size Switch, Tray In
Switch. +5VDC is measured at pins NO and C of P/J-849 at the HCF Paper Size
Switch.
Y
N
+5VDC is measured between pins 5 and 6 of P/J843 on the HCF Control PWB.
Y
N
Check for +5VDC between pins 3 and 4 of J2 on the HCF Control PWB.
+5VDC is measured between pins 3 and 4 of J2 on the HCF Control PWB
Y
N
Check for +5 VDC between pins 20 and 9 of P/J45 on the Distribution
PWB. +5 VDC is measured between pins 20 and 9 of P/J45 on the Distribution PWB.
Y
N
Go to Flag 3 on BSD 8.13 and check the wiring for an open circuit.
Go to Flag 3 on BSD 7.11 and check the wiring for an open circuit.
Replace the HCF Paper Size Switch (PL 15.16).
Remove the obstruction and check/replace the following parts until the problem is resolved.
Replace any parts that are worn, broken, binding, or slipping:
High Capacity Feeder Assembly (PL 15.1)
HCF Paper Size Switch (PL 15.16)
Wiring Harness.
Reissue
DocuColor 12/DCCS50
1/05
8a-13
1/05
8a-14
Reissue
DocuColor 12/DCCS50
REP 2.7.5 HCF Assembly

Removal
WARNING
Cord.
1.
Pull out the HCF Assembly (Figure 1).
Unscrew the knurled knob

Figure 2 Preparing to remove the HCF Assembly
CAUTION
Support the HCF Drawer on a ream of paper so as not to put undue stress on the Drawer
Cover.
3.
Remove the HCF Assembly (Figure 3).
Figure 1 Pull out the HCF Drawer

2.
Prepare to remove the HCF Assembly (Figure 2).
Remove the Assembly

Figure 3 Removing the HCF Assembly
Reissue
DocuColor 12/DCCS50
1/05
8a-15
REP 2.7.5
Replacement
REP 2.7.6 HCF Elevator Motor
1.

Removal
Reverse the above procedures to replace the HCF Assembly.
WARNING
Cord.
1.
Remove the HCF Rear Cover.
2.
Remove the HCF Assembly (REP 2.7.5).
3.
Remove the HCF Elevator Motor (Figure 1).

1. Disconnect P/J-845
3. Remove the
HCF Elevator
Motor
2. Remove the Screws (2) from

the Motor.
Figure 1 Removing the HCF Elevator Motor
Replacement
1.
REP 2.7.5, REP 2.7.6
1/05
8a-16
Reverse the above procedures to replace the Elevator Motor.
Reissue
DocuColor 12/DCCS50
REP 2.7.7 HCF Elevator Long/Short Cables

Removal
WARNING
3. Pull out the cables
Cord.
1.
2.
Remove the Front Cover to access the Long Cables only. (Figure 1).
2. Remove the cover
1. Remove the
Screws (4)
1. Remove the screw
2. Slide the Pulley

Figure 2 Removing the Cable from the Drive Shaft.
Figure 1 Removing the Front Cover
3.
4.
Remove the Cables from the Front Pulley's (Figure 3).
Remove the Cables (Figure 2).
Reissue
DocuColor 12/DCCS50
1/05
8a-17
REP 2.7.7
2. Remove the
Cables from
Pulleys
2. Remove the Cables

from the Pulleys
1. Lift the Elevator

Plates
1. Lift the Elevator Plates
Figure 3 Removing the Cables from the Front Pulleys.

5.
Remove the Cables from the Rear Pulleys (Figure 4).
Figure 4 Removing the Cables from the Rear Pulleys
Replacement
1.
REP 2.7.7
1/05
8a-18
Ensure that the Cables are positioned correctly (Figure 5).
Reissue
DocuColor 12/DCCS50
REP 2.7.8 HCF Brake

Removal
Cable guides
WARNING
Cord.
Short cable
1.
Pull open the HCF Drawer.
2.
Remove the HCF Brake (Figure 1).
Remove the screws (2) while

holding Brake
Long cable
Figure 5 Positioning the Cables in the correct position

2.
Figure 1 Removing the HCF Brake
Reconnect the Cable Ends to the Shaft refer to (Figure 2).
Replacement
NOTE: Position the Long Cable to the rear of the short cable on the two pulleys.
3.
1.
Reverse the above procedures to replace the HCF Brake.
Manually rotate the drive shaft to check that the elevator plate raises and lowers evenly
and without interference.
Reissue
DocuColor 12/DCCS50
1/05
8a-19
REP 2.7.7, REP 2.7.8
REP 2.7.9 HCF Control PWB

Removal
WARNING
Cord.
1.
Remove the HCF Rear Cover.
2.
Remove the Control PWB (Figure 1).
Disconnect the P/Js

and remove the PWB
Figure 1 Removing the Control PWB
Replacement
1.
Reverse the above procedures to replace the Feeder Control PWB.
REP 2.7.9
1/05
8a-20
Reissue
DocuColor 12/DCCS50
REP 2.8.26 HCF Feed Motor
REP 2.8.27 HCF Feeder Assembly

Removal

Removal
WARNING
WARNING
Cord.
Cord.
1.
Remove the HCF Paper Tray Assembly (REP 2.7.5).
1.
2.
Remove the HCF Rear Cover (PL 15.3)
2.
Remove the HCF Rear Cover (PL 15.10).
3.
Remove the HCF Feed Motor (Figure 1).
3.
Disconnect P/J 841 from the HCF Control PWB (PL 15.16).
2. Remove the Screws (4)
4.
Remove the 2 screws on the right side and 1 from the front of the HCF.
5.
Remove the HCF Feeder Assembly (Figure 1).
1. Remove the Feed Belt
1. Disconnect
P/J-842
2. Remove the Feeder Assembly
3. Remove the Feed Motor
Figure 1 Removing the HCF Feed Motor
Replacement
Figure 1 Removing the HCF Feeder Assembly
NOTE: Do not over tension the Feed Belt. The tension produced by the weight of the motor is
sufficient.
Replacement
1.
Reverse the above procedures to replace the HCF Feed Motor.
NOTE: Ensure that the Clutch and Locator Tab are engaged.
2.
Set the belt tension by loosening the four screws securing the Feed Motor and bias the
motor down to the bottom of the slots and tighten the four screws.
NOTE: Do not over tension the Feed Head Drive Belt. The tension produced by the spring is
sufficient.
3.
Loosen the screw securing the tensioning bracket and allow it to pivot into the drive belt.
Tighten the screw
1.
Reverse the above procedures to replace the HCF Feeder Assembly.
2.
Set the belt tension by loosening the four screws securing the Feed Motor and bias the
motor down to the bottom of the slots and tighten the four screws.
3.
Loosen the screw securing the tensioning bracket and allow it to pivot into the drive belt.
Tighten the screw.
Reissue
DocuColor 12/DCCS50
1/05
8a-21
REP 2.8.26, REP 2.8.27
REP 2.8.35 HCF Front/Rear Spring

Removal
2.
Remove the HCF Feeder Assembly (REP 2.8.27).
3.
Remove the HCF Front/Rear Spring (Figure 1).
WARNING
Cord.
1.

4. Slide the shaft left/right to remove the Front/Rear Springs
1. Remove the KL-clips and Bushings (2) at shaft ends
3. Release the Spring from the Spring Stop

2. Remove the Retard Spring at rear
Figure 1 Removing the Front/Rear Spring
Replacement
1.
Reverse the above procedures to replace the Front/Rear Spring.
REP 2.8.35
1/05
8a-22
Reissue
DocuColor 12/DCCS50
REP 2.8.36 HCF Baffle Assembly
2.

Removal
3.
Remove the HCF Front/Rear Springs (REP 2.8.35).
4.
Remove the HCF Baffle Assembly (Figure 1).
WARNING
Cord.
1.
1. Remove the KL-clip and Bushing at

each end of shaft
2. Remove the Baffle Assembly
Figure 1 Removing the Baffle Assembly
Replacement
1.
Reverse the above procedures to replace the HCF Baffle Assembly.
Reissue
DocuColor 12/DCCS50
1/05
8a-23
REP 2.8.36
REP 2.8.37 HCF Feed Belt
REP 2.8.38 HCF Feed/Nudger/Retard Rolls

Removal

Removal
WARNING
WARNING
Cord.
Cord.
1.
1.
2.
Remove the HCF Rear Cover (PL 15.10).
2.
Remove the HCF Feed/Nudger/Retard Rolls (Figure 1).
3.
Remove the HCF Feed Belt (Figure 1).
NOTE: The Front Chute must be removed to allow clearance to remove the Feed Roll.
Rolls are identical and interchangeable.
3. Remove Drive Motor

and Mounting Bracket as
one (4 screws)
2. Remove KL-clip and Pulley
Feed Roll
Front Chute
Nudger Roll
Retard Roll
Push the Lock

Tab and slip Roll
off shaft (3)
Figure 1 Removing the Feed/Nudger/Retard Rolls

4. Remove Feed Belt
Replacement
1.
Reverse the above procedures to replace the Rolls.
1. Remove the KL-clip and Feed Clutch
Figure 1 Removing the Feed Belt
Replacement
NOTE: Place the Feed Belt on the Pulley before replacing the Drive Motor.
NOTE: Do not over tension the Feed Belt. The tension produced by the spring is sufficient.
1.
Reverse the above procedures to replace the Feed Belt.
REP 2.8.37, REP 2.8.38
1/05
8a-24
Reissue
DocuColor 12/DCCS50
REP 2.8.39 HCF One-Way Feed/Gear Clutch
REP 2.8.40 HCF Friction Clutch

Removal

Removal
WARNING
WARNING
Cord.
Cord.
1.
1.
2.
2.
Remove the Friction Clutch (Figure 1).
3.
Remove the One-Way Feed/Gear Clutch (Figure 1).

1. Remove the Front Chute
2. Remove the Spacer
3. Remove the Friction Clutch

2. Push the Lock Tab and slide
the Feed Roll off shaft
3. Remove the C-clip and Gear
1. Push the Release

Tab and slide the
Retard Roll off shaft
4. Remove the Feed and

Gear Clutch
Figure 1 Removing the Friction Clutch

Figure 1 Removing the Feed/Gear Clutch
Replacement
1.
Replacement
1.
Reverse the above procedures to replace the Friction Clutch.
Reverse the above procedures to replace the One-Way Feed/Gear Clutch.
Reissue
DocuColor 12/DCCS50
1/05
8a-25
REP 2.8.39, REP 2.8.40
REP 2.8.41 HCF Feed Clutch
REP 2.8.42 HCF TAR Sensor

Removal

Removal
WARNING
WARNING
Cord.
Cord.
1.
Remove the HCF Rear Cover (PL 15.10)
1.
2.
Remove the Feed Clutch (Figure 1).
2.
3.
Remove the Feed Sensor (Figure 1).
1.Remove the KL-clip
2. Disconnect P/J851
2. Remove Screws (2) and Bracket
1. Disconnect P/J-853
3. Remove the Sensor

3. Remove the Feed Clutch
Figure 1 Removing the Feed Clutch

Figure 1 Removing the Feed Sensor
Replacement
1.
Reverse the above procedures to replace the Feed Clutch
Replacement
1.
REP 2.8.41, REP 2.8.42
1/05
8a-26
Reverse the above procedures to replace the Feed Sensor.
Reissue
DocuColor 12/DCCS50
REP 2.8.43 HCF Tray Empty/Stack Height Sensors

Removal
WARNING
Cord.
1.
Remove the HCF (REP 2.7.5).
2.
Remove the Tray Empty/Stack Height Sensor (Figure 1).

1. Disconnect the connectors
2. Remove the
Sensor (s)
Figure 1 Removing the Sensor(s)
Replacement
1.
Reverse the above procedures to replace the Sensor.
Reissue
DocuColor 12/DCCS50
1/05
8a-27
REP 2.8.43
REP 2.8.43
1/05
8a-28
Reissue
DocuColor 12/DCCS50
ADJ 2.1 HCF Registration

Purpose
The purpose of this adjustment is to set HCF Side Edge Registration to within specification.
Check
1.
Load HCF with 8.5X11/A4 long edge feed paper.
2.
Make a 100% copy of Test Pattern 82P522 side A (USO) 82P521 side A (XL).
3.
Registration should be 5.0 +/-1.1mm (Figure 1).
Side Registration 5.0 +/-1.1mm

Figure 1 Checking the Registration
Reissue
DocuColor 12/DCCS50
1/05
8a-29
ADJ 2.1
Adjustment
NOTE: It may be necessary to perform this adjustment more than once to obtain the correct
Side Edge Registration.
1.
Pull out the HCF.
2.
Adjust the HCF Side Edge Registration (Figure 2).
3.
If necessary, loosen the two Front Cover alignment screws and adjust the Front Cover
gap (Figure 2).
ADJ 2.1
1/05
8a-30
Reissue
DocuColor 12/DCCS50
1. Loosen Two Screws on Both Sides
Front Cover Alignment Screws
2. Adjust the Tray
Scale
Figure 2 Adjusting the Registration

NOTE: Ensure that both sides of the High Capacity Feeder are positioned at the same point on
Reissue
DocuColor 12/DCCS50
the scales before tightening the screws.
1/05
8a-31
ADJ 2.1
ADJ 2.1
1/05
8a-32
Reissue
DocuColor 12/DCCS50
PL 15.1 Elevator Assembly: Part 1 OF

3
Item
Part
Description
2
3
4
5
6
7
8
010K02271
026E57490
110E10051
017E09330
030K68140
Elevator Assembly (Not Spared)

(REP 2.7.5)
Slide
Plate (Not Spared)
Screw
HCF Interlock Switch
Front Caster (Adjustable)
Rear Caster (Not Spared)
Docking Bracket
Reissue
DocuColor 12/DCCS50
1/05
8a-33
PL 15.1

3
Item
1
2
3
4
5
6
7
Part
Description
802K21821
Flexure Spring (Not Spared)

Elevator Housing (Not Spared)
Front Cover (Includes Brackets)
Paper Guide (Not Spared)
Left Hand Bracket (Not Spared)
Latch (Not Spared)
Spring (Not Spared)
PL 15.2
1/05
8a-34
Reissue
DocuColor 12/DCCS50

3
Item
1
2
3
4
5
6
7
8
9
10
Part
Description
Long Cable (Not Spared)

Elevator Housing (Not Spared)
Wire Guide (Not Spared)
Pulley (Not Spared)
Short Cable (Not Spared)
Cable Pulley (Not Spared)
Shaft (Not Spared)
Gear (Not Spared)
Brake (Not Spared)
Bumper (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
8a-35
PL 15.3
PL 15.10 Paper Feeder Assembly:

Part 1 OF 6
Item
Part
Description
022K78881
604K22210
892E26370
3
4
5
6
127K34670
004E11220
003E28840
HCF Feeder Assembly (W/TAG

HCF2) (REP 2.8.27)
HFC Feeder Assmebly Kit (W/TAG
6)
Paper Jam Instruction Label (REP
2.8.37)
HCF Feed Motor
Bumper
Pin Lock (Not Spared)
Latch
PL 15.10
1/05
8a-36
Reissue
DocuColor 12/DCCS50

Part 2 OF 6
Item
Part
Description
1
2
3
030K70290
4
5
130E81311
6
7
913W01205
Bumper (P/O PL15.10 Item 1)

Feeder Housing
Sensor Bracket (P/O PL15.10 Item
1)
HCF Tar Sensor (REP 2.8.42)
Wire Harness (P/O PL15.10 Item
1)
Wire Clip (P/O PL15.10 Item 1)
Connector
Reissue
DocuColor 12/DCCS50
1/05
8a-37
PL 15.11

Part 3 OF 6
Item
Part
Description
1
2
007E89010
3
4
5
6
054E06492
120E15182
074E91050
107E08680
7
8
9
10
11
12
13
14
15
022K55041
413W29457
020E31540
121K10533
023E23160
007E88990
Gear (22/20T)
Feeder Housing (P/O PL15.11 Item
2)
Front Chute
Sensor Actuator
Actuator Support
Tray Empty Sensor (REP 2.8.43),
Stack Height Sensor (REP 2.8.43)
Drive Roll
Bearing
Pulley
Gear/Pulley (P/O PL15.10 Item 1)
Clutch
Feed Belt
Idler Bracket (P/O PL15.10 Item 1)
Idler Roller (P/O PL15.10 Item 1)
Gear (22T)
PL 15.12
1/05
8a-38
Reissue
DocuColor 12/DCCS50

Part 4 OF 6
Item
Part
Description
1
2
005K04490
3
4
6
7
8
809E25230
809E02540
023E15032
One Way Clutch (REP 2.8.41)

2)
Bearing (P/O PL15.10 Item 1)
Front Spring (P/O PL15.10 Item 1)
(REP 2.8.35)
Rear Spring (P/O PL15.10 Item 1)
(REP 2.8.35)
Retard Spring
Link Spring
Stopper Link
Reissue
DocuColor 12/DCCS50
1/05
8a-39
PL 15.13

Part 5 OF 6
Item
Part
Description
3
4
5
6
7
8
9
10
11
12
005K04460
007E88971
013E92890
022K64850
059K27640
022K49980
006E58342
413W29357
007E88961
005K04470

2)
Nudger Feeder Assembly (P/O
PL15.10 Item 1)
One Way Clutch (REP 2.8.39)
Gear (25T)
Bearing
Feed/Nudger Roller (REP 2.8.38)
Feed/Nudger Roller (Alternate)
Feed/Nudger Roller (Alternate)
Support (P/O Item 2)
Feed Shaft
Bearing
Gear (31T)
Nudger Shaft (P/O Item 2)
Gear Clutch (25T) (REP 2.8.39)
PL 15.14
1/05
8a-40
Reissue
DocuColor 12/DCCS50

Part 6 OF 6
Item
Part
Description
2
3
4
5
6
7
059K00470
8
9
10
11
12
005K04480
014E83230
022K64850
022K49980
059K27640
13
14
15
013E14600
600K89040
Retard Assembly (P/O PL15.10

Item 1)
Pivot Shaft (P/O PL15.10 Item 1)
Exit Baffle (P/O PL15.10 Item 1)
(REP 2.8.36)
Pinch Roll
Extension Spring P/O PL15.10 Item
1)
Friction Clutch (REP 2.8.40)
Retard Shaft (P/O PL15.10 Item 1)
Spacer
Retard Roller
Retard Roller (Alternate)
Retard Roller (Alternate)
Retard Support (P/O PL15.10 Item
1)
2)
Bearing
HCF Skew Repair Kit (W/TAG 3)
Reissue
DocuColor 12/DCCS50
1/05
8a-41
PL 15.15
PL 15.16 Elevator Motor and Feed

Motor
Item
Part
Description
1
2
3
4
127K40720
127K34670
160K72183
5
6
7
8
9
10
11
12
13
14
15
001E51850
162K51600
420W10201
116P20301
116P20612
162K21160
110E07300
16
17
HCF Elevator Motor Assembly

Feed Motor (REP 2.8.26)
Damper (Not Spared)
HCF Control PWB (W/TAG HCF1,
TAG HCF4, TAG HCF5) (REP
2.7.9)
Rear Frame
Spring (P/O Item 1)
Harness Clip (Not Spared)
HCF/IOT Interface Harness
Bushing (Not Spared)
Cable Tie
PWB Standoff
Standoff
Harness (Not Spared)
Switch Harness
HCF Paper Size Switch, Tray In
Switch
Coupler (P/O Item 1)
HCF Elevator Motor (P/O Item 1)
(REP 2.7.6)
PL 15.16
1/05
8a-42
Reissue
DocuColor 12/DCCS50
Part Number Index

Part Number
Part List
054E06492
PL 15.12
Part Number
Part List
059K00470
PL 15.15
001E51850
PL 15.16
059K27640
PL 15.14
003E28840
PL 15.10
003E80700
PL 15.3
068K26210
PL 15.12
004E11220
PL 15.10
068K91010
PL 15.2
005K04460
PL 15.14
074E91050
PL 15.12
005K04470
PL 15.14
107E08680
PL 15.12
005K04480
PL 15.15
110E07300
PL 15.16
005K04490
PL 15.13
110E10051
PL 15.1
006E58342
PL 15.14
116P20301
PL 15.16
007E88961
PL 15.14
116P20612
PL 15.16
007E88971
PL 15.14
120E15182
PL 15.12
007E88990
PL 15.12
121K10533
PL 15.12
007E89010
PL 15.12
127K34670
PL 15.10
010K02271
PL 15.1
012E07691
PL 15.3
127K40720
PL 15.16
013E14600
PL 15.15
130E81311
PL 15.11
013E82480
PL 15.15
160K72183
PL 15.16
013E92890
PL 15.14
162K21160
PL 15.16
014E83230
PL 15.15
162K51600
PL 15.16
017E09330
PL 15.1
413W29357
PL 15.14
017E09680
PL 15.1
413W29457
PL 15.12
020E17410
PL 15.3
420W10201
PL 15.16
020E25770
PL 15.3
600K89040
PL 15.15
020E31540
PL 15.12
604K22210
PL 15.10
022E24880
PL 15.12
802K21821
PL 15.2
022K49980
PL 15.14
809E02540
PL 15.13
PL 15.15
809E25230
PL 15.13
022K55041
PL 15.12
892E26370
PL 15.10
022K64850
PL 15.14
913W01205
PL 15.11
PL 15.15
PL 15.16
PL 15.15
022K78881
PL 15.10
023E15032
PL 15.13
023E23160
PL 15.12
026E57490
PL 15.1
029E29580
PL 15.10
030K68140
PL 15.1
030K70290
PL 15.11
032E91250
PL 15.3
050K39670
PL 15.15
Reissue
DocuColor 12/DCCS50
1/05
8a-43
Part Number Index
Part Number Index
1/05
8a-44
Reissue
DocuColor 12/DCCS50
Plug/Jack Index

1.
2.
Table 1 Plug/Jack Index
P/J No.
Figure No.
Item No.
J1
Figure 1
J2
Figure 1
a.
P/J7
Figure 1
b.
P/J841
Figure 1
c.
P/J842
Figure 1
P/J843
Figure 1
P/J845
Figure 1
Refer to Figure 1 for an example of the Plug/Jack Index connector list.
Figure x
1056
Item number in the

a Plug/Jack.
P/J Number

can be located.
Reissue
DocuColor 12/DCCS50
1/05
8a-45
Wiring Connector List, Plug/Jack Index
Plug/Jack Locator Diagram
Figure 1 HCF Control PWB

1/05
8a-46
Reissue
DocuColor 12/DCCS50
HCF BSDs
Purpose
The Block Schematic Diagrams (BSDs) show the distribution of electrical and mechanical
power.
electrical information and mechanical inputs and outputs. The functional flow is from left to right
(inputs on the left and outputs on the right).
The HCF BSDs are divided into the following functional chains:
Chain 7 Paper Supply
Chain 8 Paper Feed
Reissue
DocuColor 12/DCCS50
1/05
8a-47
HCF BSDs
Chain 7 Paper Supply
Figure 1 BSD 7.11 HCF Paper Stacking
HCF BSDs
1/05
8a-48
Reissue
DocuColor 12/DCCS50
Figure 2 BSD 7.12 HCF Elevator Motor Control
Reissue
DocuColor 12/DCCS50
1/05
8a-49
HCF BSDs
Chain 8 Paper Feed
Figure 3 BSD 8.11 HCF Drive Control
HCF BSDs
1/05
8a-50
Reissue
DocuColor 12/DCCS50
Figure 4 BSD 8.12 HCF Paper Feed
Reissue
DocuColor 12/DCCS50
1/05
8a-51
HCF BSDs
Figure 5 BSD 8.13 HCF Communication
HCF BSDs
1/05
8a-52
Reissue
DocuColor 12/DCCS50
8B Convenience Stapler
Convenience Stapler RAPs
ST-1 Convenience Stapler RAP......................................................................................
OF-8 Staple Cartridge Checkout Procedure ..................................................................
8b-3
8b-5
Repairs
REP 15-1 Convenience Stapler Internal DC Harness.....................................................
8b-7
Parts Lists
Convenience Stapler
PL 16.1 Convenience Stapler .........................................................................................
Reissue
DocuColor 12/DCCS50
8b-9
8b-10
1/05
8b-1
Convenience Stapler
Convenience Stapler
1/05
8b-2
Reissue
DocuColor 12/DCCS50
ST-1 Convenience Stapler RAP
The Convenience Stapler Top Cover closes securely and remains closed during
operation of the Stapler.
Y
N
Replace the Convenience Stapler Top Cover (PL 16.1).
The Convenience Stapler is exhibiting one or more of the following problems:
The Stapler is not operating correctly; poorly clinched staples, no staples.
The green LED is not illuminated; indicating low staples, jammed staple, or loss of power
to the Stapler.
The red LED is illuminated; indicating low staples.
Check the red LED on the Convenience Stapler. The red LED is illuminated.
Y
N
Go to the Stapler Checkout Procedure.
Initial Actions
Ensure there is power to the Convenience Stapler.
Ensure that the Stapler Top Cover is closed and that Interlock Actuator is not damaged.
Replace the Staple Cartridge. If the problem continues after replacing the Staple Cartridge, replace the Convenience Stapler Assembly (PL 16.1).
Do the following:
Check the position of the Stapler Head.

The Convenience Stapler is stuck in the down (clinched or stapled) position.
Y
N
Close the Convenience Stapler Top Cover and attempt to staple a stack of paper.
Check the green LED on the Convenience Stapler. The green LED is illuminated.
Y
N
Check the Stapler Interlock Switch Actuator, located on the Convenience Stapler Top
Cover. Ensure that it is not missing or damaged. The check of the Stapler Interlock Switch Actuator is good.
Y
N
Replace the Convenience Stapler Top Cover (PL 16.1).
Close the Convenience Stapler Top Cover to actuate the interlock switch.
Ensure there is power at the Convenience Stapler.
Check the position of the Stapler Head. The Convenience Stapler remains stuck in the
down (clinched or stapled) position.
Y
N
Replace the Convenience Stapler Assembly (PL 16.1).
Convenience Stapler Electrical Check

Check for 110 VAC at the Convenience Stapler. The voltage is 110 VAC.
Y
N
Remove the Stapler PWB Cover to gain access to Stapler Power Cord to PWB connector.
Measure the voltage across the connector. The voltage is 110 VAC.
Y
N
Ensure that the wires are seated securely into the connector on the PWB. Repair as
required.
Check the Convenience Stapler Power Cord. The Power Cord for the Convenience Stapler is connected securely to the Convenience Stapler.
Y
N
Ensure the Convenience Stapler Power Cord is connected securely.
Check the green LED on the Convenience Stapler. The green LED is illuminated.
Y
N
Go to the Convenience Stapler Electrical Check.
Do the following:
Y
N
Remove and the reinstall the Staple Cartridge. The Convenience Stapler
operates correctly after reinstalling the Staple Cartridge.
Y
N
Ensure the Stapler Harness is connected to the Convenience Stapler PWB.
Remove the Staple Cartridge.
Close the Convenience Stapler Top Cover.
Y
N
Replace the Convenience Stapler PWB (PL 16.1). If the problem continues, replace
the Convenience Stapler Assembly (PL 16.1).
Replace the Staple Cartridge. If the problem continues after replacing the Staple Cartridge, replace the Convenience Stapler Assembly (PL 16.1)
Go to the Convenience Stapler Electrical Check.
A
B
Reissue
DocuColor 12/DCCS50
1/05
8b-3
Convenience Stapler
Stapler Checkout Procedure

Convenience
Stapler Top
Cover
NOTE: The customer has described the problem as poorly clinched staples or missing staples.
The customer describes the problem as poorly clinched staples.
Y
N
Remove and then reinstall the Staple Cartridge. The Convenience Stapler operates
correctly after reinstalling the Staple Cartridge.
Y
N
The unformed staple roll may be wound too tightly or the Driver Bar may be out of
position.
Do the following:
Remove the Staple Cartridge.
Perform the OF-8 Staple Cartridge Checkout Procedure OF-8 Staple Cartridge
Checkout Procedure.
Reinstall the Staple Cartridge.
Stapler
Head
The Convenience Stapler operates correctly after performing the Staple Cartridge Checkout Procedure.
Y
N
Replace the Staple Cartridge and attempt to staple a stack of documents. The
Convenience Stapler operates correctly after replacing the Staple Cartridge.
Y
N
red LED
green LED
Figure 1 Stapler Components
The customer is attempting to staple a set that is greater than 50 sheets of 24 lb (120
gsm) or equivalent thickness.
Y
N
Replace the Staple Cartridge in the Convenience Stapler
Inform the customer the stapling capacity of the Convenience Stapler is 50 sheets of 24 lb (120
gsm) or equivalent thickness.
Convenience Stapler
1/05
8b-4
Reissue
DocuColor 12/DCCS50
OF-8 Staple Cartridge Checkout Procedure

The unformed staple roll is wound too tightly in the Staple Cartridge and/or the Driver Bar is out
of position. This may cause the following:
The Convenience Stapler is failing to staple documents.
The Staple Cartridge cannot be installed correctly in the Convenience Stapler.
The Staple Cartridge pops out of the Convenience Stapler when attempting to staple.
NOTE: Do not grasp the

exposed staple roll
Staple Cartridge Checkout

To ensure the unformed staple roll in the Staple Cartridge is not wound too tight, do the following:
Orient the Staple Cartridge as shown in Figure 1.
Using one hand, grasp the Staple Cartridge along the top and bottom.
Vigorously snap the cartridge in the direction of the arrow (refer to Figure 1) about 10
times being careful not to squeeze the cartridge too tightly. You should be able to hear the
roll clunking back and forth inside the cartridge.
To ensure the Driver Bar is in the correct position, do the following:
Check to see if the Driver Bar is flush with the leading edge of the cartridge as shown in
Figure 2.
If necessary, use a pen or other pointed tool to move the plate edge tab located on the left
side of the cartridge.
Move the tab until the Driver Bar is even with the leading edge of the cartridge.
Ensure the stapler is in the home position when re-inserting the cartridge into the Staple
Head.
Ensure the first staple is in the correct position and the staple is not damaged:
If correctly positioned, the staple will be laying down flat on the Driver Bar.
If the staple is oriented on end, as shown in Figure 3, or if the staple appears to be malformed in any way, remove it.
Figure 1 Checking the Cartridge
Reissue
DocuColor 12/DCCS50
1/05
8b-5
Convenience Stapler
Incorrect edge Correct edge

tab position
tab position
If the Driver Bar is not even

with the edge of the cartridge,
use a pen or other pointed tool
to move the edge tab to the
correct position.
Ensure the Driver Bar is even

with the edge of the cartridge.
Figure 2 Checking the Driver Bar
Remove the staple if it is malformed, or it is in this position.
Figure 3 Checking the Staples
Convenience Stapler
1/05
8b-6
Reissue
DocuColor 12/DCCS50
REP 15-1 Convenience Stapler Internal DC Harness

Removal
1.
Disconnect the Convenience Stapler Harness from the back of the Convenience Stapler.
2.
Remove the bottom plate from the Convenience Stapler (Figure 1).
3.
Remove the Convenience Stapler Internal DC Harness (Figure 2).
1
Remove the screws (3).
1
Disconnect the
connectors.
2
Carefully separate the
bottom plate just enough
to access the connector
for the stapler.
2
Remove the harness
Figure 2 Remove the Harness
Replacement
Disconnect the stapler

connector from the
PWB.
1.
Install the new Convenience Stapler Internal DC Harness.
2.
Reconnect the stapler connector to the PWB.
3.
Reinstall the bottom plate.
Figure 1 Remove the Plate
Reissue
DocuColor 12/DCCS50
1/05
8b-7
4.
Connect the Convenience Stapler Harness to the Convenience Stapler.
5.
Check the operation of the Convenience Stapler by removing the Staple Cartridge and
closing the Convenience Stapler Cover. The red LED should be illuminated.
Convenience Stapler
REP 15-1
Convenience Stapler
REP 15-1
1/05
8b-8
Reissue
DocuColor 12/DCCS50
PL 16.1 Convenience Stapler

Item
Part
Description
1
2
3
4
802K22721
014K06500
108R00152
802K23162
5
6
7
160K65236
117E22380
Stapler Cover
Stapler Head
Cartridge (3 Packs)
Stapler Mounting Cover (Not
Spared)
PWB Cover (Not Spared)
Stapler PWB
Wire
Reissue
DocuColor 12/DCCS50
1/05
8b-9
Convenience Stapler
PL 16.1
Part Number Index

Part Number
Part List
014K06500
PL 16.1
108R00152
PL 16.1
117E22380
PL 16.1
160K65236
PL 16.1
802K22721
PL 16.1
802K23162
PL 16.1
Convenience Stapler
Part Number Index
1/05
8b-10
Reissue
DocuColor 12/DCCS50
8C Edit Pad
02-282 Edit Pad PWB Communication Fail RAP ............................................................
OF-2 LED/Switch Panel PWB Communication Fail RAP ...............................................
8c-3
8c-3
Parts Lists
Edit Pad Components
PL 17.1 Edit Pad Components (1 of 2) ...........................................................................
PL 17.2 Edit Pad Components (1 of 2) ...........................................................................
8c-5
8c-6
Common Hardware
Common Hardware .........................................................................................................
8c-7
8c-8
Plug/Jacks
Plug/Jack Index...............................................................................................................
8c-9
8c-10

Edit Pad BSDs ................................................................................................................
Reissue
DocuColor 12/DCCS50
8c-13
1/05
8c-1
Edit Pad
Edit Pad
1/05
8c-2
Reissue
DocuColor 12/DCCS50
02-282 Edit Pad PWB Communication Fail RAP
OF-2 LED/Switch Panel PWB Communication Fail RAP

The UI PWB detected a communication fault between the UI PWB and the LED/Switch Panel
PWB.
The UI PWB detected a communication fault between the UI PWB and the Edit Pad PWB.
Initial Actions
Verify that P800 at the rear of machine is firmly connected.
Verify that P/J820 and P/J824 on the Edit Pad are firmly connected.
Initial Actions
Procedure
There is +24 VDC between P/J824-19 and P/J824-18,20,21.
Y
N
Switch off the power. Disconnect P800. Switch on the power. There
between P800-19 and P800-18,20,21.
Y
N
Go to the +24 VDC Power (IIT/IPS LVPS) RAP.
Verify that P800 at the rear of machine is firmly connected.
Verify that P/J821 and P/J824 on the Edit Pad are firmly connected.
is
+24
Select the Edit Pad option. The LEDs on the Edit Pad Switch Panel light.
Y
N
There is +5 VDC between P800-5,6,23,24 and P800-10,25,26 on the Edit Pad.
Y
N
Switch off the power. Disconnect P800. Switch on the power. There is +5 VDC
between P800-5,6,23,24 and P800-10,25,26.
Y
N
Switch off the power. Go to the +5VDC Power (IIT/IPS) RAP.
VDC
Switch off the power. Go to Flag 1 and check the harness between P800 and P/
J821 for an open circuit.
There is +24 VDC between P/J820-7 and P/J820-6,8,9.

Y
N
Switch off the power. Go to Flag 4 and check the harness between P/J824 and P/J820
for an open circuit.
There is +5 VDC between P/J824-5,6,23,24 and P/J824-10,25,26 on the Edit Pad.

Y
N
Switch off the power. Go to Flag 1 and check the harness between P800 and P/
J821 for an open circuit.
There is +24 VDC between CN1-7 and CN1-6,8,9.

Y
N
Switch off the power. Go to Flag 4 and check the harness between P/J820 and CN1 for
an open circuit.
Switch off the power. Go to Flag 2 and check the harness for an open circuit. If the harness is OK replace the LED/Switch Panel (PL 17.1). If the problem continues replace the
UI PWB (PL9.5).
Switch off the power. Go to Flag 5 and Flag 6 and check the harness for an open circuit. If the
harness is OK replace the Edit Pad Control PWB (PL 17.2). If the problem continues replace
the UI PWB (PL 9.5). If the problem continues replace the IPS-EDIT PWB (PL 3.5).
Reissue
Refer to BSD 2.5 and BSD 2.6 on the following procedure.
Procedure
Switch off the power. Go to Flag 4 and check the harness between P800 and P/J824 for
an open circuit.
DocuColor 12/DCCS50
Switch off the power. Go to Flag 3 and check the harness for an open circuit. If the harness is
OK replace the LED/Switch Panel (PL 17.1). If the problem continues replace the UI PWB (PL
9.5).
1/05
8c-3
Edit Pad
02-282 Edit Pad PWB Communication Fail RAP,
Edit Pad
02-282 Edit Pad PWB Communication Fail RAP, OF-2
1/05
8c-4
Reissue
DocuColor 12/DCCS50
PL 17.1 Edit Pad Components (1 of 2)

Item
Part
Description
1
2
3
4
5
802K10992
802K10950
802K08940
6
7
8
9
10
003E48130
177K99192
11
12
13
14
15
16
17
18
19
20
21
22
23
117K19730
019E31060
121E90620
004E99060
120K91660
048E35191
048K37862
892E27311
892E27301
892E27291
Edit Pad Assembly

Edit Panel Assembly
Platen Cover Assembly
Platen Stopper (P/O PL 17.1 Item
1)
Hinge
Inner Cover (P/O PL 17.1 Item 1)
Clamp (P/O PL 17.1 Item 1)
Edit Cable
Connector Support (P/O PL 17.1
Item 1)
Led/Switch Cable
Pen Holder
Magnet
Cushion
Platen Cover (P/O PL 17.1 Item 4)
Actuator
Sheet (P/O PL 17.1 Item 3)
Color Sheet
Led/Switch Panel
Top Overlay (P/O PL 17.1 Item 3)
Top Overlay (Portugese)
Top Overlay (Spanish)
Top Overlay (French)
Platen Cushion (Not Spared)
Platen Inner Cover (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
8c-5
Edit Pad
PL 17.1
PL 17.2 Edit Pad Components (1 of 2)

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part
Description
802K10940
802K10960
802E09660
002K48500
120E92600
071K90530
160K62600
Edit Pad Assembly

PWB Cover (P/O PL 17.2 Item 1)
Edit Pad
Sheet
Sheet Cover
Clamp Plate (P/O PL 17.2 Item 1)
Lock Pin
Pen
Edit Pad Control PWB
Shield Sheet (P/O PL 17.2 Item 1)
Edit Pad Control PWB Kit (Not
Spared)
Edit Pad
PL 17.2
1/05
8c-6
Reissue
DocuColor 12/DCCS50
Common Hardware
Item
A
B
C
D
E
Part
Description
113W20857
113W36057
158W27855
153W16055
153W27850
Screw (M5 x 8)
Screw (M4 x 10)
Screw (M3 x 8)
Screw (M2 x 10)
Screw (M3 x 8)
Reissue
DocuColor 12/DCCS50
1/05
8c-7
Edit Pad
Common Hardware
Part Number Index

Part Number
Part List
002K48500
PL 17.2
003E48130
PL 17.1
004E99060
PL 17.1
019E31060
PL 17.1
048E35191
PL 17.1
048K37862
PL 17.1
071K90530
PL 17.2
117K19730
PL 17.1
120K91660
PL 17.1
120E92600
PL 17.2
121E90620
PL 17.1
160K62600
PL 17.2
177K99192
PL 17.1
802K08940
PL 17.1
802E09660
PL 17.2
802K10940
PL 17.2
802K10950
PL 17.1
802K10960
PL 17.2
802K10992
PL 17.1
892E27291
PL 17.1
892E27301
PL 17.1
892E27311
PL 17.1
Edit Pad
Part Number Index
1/05
8c-8
Reissue
DocuColor 12/DCCS50

1.
2.
a.
b.
c.
Refer to Figure 1 for an explanation of each column heading in the Plug/Jack Index.
Figure No.
P/J No.
Item No.
Item number in the

a Plug/Jack.
P/J Number or
Designator

can be located.
Reissue
DocuColor 12/DCCS50
1/05
8c-9
Edit Pad
Plug/Jack Index
Edit Pad
Plug/Jack Index
P/J No.
Figure No.
Item No.
CN1
Figure 1
CN2
Figure 1
CN3
Figure 1
P800
Figure 1
P/J820
Figure 1
P/J821
Figure 1
P/J824
Figure 1
1/05
8c-10
Reissue
DocuColor 12/DCCS50
Figure 1 Edit Pad
Reissue
DocuColor 12/DCCS50
1/05
8c-11
Edit Pad
Plug/Jack Index
Edit Pad
Plug/Jack Index
1/05
8c-12
Reissue
DocuColor 12/DCCS50
Edit Pad BSDs

Purpose
power.
Reissue
DocuColor 12/DCCS50
1/05
8c-13
Edit Pad
Edit Pad BSDs
Figure 1 BSD 2.5 Edit Pad
Edit Pad
Edit Pad BSDs
1/05
8c-14
Reissue
DocuColor 12/DCCS50
Figure 2 BSD 2.6 Edit Pad Monitoring
Reissue
DocuColor 12/DCCS50
1/05
8c-15
Edit Pad
Edit Pad BSDs
Edit Pad
Edit Pad BSDs
1/05
8c-16
Reissue
DocuColor 12/DCCS50
8D Finisher
Chain 03
3-319 Finisher/Sorter Communication Failure RAP ........................................................
12-246 RAP.....................................................................................................................
12-248 RAP.....................................................................................................................
12-249 RAP.....................................................................................................................
12-251 RAP.....................................................................................................................
12-253 RAP.....................................................................................................................
12-254 RAP.....................................................................................................................
12-255 RAP.....................................................................................................................
12-256 RAP.....................................................................................................................
12-264 RAP.....................................................................................................................
12-265 RAP.....................................................................................................................
12-266 RAP.....................................................................................................................
12-302 RAP.....................................................................................................................
12-303 RAP.....................................................................................................................
12-305 RAP.....................................................................................................................
12-306 RAP.....................................................................................................................
12-400/12-538 RAP.........................................................................................................
12-531 RAP.....................................................................................................................
12-536 RAP.....................................................................................................................
12-537 RAP.....................................................................................................................
12-570 RAP.....................................................................................................................
12-571 RAP.....................................................................................................................
12-580 RAP.....................................................................................................................
8d-3
Chain 11
11-107 SCT Exit Sensor On Jam Long RAP ..................................................................
11-108 SCT Exit Sensor Off Jam RAP ...........................................................................
11-109 SCT Exit Sensor On Jam Short RAP .................................................................
11-110 Paper Remains at Decurler Exit Sensor Long RAP ............................................
11-111 Paper Remains at Decurler Exit Sensor Short RAP ...........................................
11-115 Mailbox Vertical Sensor / Bin 1 Sensor On Jam RAP.........................................
11-116 Mailbox Vertical Sensor / Bin 1 Sensor Off Jam RAP.........................................
11-142 Mailbox Entrance Sensor On Jam Long RAP.....................................................
11-143 Mailbox Entrance Sensor Off Jam RAP ..............................................................
11-144 Mailbox Entrance Sensor On Jam Short RAP ....................................................
11-145 Decurler Exit Sensor On Jam Long RAP ............................................................
11-146 Decurler Exit Sensor On Jam Short RAP ...........................................................
11-190 Paper Remains on V-Tra In Sensor RAP ...........................................................
11-191 Paper Remains at Mailbox Vertical Sensor / 1 Bin Sensor RAP ........................
11-192 Paper Remains at SCT Exit Sensor RAP ...........................................................
11-193 Decurler Exit Sensor Static Jam RAP .................................................................
11-301 Mailbox Door Interlock Open RAP ......................................................................
11-302 Decurler Door Interlock Open RAP .....................................................................
11-303 Docking Interlock Open RAP ..............................................................................
11-350 Decurler 1 Fail RAP ............................................................................................
11-512 Simple Catch Tray (SCT) Full Stack RAP...........................................................
11-920 Bin 10 Full Stack RAP.........................................................................................
11-921 SCT Tray Full Stack RAP ...................................................................................
11-922 Sorter Stacker Full RAP......................................................................................
8d-5
8d-7
8d-8
8d-10
8d-10
8d-11
8d-12
8d-13
8d-15
8d-16
8d-17
8d-19
8d-21
8d-22
8d-22
8d-23
8d-23
8d-24
8d-24
8d-25
8d-26
8d-27
8d-27
8d-28
8d-28
8d-29
8d-29
8d-30
8d-30
8d-31
8d-31
8d-32
8d-32
15.1
REP 15.1.1 Decurler .......................................................................................................
REP 15.1.2 Decurler Rolls 1 and 2 .................................................................................
REP 15.1.3 Reflector and Cam .......................................................................................
REP 15.1.4 Decurler Stepper Motor................................................................................
REP 15.1.5 Entrance Lower Chute and Pinch Roll .........................................................
REP 15.1.6 Exit Lower Baffle and Pinch Roll..................................................................
REP 15.1.7 Decurler PWB ..............................................................................................
REP 15.1.8 Cam Drive Shaft...........................................................................................
REP 15.1.9 Torque Limiter Gear and Stopper ................................................................
REP 15.1.10 Decurler Drive Roll 2..................................................................................
REP 15.1.11 Decurler Drive Roll 1..................................................................................
REP 15.1.12 Decurler Entrance Roll...............................................................................
REP 15.1.13 Decurler Exit Roll .......................................................................................
REP 15.1.14 Entrance Upper Baffle and Pinch Roll .......................................................
REP 15.1.15 Finisher Transport Motor............................................................................
REP 15.1.16 Finisher Drive Belt......................................................................................
REP 15.1.17 Single Catch Tray (SCT) Assembly ...........................................................
REP 15.1.18 SCT Static Eliminator.................................................................................
REP 15.1.19 SCT Exit Sensor ........................................................................................
REP 15.1.20 SCT Pinch Roll...........................................................................................
REP 15.1.21 Finisher Transport Roll 1............................................................................
REP 15.1.22 Finisher Transport Roll 2............................................................................
Chain 12
12-120 RAP.....................................................................................................................
12-121 RAP.....................................................................................................................
12-170 RAP.....................................................................................................................
12-180 RAP.....................................................................................................................
12-181 RAP.....................................................................................................................
12-240 RAP.....................................................................................................................
12-243 RAP.....................................................................................................................
12-244 RAP.....................................................................................................................
12-245 RAP.....................................................................................................................
Reissue
DocuColor 12/DCCS50
8d-41
8d-42
8d-43
8d-43
8d-44
8d-45
8d-46
8d-47
8d-48
8d-49
8d-50
8d-51
8d-51
8d-52
8d-52
8d-53
8d-53
8d-54
8d-55
8d-55
8d-56
8d-57
8d-33
8d-34
8d-36
8d-37
8d-37
8d-38
8d-39
8d-39
8d-40
8d-59
8d-59
8d-62
8d-63
8d-64
8d-65
8d-65
8d-66
8d-67
8d-68
8d-69
8d-70
8d-71
8d-72
8d-73
8d-73
8d-74
8d-75
8d-75
8d-76
8d-76
8d-77
15.2
1/05
8d-1
Finisher/Sorter
REP 15.2.1 Compiler Tray Solenoid ...............................................................................

REP 15.2.2 Stacker Tray Assembly................................................................................
REP 15.2.4 Stacker Full Sensors....................................................................................
REP 15.2.5 Stacker Upper and Lower Limit Sensors .....................................................
REP 15.2.6 Stacker Tray Paper Sensor .........................................................................
REP 15.2.7 Stacker Motor ..............................................................................................
REP 15.2.8 Lower Exit Chute Assembly .........................................................................
REP 15.2.9 Stacker Tray Drive Belts ..............................................................................
REP 15.2.10 Stacker Tray ..............................................................................................
REP 15.2.11 Tamper Motor ............................................................................................
REP 15.2.12 Tamper Home Sensor ...............................................................................
REP 15.2.13 Compiler Paper Sensor .............................................................................
REP 15.2.14 End Wall Open Sensor ..............................................................................
REP 15.2.15 Tamper Motor Drive Belt............................................................................
REP 15.2.16 End Wall Motor ..........................................................................................
REP 15.2.17 Eject Clamp Sensor ...................................................................................
REP 15.2.18 Stacker Offset Home Sensor .....................................................................
REP 15.2.19 Eject Bracket Assembly .............................................................................
REP 15.2.20 Eject Paddle Motor and Drive Belt .............................................................
REP 15.2.21 Eject Shaft Assembly .................................................................................
REP 15.2.22 Compiler Cover Assembly .........................................................................
REP 15.2.23 Eject Pinch Roll Shaft Assembly................................................................
REP 15.2.24 Upper Exit Chute Assembly .......................................................................
REP 15.2.25 Exit Roll......................................................................................................
REP 15.2.26 Compiler Paddle Shaft Assembly ..............................................................
REP 15.2.27 Paddle Drive Belt .......................................................................................
REP 15.2.28 Stacker Height Sensor...............................................................................
REP 15.2.29 Unload While Run Switch ..........................................................................
REP 15.2.30 Compiler Entrance Sensor.........................................................................
REP 15.2.31 Eject Paddle Home Sensor........................................................................
REP 15.2.32 Eject Motor.................................................................................................
REP 15.2.33 Eject Clamp/Offset Motor...........................................................................
8d-79
8d-80
8d-81
8d-82
8d-82
8d-83
8d-83
8d-84
8d-85
8d-87
8d-88
8d-89
8d-90
8d-91
8d-92
8d-93
8d-94
8d-95
8d-96
8d-97
8d-98
8d-99
8d-100
8d-101
8d-102
8d-104
8d-105
8d-106
8d-106
8d-107
8d-108
8d-109
REP 15.3.19 Stapler Position Motor................................................................................

REP 15.3.20 Mailbox Drive Motor ...................................................................................
REP 15.3.21 Mailbox Drive Belt ......................................................................................
REP 15.3.23 Docking Interlock Switch............................................................................
REP 15.3.25 Decurler Door Interlock Switch ..................................................................
REP 15.3.28 Finisher PWB .............................................................................................
REP 15.3.29 Finisher PWB EPROM...............................................................................
REP 15.3.30 Vertical LED and Sensor............................................................................
REP 15.3.31 Bin Tray 1...................................................................................................
REP 15.3.32 Bin Trays 2 - 10..........................................................................................
Adjustments
ADJ 15.3.1 Staple Position Adjustment........................................................................... 8d-131
ADJ 15.3.2 Stacker Tray Level........................................................................................ 8d-132
Parts Lists
Sorter/Finisher
PL 18.1 Finisher Accessory.............................................................................................
PL 18.2 Covers - Left, Front ............................................................................................
PL 18.3 Covers - Right, Rear ..........................................................................................
PL 18.4 Finisher Components.........................................................................................
PL 18.5 Decurler Cover...................................................................................................
PL 18.6 Decurler Chute, PWB.........................................................................................
PL 18.7 Decurler Roll ......................................................................................................
PL 18.8 Decurler Transport Roll......................................................................................
PL 18.9 Mailbox - Stapler Entrance Roll .........................................................................
PL 18.10 Mailbox Entrance Roll, Sct Exit Roll.................................................................
PL 18.11 Mailbox - Gate, PWB, Interlock Switch ............................................................
PL 18.12 Mailbox - Stapler Entrance Chute ....................................................................
PL 18.13 Mailbox Chute ..................................................................................................
PL 18.14 Stapler - Exit Chute..........................................................................................
PL 18.15 Stapler-Compiler ..............................................................................................
PL 18.16 Compiler Tray Components .............................................................................
PL 18.17 Stapler Accessory ............................................................................................
PL 18.18 Stapler Rail Component...................................................................................
PL 18.19 Offset And Set Eject.........................................................................................
PL 18.20 Eject And Paddle Components ........................................................................
PL 18.21 Eject And Offset Components..........................................................................
PL 18.22 Bin Tray 1.........................................................................................................
PL 18.23 Bin Tray 2/4/6/8................................................................................................
PL 18.24 Bin Tray 3/5/7/9................................................................................................
PL 18.25 Bin Tray 10.......................................................................................................
PL 18.26 Stacker Tray Drive ...........................................................................................
PL 18.27 Stacker Tray.....................................................................................................
15.3
REP 15.3.1 Finisher ........................................................................................................
REP 15.3.2 Stapler Door Assembly ................................................................................
REP 15.3.3 Stapler Cover Assembly ..............................................................................
REP 15.3.4 Decurler Door Assembly..............................................................................
REP 15.3.5 Mailbox Door Assembly ...............................................................................
REP 15.3.6 Left Lower Cover .........................................................................................
REP 15.3.7 Rear Upper Cover........................................................................................
REP 15.3.8 IOT Connector Cover...................................................................................
REP 15.3.9 Finisher PWB Cover ....................................................................................
REP 15.3.10 Left Upper Cover .......................................................................................
REP 15.3.11 Top Cover ..................................................................................................
REP 15.3.12 Decurler Top Cover ...................................................................................
REP 15.3.13 Decurler Rear Cover..................................................................................
REP 15.3.14 Decurler Inner Cover .................................................................................
REP 15.3.15 Rear Lower Cover......................................................................................
REP 15.3.16 Stapler Assembly .......................................................................................
REP 15.3.17 Stapler Position Sensors ...........................................................................
REP 15.3.18 Stapler Rail Belt .........................................................................................
Finisher/Sorter
8d-123
8d-123
8d-124
8d-125
8d-125
8d-126
8d-126
8d-127
8d-128
8d-129
8d-111
8d-111
8d-112
8d-112
8d-113
8d-113
8d-114
8d-114
8d-115
8d-115
8d-116
8d-116
8d-117
8d-117
8d-118
8d-118
8d-119
8d-121
8d-135
8d-136
8d-137
8d-138
8d-139
8d-140
8d-141
8d-142
8d-143
8d-144
8d-145
8d-146
8d-147
8d-148
8d-149
8d-150
8d-151
8d-152
8d-153
8d-154
8d-155
8d-156
8d-157
8d-158
8d-159
8d-160
8d-161
Common Hardware
Common Hardware ......................................................................................................... 8d-162
Part Number Index .......................................................................................................... 8d-163
Finisher Plug/Jacks
Wiring Connector List ...................................................................................................... 8d-167
Plug/Jack Locator Diagrams .......................................................................................... 8d-169
1/05
8d-2
Reissue
DocuColor 12/DCCS50
Wirenets
Finisher Wirenets ............................................................................................................ 8d-175

Finisher BSDs ................................................................................................................. 8d-183
Reissue
DocuColor 12/DCCS50
1/05
8d-3
Finisher/Sorter
Finisher/Sorter
1/05
8d-4
Reissue
DocuColor 12/DCCS50
3-319 Finisher/Sorter Communication Failure RAP

The 3-319 Fault Code indicates a communication failure between the IOT PWB and the Finisher PWB.
Initial Actions
Refer to BSD12.4 PWB Communications (Finisher) and to BSD 12.7, Monitoring, in this procedure.
Procedure
Y
N
If an intermittent is suspected, perform the following:
Check the connections to the IOT CPU PWB and the Finisher PWB, and the interconnecting harness
Reseat P/J405 at the IOT CPU PWB, P/J1027, and P/J1026 at the Finisher PWB,
and P880, the Double Plug
Check for +5 VDC at P/J1026-3. +5 VDC is measured at P/J1026-2 on the Finisher PWB.
Y
N
Go to +5VDC Wire Nets and check for an open/short circuit
Check for +24 VDC at P/J1026-1 on the Finisher PWB. +24 VDC is measured at P/J1026 4.
Y
N
Go to +24VDC-1 Wire Net and check for an open/short circuit
Go to Flag 1 on BSD 12.4, and check the following wires for an open/short circuit:
J405-1
J405-2
J405-3
J405-4
Replace the Finisher PWB (PL 18.4)
Reissue
DocuColor 12/DCCS50
1/05
8d-3
Finisher/Sorter
Finisher/Sorter
1/05
8d-4
Reissue
DocuColor 12/DCCS50
11-107 SCT Exit Sensor On Jam Long RAP
F
Y
The SCT Exit Sensor did not detect the lead edge of the paper within the specified time after
the Decurler Exit Sensor detected the lead edge of the same paper.
N
Go to Flag 7 on BSD 12.5. Check for an open circuit. If the
wires are OK, replace the Finisher PWB (PL 18.4).
Go to Flag 1 and Flag 2 on BSD12.5. Check for an open circuit.

If the wires are good, replace the Mailbox PWB (PL 18.11).
NOTE: Long indicates that the trail edge of the paper has not passed through the Machine
Exit Sensor.
Refer to BSD12.1, BSD12.5, BSD12.10 and BSD12.17 for the following procedure.
Press Start. There is less than +1 VDC from P/J1021-3 to GND.

Y
N
Replace the Mailbox PWB (PL 18.11).
Replace the Mailbox Drive Motor (PL 18.10).
Initial Actions
Obstructions in the Mailbox/Sorter paper path
Bent or out of position paper chutes/guides in the Mailbox/Sorter paper path
Ensure that there is sufficient nip force at the Mailbox/Sorter Entrance Roll and the SCT
Exit Roll.
Ensure that connectors P/J1040 on the Finisher PWB, P/J1076, and P/J1078 on the
SCT Exit Sensor are seated correctly and there are no obvious crimped or broken wires.
Ensure that the Mailbox Drive Motor Pulley is fastened to the motor shaft.
Check the Drive Belt Tension Pulley for proper tension
Procedure
The lead edge of the paper is at or past the SCT Exit Sensor.
Y
N
Y
N
Enter dC330 012-005 Mailbox Drive Motor. Press Start. The Mailbox Transport
Roll is rotating.
Y
N
The Mailbox Drive Belt is moving.
Y
N
The Mailbox Drive Motor is rotating.
Y
N
+24 VDC is measured between P/J1021-1 and P/J1021-2,4 of
the Mailbox Drive Motor.
Y
N
There is +24 VDC from pin 1 to pin 4 of P/J1025 on the Mailbox PWB.
Y
N
Go to Flag 6 on BSD 12.5. Check for an open circuit. If the
wires are OK, go to Flag 1 through Flag 5 on BSD 12.1.
Check the interlock circuit for an open wire or a malfunctioning interlock switch. If the circuit is OK, replace the Finisher PWB (PL 18.4).
Mailbox Entrance Roll (PL 18.10)
SCT Exit Roll (PL 18.10)

The Mailbox Gate is in the Up position
Y
N
Enter dC330 012-081 Mailbox Gate Solenoid Closed. Press Start. The
Mailbox
Gate Solenoid energized.
Y
N
+24 VDC is measured between P/J1042-15 and P/J1042-13 on the Finisher PWB.
Y
N
+24 VDC is measured between P/J1042-15 on the Finisher PWB and
GND.
Y
N
+24 VDC is measured between P/J1042-13 on the Finisher PWB
and GND.
Y
N
P/J1042-13 on the Finisher PWB and P/J45-6 on the Distribution PWB.
Go to Flag 3 on BSD 12.5. Check the wires for an open circuit. If

the wires are good, replace the Mailbox PWB (PL 18.11).

Y
N
There is +5 VDC from pin 3 to pin 4 of P/J1025 on the Mailbox PWB.
A
B
C
Reissue
DocuColor 12/DCCS50
Less than +1 VDC is measured between P/J1042-15 on the Finisher

PWB and GND
Y
N
A
F
1/05
8d-5
J
Finisher/Sorter
J
are good, replace the Mailbox Gate Solenoid (PL 18.11).
Go to Flag 5 on BSD12.7. Check the wires for an open circuit. If the wires are
good, ensure that the Mailbox gate is connected to the Mailbox Gate Solenoid
and that it moves freely. If the problem continues replace the Mailbox Gate (PL
18.11) and the Mailbox Gate Solenoid (PL 18.11).
Ensure that the Finisher Gate moves freely. If the problem continues replace the Finisher Gate (PL 18.11) and the Finisher Gate Solenoid (PL 18.11).
Enter dC330 012-107 SCT Entrance Sensor. Manually actuate the SCT Exit Sensor actuator.
The display changes from L to H to L as the actuator moves in and out of the sensor.
Y
N
Y
N
Go to Flag 3 on BSD12.10. Check the harness for a short circuit to ground. If the
harness is good, replace the SCT Exit Sensor (PL 18.13).
Ensure that the Mailbox gate is connected to the Mailbox Gate Solenoid and that it
moves freely. If the problem continues replace the Mailbox Gate (PL 18.11) and the
Mailbox Gate Solenoid (PL 18.11).
The Finisher Gate is in the Down position
Y
N
Enter dC330 012-070 Finisher Gate Solenoid Closed. Press Start. The
Finisher
Y
N
Y
N
+24 VDC is Measured between P/J1042-16 on the Finisher PWB and
GND
Y
N
and GND.
Y
N
P/J1042-14 on the Finisher PWB and P/J45-6 on the Distribution PWB
+5 VDC is measured between P/J1078-1 and P/J1078-3 at the SCT Exit Sensor.
Y
N
Y
N
+5 VDC is measured between P/J1026-3 and P/J1026-2 on the Finisher
PWB.
Y
N
Y
N
Go to the +5VDC Figure 1 wirenet and check wires for an open or
short circuit.
Go to Flag 17 on BSD12.1 and check the harness for an open circuit.
Replace the Finisher PWB (PL 18.4).
Go to Flag 2 on BSD12.10 and check the harness for an open or a short circuit.
Replace or repair as required.

PWB and GND
Y
N
Go to Flag 3 on BSD12.10. Check the harness for an open circuit. If the harness is good,
replace the SCT Exit Sensor (PL 18.13).
Y
N
Replace the SCT Exit Sensor (PL 18.13).
are good, replace the Finisher Gate Solenoid (PL 18.11).
good, ensure that the Finisher gate is connected to the Finisher Gate Solenoid
and that it moves freely. If the problem continues replace the Finisher Gate (PL
18.11) and the Finisher Gate Solenoid (PL 18.11).
Ensure that the Finisher Gate is connected to the Finisher Gate Solenoid and that it
moves freely. If the problem continues replace the Finisher Gate (PL 18.11) and the
Finisher Solenoid (PL 18.11).
Vertical Transport.
A
Finisher/Sorter
1/05
8d-6
Reissue
DocuColor 12/DCCS50
11-108 SCT Exit Sensor Off Jam RAP

The SCT Exit Sensor did not deactuate within the specified time after the SCT Exit Sensor
actuated.
Initial Actions
Obstructions in the Mailbox paper path

Bent or out of position paper chutes/guides in the Mailbox paper path
Ensure that there is sufficient nip force at the Mailbox Transport Roll and the SCT Exit
Roll.
Ensure that connectors P/J1040 on the Mailbox PWB and P/J1076 on the SCT Exit Sensor are seated correctly and there are no obvious crimped or broken wires.
Check the SCT Exit Sensor Actuator for binding as it moves in and out of the sensor. The
actuator is binding.
Y
N
belts that would cause the copy to be slow to actuate the SCT Exit Sensor.
B
Procedure
The trail edge of the paper is past the SCT Exit Sensor
Y
N
Enter dC330 012-005 Mailbox Drive Motor. Press Start. The Mailbox Transport Roll is
rotating.
Y
N
Y
N
The Mailbox Drive Motor is rotating
Y
N
+24 VDC is measured between P/J1021-1 and P/J1021-2 of the Mailbox Drive Motor
Y
N
wires are good, replace the Mailbox PWB (PL 18.11).
Y
N
Go to Flag 1 and Flag 2 on BSD12.5. Check the wires for an open
circuit. If the wires are good, replace the Mailbox PWB (PL 18.11).
GND.
Y
N
Replace the Mailbox PWB (PL 18.11)
A
B
Reissue
DocuColor 12/DCCS50
1/05
8d-7
Finisher/Sorter
11-108 SCT Exit Sensor Off Jam RAP
E
11-109 SCT Exit Sensor On Jam Short RAP

The SCT Exit Sensor did not detect the lead edge of the paper within the specified time after
the Decurler Exit Sensor detected the trail edge of the same paper.
NOTE: Short indicates that the trail edge of the paper has passed through the Machine Exit
Sensor.
Initial Actions
Refer to BSD12.5, BSD12.7, BSD12.10 and BSD12.17 for the following procedure.
Ensure that there is sufficient nip force at the Mailbox Transport Roll and the SCT Exit
Roll.
Ensure that connectors P/J1040 on the Mailbox PWB and P/J1076 on the SCT Exit Sensor are seated correctly and there are no obvious crimped or broken wires.
The SCT Gate is in the Up position.

Y
N
Enter dC330 012-061 Tamper Motor Top Front. Press Start. The SCT Gate Solenoid energized.
Y
N
+24 VDC is measured between P/J1042-15 and P/J1042-13 on the Mailbox PWB.
Y
N
+24 VDC is Measured between P/J1042-15 Mailbox PWB and GND
Y
N
+24 VDC is measured between P/J1042-13 on the Mailbox PWB
and GND.
Y
N
P/J1042-13 on the Mailbox PWB and P/J45-6 on the Distribution PWB
Procedure
The lead edge of the paper is at or past the SCT Exit Sensor
Y
N
Y
N
Enter dC330 012-005 Mailbox Drive Motor. Press Start. The Mailbox Transport
Roll is rotating.
Y
N
Y
N
Y
N
Mailbox Drive Motor
Y
N
the wires are good, replace the Mailbox PWB (PL 18.11).

Y
N
are good, replace the SCT Gate Solenoid (PL 18.11).

Y
N
Go to Flag 1 and Flag 2 on BSD12.5. Check the wire for an
open circuit. If the wire is good, replace the Mailbox PWB (PL
18.11).
good, ensure that the SCT gate is connected to the SCT Gate Solenoid and
that it moves freely. If the problem continues replace the SCT Gate (PL 18.11)
and the SCT Gate Solenoid (PL 18.11).

and GND.
Y
N
Ensure that the SCT gate is connected to the SCT Gate Solenoid and that it moves
freely. If the problem continues replace the SCT Gate (PL 18.11) and the SCT Gate
Solenoid (PL 18.11).

A
B
C
D
Finisher/Sorter
The Finisher Gate is in the Down position

A
1/05
8d-8
Reissue
DocuColor 12/DCCS50
F
Y
N
Enter dC330 012-070 Finisher Gate Solenoid Closed. Press Start. The
Finisher
Y
N
Y
N
+24 VDC is Measured between P/J1042-16 on the Finisher PWB and
GND
Y
N
and GND.
Y
N
P/J1042-14 on the Finisher PWB and P/J45-6 on the Distribution PWB
G
+5 VDC is measured between P/J1078-1 and v-3
Y
N
Y
N
Y
N
Y
N
Go to the +5VDC Figure 1 wirenet and check wires for an open or
short circuit.
Go to Flag 2 on BSD12.10 and check the harness for an open or a short circuit.
Replace or repair as required.

Go to Flag 3 on BSD12.10. Check the harness for an open circuit. If the harness is good,
replace the SCT Exit Sensor (PL 18.13).

PWB and GND
Y
N
Y
N
are good, replace the Finisher Gate Solenoid (PL 18.11).
good, ensure that the Finisher gate is connected to the Finisher Gate Solenoid
and that it moves freely. If the problem continues replace the Finisher Gate (PL
18.11) and the Finisher Gate Solenoid (PL 18.11).

Ensure that the Finisher Gate is connected to the Finisher Gate Solenoid and that it
moves freely. If the problem continues replace the Finisher Gate (PL 18.11) and the
Finisher Solenoid (PL 18.11).
Vertical Transport.
Ensure that the Mailbox Gate moves freely. If the problem continues replace the
Mailbox Gate (PL 18.11) and the Mailbox Gate Solenoid (PL 18.11).
Enter dC330 012-107 SCT Entrance Sensor. Manually actuate the SCT Exit Sensor actuator.
The display changes from L to H to L as the actuator moves in and out of the sensor.
Y
N
Y
N
Go to Flag 3 on BSD12.10. Check the harness for a short circuit to ground. If the
harness is good, replace the SCT Exit Sensor (PL 18.13).
F
G
Reissue
DocuColor 12/DCCS50
1/05
8d-9
Finisher/Sorter
11-110 Paper Remains at Decurler Exit Sensor Long RAP
11-111 Paper Remains at Decurler Exit Sensor Short RAP
Initial Actions
Initial Actions
Ensure that P/J651 and P/J654 on the Decurler Control PWB, and P/J658 on the
Decurler Exit Sensor are connected before beginning this RAP.
Procedure
Procedure
Y
N
Go to Flag 9, Flag 10, and Flag 11 on BSD12.6 and check the harness for a short circuit.
If the harness is good, replace the Decurler Exit Sensor (PL 18.6). If the problem continues, replace the Decurler PWB (PL 18.6).
Y
N
+5VDC is measured between P/J654-2 and GND on the Decurler PWB.

Y
N

Y
N
Decurler PWB (PL 18.6).
Finisher/Sorter
11-110 Paper Remains at Decurler Exit Sensor Long
1/05
8d-10
Reissue
DocuColor 12/DCCS50
11-115 Mailbox Vertical Sensor / Bin 1 Sensor On Jam RAP
The Mailbox Vertical Sensor did not detect the lead edge of the paper within the specified time
after the Decurler Exit Sensor detected the lead edge of the same paper.
Initial Actions
Refer to BSD12.5, BSD12.8 , BSD12.9, and BSD12.17 for the following procedure.
Ensure that the Mailbox front Door is closed properly, in order to provide proper nip pressure to the Vertical Transport Rolls.
Ensure that connectors P/J1004 on the Mailbox PWB, P/J1022 double plug, P/J1023
and P/J1024, on the Mailbox Vertical Sensor is seated correctly and there are no obvious

GND.
Y
N
Replace the Mailbox PWB (PL 18.11). If the problem continues,
replace the Finisher PWB (PL 18.4).
A
B
Reissue
DocuColor 12/DCCS50


Y
N
The Vertical LED is on.

Y
N
Y
N
+5 VDC is measured between P/J1025-3 and P/J1025-4 on the Mailbox
PWB.
Y
N
+5 VDC is measured between P/J1029-3 and P/J1029-4 on the Finisher PWB
Y
N
Go to the +5 VDC wirenet and troubleshoot the wires between P/
J1029-1 and P/J44-22 on the Distribution PWB.
The lead edge of the paper is at or past the Mailbox Vertical Sensor
Y
N
rotating.
Y
N
Y
N
Y
N
+24 VDC is measured between P/J1021-1 and P/J1021-2, 4, 6 of the
Mailbox Drive Motor
Y
N
Enter dC330 012-115 Vertical Sensor. Manually block the Mailbox Vertical Sensor with a sheet
of paper. The display changes from L to H to L as the paper moves in and out of the sensor.
Y
N
Y
N
Go to Flag 21 and Flag 22 on BSD12.8. Check the harness for a short circuit to
ground. If the harness is good, replace the Mailbox Vertical Sensor (PL 18.13).
Procedure
Go to Flag 19 and Flag 20 on BSD12.8. Check the harness for an open circuit. If the
harness is good, replace the Vertical LED (PL 18.22).
Go to Flag 21 and Flag 22 on BSD12.8. Check the wire for an open circuit. If the wire is
good, replace the Mailbox Vertical Sensor (PL 18.13).
With paper at the sensor, more than +4.3 VDC is measured between P/J1004-3 and DC
Com.
Y
N
Replace the Mailbox Vertical Sensor (PL 18.13).
1/05
8d-11
Finisher/Sorter
11-115 Mailbox Vertical Sensor / Bin 1 Sensor On
11-116 Mailbox Vertical Sensor / Bin 1 Sensor Off Jam RAP

The Mailbox Vertical Sensor did not detect the Trail edge of the paper within the specified time
after the Mailbox Vertical Sensor detected the lead edge of the same paper.
Initial Actions
Procedure
The trail edge of the paper is past the Mailbox Vertical Sensor
Y
N
rotating.
Y
N
Y
N
Y
N
+24 VDC is measured between P/J1021-1 and P/J1021-2, 4, 6 of the
Mailbox Drive Motor
Y
N
Y
N
GND.
Y
N
A
Finisher/Sorter
11-115 Mailbox Vertical Sensor / Bin 1 Sensor On Jam
1/05
8d-12
B
Reissue
DocuColor 12/DCCS50
11-142 Mailbox Entrance Sensor On Jam Long RAP
Ensure that the Mailbox front Door is closed properly, in order to provide proper nip
pressure to the Vertical Transport Rolls.

Initial Actions
Refer to BSD12.5, BSD12.7 and BSD12.17 for the following procedure.
The Mailbox Entrance Sensor did not detect the lead edge of the paper within the specified
time after the Decurler Exit Sensor detected the lead edge of the same paper.

Check the Mailbox Vertical Sensor for intermittent operation. Replace the Mailbox Vertical
Sensor (PL 18.13) if the problem is not resolved.
Procedure
The lead edge of the paper is at or past the Mailbox Entrance Sensor.
Y
N
Y
N
The Mailbox Gate is in the down or Bin Tray position.
Y
N
Enter dC330 012-082 Mailbox Gate Solenoid Open. Press Start. The Mailbox
Y
N
+24 VDC is measured between P/J1024-15 and P/J1024-17 on the
Finisher PWB.
Y
N
+24 VDC is measured between P/J1024-15 Finisher PWB and
GND
Y
N
+24 VDC is measured between P/J1042-13 on the Finisher
PWB and GND.
Y
N
between P/J1042-13 on the Finisher PWB and P/J45-6
on the Distribution PWB
Y
N
circuit. If the wires are good, replace the Mailbox Gate Solenoid (PL
18.11).
A
Reissue
DocuColor 12/DCCS50
1/05
8d-13
E
Finisher/Sorter
11-116 Mailbox Vertical Sensor / Bin 1 Sensor Off
E
are good, ensure that the Mailbox gate is connected to the Mailbox Gate
Solenoid and that it moves freely. If the problem continues, replace the
Ensure that the Mailbox Gate is connected to the Mailbox Gate Solenoid and
that it moves freely. If the problem continues replace the Mailbox Gate (PL

GND.
Y
N

Enter dC330 012-142 Mailbox Entrance Sensor. Manually actuate the Mailbox Entrance Sensor actuator. The display changes from L to H to L as the actuator moves in and out of
the sensor.
Y
N
Y
N
Go to Flag 8 on BSD12.7. Check the harness for a short circuit to ground. If the harness is good, replace the Mailbox Entrance Sensor (PL 18.13).
+5 VDC is measured between P/J1017-1 and P/J1017-3 on the Mailbox Entrance
Sensor.
Y
N
Y
N
Y
N
Go to the +5VDC Figure 1 wirenet and check wires for an open or short
circuit.
rotating.
Y
N
Y
N
Y
N
Y
N
circuit. If the wires are good, replace the Mailbox PWB (PL 18.11). If
the problem continues, replace the Finisher PWB (PL 18.4).
Y
N
Go to Flag 1 and Flag 2 on BSD12.5. Check the wire for an open circuit. If the wire is good, replace the Mailbox PWB (PL 18.11).

Go to Flag 7 on BSD12.7. Check the wires for an open. If the wires are OK, replace
the Finisher PWB (PL 18.4).
Go to Flag 8 and Flag 7 on BSD12.7. Check the harness for an open circuit. If the harness is good, replace the Mailbox Entrance Sensor (PL 18.13).
Y
N
Replace the Mailbox Entrance Sensor (PL 18.13).
A
Finisher/Sorter
11-142 Mailbox Entrance Sensor On Jam Long RAP
1/05
8d-14
Reissue
DocuColor 12/DCCS50
11-143 Mailbox Entrance Sensor Off Jam RAP
The Mailbox Entrance Sensor did not deactuate within the specified time after the V-Tra In Sensor actuated.
Initial Actions
Check the Mailbox Entrance Sensor Actuator for binding as it moves in and out of the sensor.
The actuator is binding.
Y
N
belts that would cause the fed paper to be slow to deactuate the Mailbox Entrance Sensor.
Procedure
The trail edge of the paper is past the SCT Exit Sensor
Y
N
rotating.
Y
N
Y
N
Y
N
Y
N
Y
N
GND.
Y
N
A
B
Reissue
DocuColor 12/DCCS50
1/05
8d-15
Finisher/Sorter
11-143 Mailbox Entrance Sensor Off Jam RAP
11-144 Mailbox Entrance Sensor On Jam Short RAP

The Mailbox Entrance Sensor did not detect the lead edge of the paper within the specified
time after the Decurler Exit Sensor detects the lead edge of the same paper.
Initial Actions
rotating.
Y
N
Y
N
Y
N
Y
N
Procedure
The lead edge of the paper is at or past the Mailbox Entrance Sensor.
Y
N
Y
N
The Mailbox Gate is in the down or Bin Tray position.
Y
N
Enter dC330 012-082 Mailbox Gate Solenoid Open. Press Start. The Mailbox
Y
N
+24 VDC is measured between P/J1042-15 and P/J1042-17 on the
Finisher PWB.
Y
N
+24 VDC is Measured between P/J1042-15 Finisher PWB and
GND
Y
N
+24 VDC is measured between P/J1042-13 on the Finisher
PWB and GND.
Y
N
between P/J1042-13 on the Finisher PWB and P/J45-6
on the Distribution PWB

Y
N
GND.
Y
N

Y
N
11-144 Mailbox Entrance Sensor On Jam Short RAP

circuit. If the wires are good, replace the Mailbox Gate Solenoid (PL
18.11).
E
E
Go to Flag 2 and Flag 3 on BSD12.7. Check the wires for an open circuit.
If the wires are good, ensure that the Mailbox gate is connected to the
Mailbox Gate Solenoid and that it moves freely. If the problem continues,
replace the Mailbox Gate (PL 18.11) and the Mailbox Gate Solenoid (PL
18.11).
Ensure that the Mailbox Gate is connected to the Mailbox Gate Solenoid and
that it moves freely. If the problem continues replace the Mailbox Gate (PL
A
B
C
D
Finisher/Sorter
A
1/05
8d-16
Reissue
DocuColor 12/DCCS50

after the M/C Exit Sensor detected the lead edge of the same paper.

Enter dC330 012-142 Mailbox Entrance Sensor. Manually actuate the Mailbox Entrance Sensor actuator. The display changes from L to H to L as the actuator moves in and out of
the sensor.
Y
N
Y
N
Go to Flag 8 on BSD12.7. Check the harness for a short circuit to ground. If the harness is good, replace the Mailbox Entrance Sensor (PL 18.13).
Y
N
CR1 on the Mailbox PWB is on.
Y
N
Go to Flag 8 and Flag 7 on BSD12.7. Check the harness for an open circuit. If the harness is good, replace the Mailbox Entrance Sensor (PL 18.13).
Y
N
Initial Actions
Ensure that connectors P/J654, P/J653, and P/J651 on the Decurler PWB, Double Plug
P/J661, P/J1028 on the Finisher PWB and P/J658 on the Decurler Exit Sensor are
Procedure
Y
N
Y
N
Y
N
Enter dC330 012-010 Decurler Stepping Motor Speed 60. The Decurler Stepping Motor rotates.
Y
N
Check F1 fuse on the Decurler PWB. The fuse is open (blown).
Y
N
+24 VDC is measured between P/J653-1 and GND on the
Decurler PWB.
Y
N
Finisher PWB.
Y
N
Go to Wire Net +24VDC-2. Check the wire for an open circuit. If
the wire is good, replace the Decurler PWB (PL 18.6).
Press Stop. +24 VDC is measured between P/J653-3, 4, 5, 6 and
GND on the Decurler PWB.
Y
N
Replace the Decurler Motor (PL 18.8). If the problem continues,
replace the Decurler PWB (PL 18.6).
Press Start. approximately +1.5 VDC is measured between P/
J653-3, 4, 5, 6 and GND on the Decurler Control PWB.
Y
N
Press Stop. +5 VDC is measured between P/J1026-3 and
GND
A
Reissue
DocuColor 12/DCCS50
1/05
8d-17
F
Finisher/Sorter
11-144 Mailbox Entrance Sensor On Jam Short
A
Y
N
Go to Wire Net +5VDC-1. Check the wire for an open circuit. If the wire is good, replace the Finisher PWB (PL
18.4).
N
Replace the Decurler PWB (PL 18.6).
Replace the Decurler Motor (PL 18.8).
Press Start. +2.5 VDC is measured between P/J651-A6 and

GND.
Y
N

Decurler
Y
N
GND.
Y
N

GND
Y
N
Go to Flag 4 on BSD12.6. Check the wire for an open circuit. If the wire is good, replace the Finisher PWB (PL
18.4).

less than +0.5 VDC is measured between P/J651-A5 and

GND.
Y
N

Go to the 10-111 Machine Exit Sensor Off Jam RAP Machine Exit Sensor Off Jam
RAP.


Y
N

Decurler
Y
N
GND.
Y
N
A
B
C
G
Finisher/Sorter
Y
N
Y
N
Y
N

Decurler
Y
N
GND.

Y
N
+5 VDC is measured between P/J654-1 and P/J654-3 on the Decurler PWB.
H
Reissue
1/05
8d-18
DocuColor 12/DCCS50
H
Y
N
Y
N
PWB.
Y
N
Y
N
Go to the +5VDC Figure 1 wirenets and check wires for an open or
short circuit.

after the MC Exit Sensor detected the lead edge of the same paper.
Initial Actions
Ensure that connectors P/J654, P/J653, and P/J651 on the Decurler PWB, Double Plug
P/J661, P/J1028 on the Finisher PWB and P/J658 on the Decurler Exit Sensor are

Go to Flag 9 on BSD12.6. Check the wire for an open circuit. If the wires are good,
More than +4.5 VDC is measured between P/J658-2 and GND on the Decurler Exit Sensor.
Y
N
Procedure
Y
N
Y
N
Y
N
Enter dC330 012-010 Decurler Stepping Motor Speed 60. The Decurler Stepping Motor rotates.
Y
N
Check F1 fuse on the Decurler PWB. The fuse is open (blown).
Y
N
Decurler PWB.
Y
N
+24 VDC is Measured between P/J1026-1 and GND on the
Finisher PWB.
Y
N
Go to Wire Net +24VDC-2. Check the wire for an open circuit. If
the wire is good, replace the Decurler PWB (PL 18.6).
Press Stop. +24 VDC is measured between P/J653-3, 4, 5, 6 and
GND on the Decurler PWB.
Y
N
Replace the Decurler Motor (PL 18.8). If the problem continues,
Press Start. approximately +1.5 VDC is measured between P/
J653-3, 4, 5, 6 and GND on the Decurler Control PWB.
Y
N
GND
A
Reissue
DocuColor 12/DCCS50
1/05
8d-19
F
Finisher/Sorter
11-145 Decurler Exit Sensor On Jam Long RAP, 11-
A
Y
N
Go to Wire Net +5VDC-1. Check the wire for an open circuit. If the wire is good, replace the Finisher PWB (PL
18.4).
N
Press Start. +2.5 VDC is measured between P/J651-A6 and

GND.
Y
N

Decurler
Y
N
GND.
Y
N

GND
Y
N
Go to Flag 4 on BSD12.6. Check the wire for an open circuit. If the wire is good, replace the Finisher PWB (PL
18.4).

less than +0.5 VDC is measured between P/J651-A5 and

GND.
Y
N

Go to the 10-111 Machine Exit Sensor Off Jam RAP Machine Exit Sensor Off Jam
RAP.


Y
N

Decurler
Y
N
GND.
Y
N
A
B
C
G
Finisher/Sorter
Y
N
Y
N
Y
N

Decurler
Y
N
GND.

Y
N
+5 VDC is measured between P/J654-1 and P/J654-3 on the Decurler PWB.
H
Reissue
1/05
8d-20
DocuColor 12/DCCS50
H
Y
N
Y
N
PWB.
Y
N
Y
N
Go to the +5VDC Figure 1 wirenets and check wires for an open or
short circuit.
11-190 Paper Remains on V-Tra In Sensor RAP

The Control Logic detected that paper remained on the V-Tra In Sensor at power on.
Initial Actions
Ensure that no paper is blocking the V-Tra In sensor and the sensor actuator moves freely.
Ensure that P/J1040 on the Finisher PWB, P/J1076 double plug, and P/J1017 on the
Mailbox Entrance Sensor are connected before beginning this RAP.
Procedure

Go to Flag 9 on BSD12.6. Check the wire for an open circuit. If the wires are good,
More than +4.5 VDC is measured between P/J658-2 and GND on the Decurler Exit Sensor.
Y
N
Reissue
DocuColor 12/DCCS50
Enter dC330 012-142 Mailbox Entrance Sensor. Press Start. The display is L.
Y
N
Go to Flag 7 and Flag 8 on BSD12.7 and check the harness for a short circuit. If the harness is good, replace the Mailbox Entrance Sensor (PL 18.13). If the problem continues,
More than +4.3 VDC is measured between P/J1040-4 and GND on the Finisher PWB.
Y
N
Check the Mailbox Entrance Sensor for intermittent operation. If the sensor is good, Replace
1/05
8d-21
Finisher/Sorter
11-146 Decurler Exit Sensor On Jam Short RAP, 11-
11-191 Paper Remains at Mailbox Vertical Sensor / 1 Bin

Sensor RAP
11-192 Paper Remains at SCT Exit Sensor RAP

The Control Logic detected that paper remained on the SCT Exit Sensor at power on.
The Control Logic detected that paper remained on the Mailbox Vertical Sensor at power on.
Initial Actions
Initial Actions
Ensure that no paper or foreign object is blocking the Mailbox Vertical sensor.
Ensure that no paper is blocking the SCT Exit sensor and the sensor actuator moves
freely.
Ensure that the Mailbox Vertical sensor and the Vertical LED are clean.
Check for excessive static on copies.
Ensure that P/J1004 on the Finisher PWB, and P/J1023 and P/J1024 on the Mailbox
Vertical Sensor are connected before beginning this RAP.
Ensure that P/J1040 on the Mailbox PWB, and P/J1017 on the Mailbox Entrance Sensor
Procedure
Enter dC330 012-115 Vertical Sensor. Press Start. The display is L.
Y
N
Y
N
Y
N
PWB
Y
N
Go to the +5 VDC wirenet and troubleshoot the wires between P/J1029-1
and P/J44-22 on the Distribution PWB.
Procedure
Enter dC330 012-107 SCT Entrance Sensor. Press Start. The display is L.
Y
N
+5VDC is measured between P/J1040-1 and GND on the Mailbox PWB.
Y
N
Go to Flag 3 on BSD12.10 and check the harness for a short circuit. If the harness is
good, replace the SCT Exit Sensor (PL 18.13).
If the problem is intermittent, ensure that the SCT Exit Sensor is clean. If the problem continues, go to Flag 2 and Flag 3 on BSD12.10 and check for loose connectors or crimped wires. If
the problem continues, replace the SCT Exit Sensor (PL 18.13).

Go to Flag 19 and Flag 20 on BSD12.8. Check the harness for an open circuit. If the harness is good, replace the Vertical LED (PL 18.13).
Less than +0.5 VDC is measured between P/J1004-3 and DC COM on the Mailbox PWB.
Y
N
Replace the Mailbox Vertical Sensor (PL 18.13).
Check the Mailbox Vertical Sensor for intermittent operation. If the sensor is good, Replace the
Mailbox PWB (PL 18.11).
Finisher/Sorter
11-191 Paper Remains at Mailbox Vertical Sensor / 1
1/05
8d-22
Reissue
DocuColor 12/DCCS50
11-193 Decurler Exit Sensor Static Jam RAP
11-301 Mailbox Door Interlock Open RAP
The Control Logic detected paper remained on the Decurler Exit Sensor.
Mailbox Door Interlock Open Failure. This status code is declared when the Mailbox Door Interlock Switch is open.
Initial Actions
Initial Actions
Ensure that P/J1033 on the Finisher PWB, and P/J1018 on the Mailbox Door Interlock
Switch are connected before beginning this RAP.
Check the Front Door for proper alignment.
Verify that the Front Door closes properly.
Procedure
Y
N
Y
N
Procedure
Enter dC330 012-301 Mailbox Door Intlk Sw. The state of the Mailbox Door Interlock
Switch is Low and switches to High when the Mailbox Door is opened.
Y
N
With the Front Cover closed, there is +0 VDC between P/J1033-1 on the Finisher
and GND.
Y
N
Go to the Flag 1 and Flag 2 on BSD12.1. Check the wires for an open circuit. If the
wires are good, replace the Mailbox Door Interlock Switch (PL 18.11). If the problem
continues, replace the Finisher PWB (PL 18.4).
Check the Mailbox Door Interlock Switch for intermittent operation. Ensure that the switch
and the cover are properly aligned and adjusted. If the problem continues, replace the
Finisher PWB (PL 18.4).
Check the Mailbox Door Interlock Switch for intermittent operation. Ensure that the switch and
the cover are properly aligned and adjusted. If the problem continues, replace the Finisher
PWB (PL 18.4).
Reissue
DocuColor 12/DCCS50
1/05
8d-23
Finisher/Sorter
11-193 Decurler Exit Sensor Static Jam RAP, 11-
11-302 Decurler Door Interlock Open RAP
11-303 Docking Interlock Open RAP
Decurler Door Interlock Open Failure. This status code is declared when the Decurler Front
Cover is open.
Docking Interlock Open failure. This status code is declared when the Mailbox is not properly
docked.
Initial Actions
Initial Actions
Ensure that P/J1033 on the Finisher PWB, and P/J1018 on the Decurler Door Interlock
Switch are connected before beginning this RAP.
Ensure that P/J1028 on the Finisher PWB, P/J664 and P/J665 on the Docking Interlock
Switches, P/J651 and P/J652 on the Decurler PWB are connected before beginning this
RAP.
Check the Finisher/Mailbox for proper alignment.
Procedure
Procedure
Enter dC330 012-302 Decurler Door Intlk Sw. The state of the Decurler Door Interlock
Switch is Low and switches to High when the Decurler Door is opened.
Y
N
With the Front Cover closed, there is +0 VDC between P/J1028-B6 on the Finisher
PWB and GND.
Y
N
Go to the Flag 1 and Flag 2 on BSD12.1. Check the wires for an open circuit. If the
wires are good, replace the Decurler Door Interlock Switch (PL 18.11). If the problem
continues, replace the Decurler PWB (PL 18.6). If the problem continues, replace
Enter dC330 012-303 Mailbox Docking INTLK Switches. The status of the Docking Interlock Switches is High and changes to Low when the Mailbox is undocked.
Y
N
With the Finisher/Mailbox docked, there is +5 VDC between P/J1028-B7 on the Finisher PWB and GND.
Y
N
Disconnect P/J665 from the Docking Interlock Switch 2. With the Finisher/Mailbox docked, there is +5 VDC between P/J1028-B7 on the Finisher PWB and
GND.
Y
N
Disconnect P/J664 from the Mailbox Docking Interlock Switch 1. With the Finisher/Mailbox docked, there is +5 VDC between P/J1028-B7 on the Finisher PWB and GND.
Y
N
Go to the Flag 10, Flag 11 and Flag 13 on BSD12.1. Check the wires for
an short circuit to ground. If the wires are good, replace the Finisher PWB
(PL 18.4).
Check the Decurler Door Interlock Switch for intermittent operation. Ensure that the
the Decurler PWB (PL 18.6). If the problem continues, replace the Finisher PWB (PL
18.4).
Check the Decurler Door Interlock Switch for intermittent operation. Ensure that the switch and
the cover are properly aligned and adjusted. If the problem continues, replace the Finisher
PWB (PL 18.4).
Replace the Docking Interlock Switch 1 (PL 18.6).

Replace the Docking Interlock Switch 2 (PL 18.6).
Check the Docking Interlock Switches for intermittent operation. Ensure that the switches
are properly aligned and adjusted. If the problem continues, replace the Finisher PWB
(PL 18.4).
Check the Mailbox Door Interlock Switch for intermittent operation. Ensure that the switch and
the cover are properly aligned and adjusted. Check that the Finisher/Mailbox is standing on an
even floor. Adjust Castors if necessary. If the problem continues, replace the Mailbox PWB (PL
18.11).
Finisher/Sorter
11-302 Decurler Door Interlock Open RAP, 11-303
1/05
8d-24
Reissue
DocuColor 12/DCCS50
This status code is declared when the Decurler Cam Position Sensor did not energize within
the specified time (1400msec) after the Decurler Cam Clutch is energized.
Go to Wire Net +24VDC-2. Check the wire for an open circuit. If the wire is good,
Initial Actions
Ensure that connectors P/J652, and P/J651 on the Decurler PWB, P/J1028 on the Finisher PWB, and P/J656 on the Decurler Cam Sensor are seated correctly and there are
no obvious crimped or broken wires.
Press Stop. +24 VDC is measured between P/J653-3, 4, 5, 6 and GND on the
Decurler PWB.
Y
N
Replace the Decurler Motor (PL 18.8). If the problem continues, replace the Decurler
PWB (PL 18.6).
Procedure
Press Start. approximately +1.5 VDC is measured between P/J653-3, 4, 5, 6 and

GND on the Decurler Control PWB.
Y
N
Press Stop. +5 VDC is measured between P/J1026-3 and GND
Y
N
Go to Wire Net +5VDC-1. Check the wire for an open circuit. If the wire is good,
At Power On, the Mailbox Drive Belt is moving

Y
N
Enter dC330 012-005 Mailbox Drive Motor. Press Start. The Mailbox Drive Motor is
rotating
Y
N
+24 VDC is measured between P/J1021-1 and P/J1021-2 of the Mailbox Drive
Motor
Y
N
Switch Off the Power. Disconnect P/ P/J1021 from the Mailbox Drive Motor.
Switch On the Power. +24 VDC is measured between P/J1021-1 and P/
J1021-2.
Y
N
Go to Flag 3 and Flag 2 on BSD12.5. Check the wires for an open circuit.
If the wires are good, replace the Mailbox PWB (PL 18.11).

Y
N
Press Stop. +5 VDC is measured between P/J1026-3 and GND
Y
N
Replace the Mailbox Drive Motor (PL 18.10)
less than +0.5 VDC is measured between P/J651-A5 and GND.

Y
N
Press Stop. +5 VDC is measured between P/J1021-3 and GND on the Mailbox
Drive Motor.
Y
N
Go to Flag 1 and Flag 2 on BSD12.5. Check the wire for an open circuit. If the
wire is good, replace the Mailbox PWB (PL 18.11).
Press Start. Less than +1 VDC is measured between P/J1021-3 and GND on
Y
N

Y
N

Ensure that the Mailbox Drive Motor Pulley is fastened to the motor shaft and the drive
belt is properly tensioned.
Enter dC330 012-010 Decurler Stepping Motor Speed 60. The Decurler Motor rotates.
Y
N
+24 VDC is measured between P/J653-1 and GND on the Decurler PWB.
Y
N
+24 VDC is Measured between P/J1026-1 and GND on the Finisher PWB.
A
B
Reissue
DocuColor 12/DCCS50
N
Y
N
Approximately +1.5VDC is measured between P/J653-3, 4, 5, 6 and GND.
Y
N
C
1/05
8d-25
Finisher/Sorter
C
Y
N
Y
N
11-512 Simple Catch Tray (SCT) Full Stack RAP

The Control Logic detected that the Simple Catch Tray is full.
Initial Actions

Y
N
Y
N
Ensure that the Simple Catch Tray is empty
Ensure that connectors P/J1040 on the Finisher PWB, Double Plug P/J1080, and P/
J1079 on the SCT Full Sensor are seated correctly and there are no obvious crimped or
broken wires.
Procedure

Enter dC330 012-276 Decurler Cam Position Sensor. Press Start. Manually move the Reflector in and out of the sensor The Decurler Cam Position Sensor alternates between H and
L as the reflector is moved in and out of the sensor.
Y
N
The Display is always L
Y
N
Y
N
Go to Flag 8 on BSD12.6. Check the wire for a short circuit to ground. If the
wire is good, replace the Decurler Cam Position Sensor (PL 18.7). If the problem continues, replace the Decurler PWB (PL 18.6).
Y
N
Go to Flag 12 on BSD12.6. Check the wire for an open circuit. If the wire is
good, replace the Decurler PWB (PL 18.6). If the problem continues, replace
Enter dC330 012-275 SCT Full Sensor. Press Start. The display is H.
Y
N
+5 VDC is measured between P/J1040-6 and DC-COM on the Finisher PWB.
Y
N
good, replace the SCT Full Sensor (PL 18.3).
Block the SCT Full Sensor with a sheet of paper. The display changes to L.
Y
N
+5 VDC is measured between P/J1079-1 and P/J1079-3 on the SCT Full Sensor.
Y
N
Y
N
Go to the +5VDC Figure 1 wirenets and check wires for an open or short circuit.
Go to Flag 1 on BSD12.4. Check the harness for an open or short circuit. If the harness is good, replace the SCT Full Sensor (PL 18.3).
Replace the SCT Full Sensor (PL 18.3).
Check the Full Stack Sensor for intermittent operation, If the problem continues, replace the
SCT Full Sensor (PL 18.3).
+5 VDC is Measured between P/J652-1 and P/J652-3 on the Decurler PWB.

Y
N
Go to Flag 7 on BSD12.6. Check the wires for an open circuit. If the wires are good,
replace the Decurler Cam Position Sensor (PL 18.7). If the problem continues, replace
the Decurler PWB (PL 18.6).
Clean the Decurler Cam Position Sensor and the Decurler Cam Position Sensor Reflector.
Ensure that there are no obstructions between the Decurler Cam Position Sensor and the
Decurler Cam Position Sensor. If the problem continues, replace the Decurler Cam Position
Sensor (PL 18.7).
Finisher/Sorter
11-350 Decurler 1 Fail RAP, 11-512 Simple Catch Tray
1/05
8d-26
Reissue
DocuColor 12/DCCS50
Initial Actions
Initial Actions
Procedure
Procedure
Enter dC330 012-281 Bin 1 Full Sensor. Press Start. Manually move the actuator in and out of
the sensor The display Changes from H to L to H as the actuator is moved in and out of
the sensor.
Y
N
Press Stop. +5VDC is measured between P/J1002-1 and DC COM on the Mailbox
PWB.
Y
N
+5VDC is measured between P/J1031-11 and DC COM on the Finisher PWB.
Y
N
the sensor.
Y
N
PWB.
Y
N
Y
N
Go to Flag 1 on BSD12.9 and check the wires for an open circuit.
Reissue
DocuColor 12/DCCS50
1/05
8d-27
Finisher/Sorter
Initial Actions
Initial Actions
Procedure
Procedure
the sensor.
Y
N
PWB.
Y
N
Y
N
the sensor.
Y
N
PWB.
Y
N
Y
N
Finisher/Sorter
1/05
8d-28
Reissue
DocuColor 12/DCCS50
Initial Actions
Initial Actions
Procedure
Procedure
the sensor.
Y
N
PWB.
Y
N
Y
N
the sensor.
Y
N
PWB.
Y
N
Y
N
Reissue
DocuColor 12/DCCS50
1/05
8d-29
Finisher/Sorter
Initial Actions
Initial Actions
Procedure
Procedure
the sensor.
Y
N
PWB.
Y
N
Y
N
the sensor.
Y
N
PWB.
Y
N
Y
N
Finisher/Sorter
1/05
8d-30
Reissue
DocuColor 12/DCCS50
Initial Actions
Initial Actions
Procedure
Procedure
the sensor.
Y
N
PWB.
Y
N
Y
N
of the sensor.
Y
N
PWB.
Y
N
Y
N
Reissue
DocuColor 12/DCCS50
1/05
8d-31
Finisher/Sorter
11-919 Bin 9 Full Stack RAP, 11-920 Bin 10 Full
11-921 SCT Tray Full Stack RAP
The Control Logic detected that the SCT Tray is full.
The Control Logic has determined that bin 10 is full while operating in the Stack Mode.
Initial Actions
Initial Actions
Ensure that there are no obstructions in the Stacker area
Ensure that the SCT Tray is empty
Ensure that connectors P/J1040 on the Finisher PWB, Shorting Plug P/J1080, and P/
J1079 on the SCT Full Sensor are seated correctly and there are no obvious crimped or
broken wires.
Procedure
Go to 11-921 SCT Tray Full Stack RAP to check out the SCT Full Sensor for any malfunctions.
Procedure
Enter dC330 012-275 SCT Full Sensor. Press Start. The display is H.
Y
N
+5 VDC is measured between P/J1040-6 and DC-COM on the Finisher PWB.
Y
N
good, replace the SCT Full Sensor (PL 18.3).
Block the SCT Full Sensor with a sheet of paper. The display changes to L.
Y
N
+5VDC is measured between P/J1079-1 and P/J1079-3 on the SCT Full Sensor.
Y
N
Y
N
Y
N
Go to the +5VDC Figure 1 wirenets and check wires for an open or short
circuit.
Check the wires between P/J44 on the Distribution PWB and P/J1026 on the
Finisher PWB. If the wires are OK, replace the Finisher PWB (PL 18.4).
Go to Flag 1 and Flag 4 on BSD12.10. Check the harness for an open or a short circuit. If the harness is good, replace the SCT Full Sensor (PL 18.3).
Go to Flag 4 and check for an open or short circuit. If the problem continues, replace the
Check the SCT Full Sensor for intermittent operation, If the problem continues, replace the
Finisher/Sorter
11-921 SCT Tray Full Stack RAP, 11-922 Sorter Stack-
1/05
8d-32
Reissue
DocuColor 12/DCCS50
12-120 RAP
The Compiler Entrance Sensor did not detect the lead edge of a sheet of paper within a specified period of time after the lead edge of the same sheet was detected by the Decurler Exit
Sensor.
Enter dC330 012-020 Finisher Transport Motor. Press Start. The Finisher Transport
Rolls are rotating.
Y
N
The Finisher Drive Belt is moving.
Y
N
The Finisher Transport Motor is rotating.
Y
N
+24 VDC is measured from P/J1084-1 to P/J1084-2 of the Finisher
Transport Motor.
Y
N
wires are good, replace the Finisher PWB (PL 18.4).
Initial Actions
Refer to BSD12.7, BSD 12.5, and BSD 12.1 for the following procedure.
Obstructions in the Finisher Transport paper path
Bent or out of position paper chutes/guides in the Finisher Transport paper path
Ensure that there is sufficient nip force at the Finisher Transport Rolls and the Exit Roll.
Ensure that connectors P/J1039 on the Finisher PWB and P/J1052 on the Compiler
Entrance Sensor are seated correctly and there are no obvious crimped or broken wires.
Procedure
Press Stop. +5 VDC is measured from P/J1084-3 to GND.

Y
N
wire is good, replace the Finisher PWB (PL 18.4).
The lead edge of the paper is at or past the Compiler Entrance Sensor.
Y
N
The paper entered the Finisher Transport.
Y
N
The Finisher Gate is in the Compiler position.
Y
N
Enter dC330 012-071 Finisher Gate Solenoid Open. Press Start. The
Finisher Gate moved to the Compiler position.
Y
N
+24 VDC is measured from P/J1081-A2 to GND.
Y
N
+24 VDC is measured from P/J1042-16 on the Finisher PWB to
GND.
Y
N
Press Start. Less than +1 VDC is measured from P/J1084-3 to GND.

Y
N
Replace the Finisher Transport Motor (PL 18.9).
Ensure that the Finisher Transport Motor Pulley (PL 18.9) is fastened to the
motor shaft.
Check the Finisher Drive Belt for slipping or damage.
Check that the gears/ pulleys are properly fastened to the drive rolls.
Go to Flag 6 on BSD 12.7. Check the wires for an open circuit.
Ensure that the Finisher Entrance Baffle is correctly positioned and free from damage.
Check the following parts for wear, glazing, or slipping:
There is +24 VDC from P/J1042-18 to GND.

Y
N
wires are good, replace the Finisher Gate Solenoid (PL 18.11).
Ensure that the Finisher Gate is connected to the Finisher Gate Solenoid
and that it moves freely. If the problem continues replace the Finisher Gate
Solenoid (PL 18.11). If this does not resolve the problem, replace the Finisher PWB (PL 18.4).
Ensure that the Finisher Gate is connected to the Finisher Gate Solenoid and
that it moves freely. If the problem continues replace the Finisher Gate and the
Finisher Gate Solenoid (PL 18.11).
A
B
C
Reissue
DocuColor 12/DCCS50
C
Check the paper path for any obstructions that could prevent the sheet from entering
the Finisher Transport.
Finisher Transport Rolls (PL 18.9)
Finisher Drive Belt (PL 18.9)
NOTE: The output of the Compiler Entrance Sensor is Low when the sensor is blocked, and
High when the sensor is not blocked. Paper on the sensor moves the actuator away from the
sensor, unblocking it.
Enter dC330 012-120 Compiler Entrance Sensor. Press Start. Manually actuate the Compiler
Entrance Sensor. The display changes from Low to High to Low as the actuator moves in
and out of the sensor.
Y
N
The display is always Low.
D
1/05
8d-33
Finisher/Sorter
12-120
D
Y
N
Disconnect P/J1052. There is +5 VDC from J1052-1 to J1052-3.
Y
N
+5 VDC is measured from P/J1039-1 to P/J1039-3.
Y
N
Y
N
Go to Flag 17 on BSD 12.1. Check the +5VDC wiring for an open circuit.
12-121 RAP
The Compiler Entrance Sensor does not detect the trail edge of a sheet of paper within a specified period of time after the lead edge of the same sheet was detected.
Initial Actions
Refer to BSD 12.1, BSD 12.5, and BSD 12.7 and for the following procedure.
Obstructions in the Finisher paper path
Obstructions in the Compiler Tray
Ensure that there is sufficient nip force at the Finisher Transport Rolls and the Entrance
Roll.
There is +5 VDC from J1052-2 to J1052-3.

Y
N
Go to Flag 10 on BSD 12.7. Check the harness for an open circuit. If the wire is
good, replace the Finisher PWB (PL 18.4)
Entrance Sensor are seated correctly and there are no obvious crimped or broken wires.
Replace the Compiler Entrance Sensor (PL 18.14). If the problem continues, replace
The trail edge of the paper is past the Compiler Entrance Sensor.
Y
N
Enter dC330012-020 Finisher Transport Motor. Press Start. The Finisher Transport
Rolls are rotating.
Y
N
The Finisher Drive Belt is moving.
Y
N
The Finisher Transport Motor is rotating.
Y
N
+24 VDC is measured from P/J1084-1 to P/J1084-2 of the Finisher
Transport Motor.
Y
N
wires are good, replace the Finisher PWB (PL 18.4).

Disconnect P/J1052. The display is High.

Y
N
Go to Flag 10 on BSD12.7. Check the wire for a short circuit to GND. If the wire is
Replace the Compiler Entrance Sensor (PL 18.14).
Check the actuator of the Compiler Entrance Sensor for binding as it moves in and out of the
sensor.
Check Flag 9 and Flag 10 on BSD12.7 for loose connectors or an intermittent short circuit.
Check the paper path for scraps of paper or other obstructions.
Finisher Transport Rolls (PL 18.9)
Finisher Drive Belt (PL 18.9)
Procedure
Press Stop. +5 VDC is measured from P/J1084-3 to GND.

Y
N
Press Start. Less than +1 VDC is measured from P/J1084-3 to GND.
Y
N
good, replace the Finisher Transport Motor (PL 18.9).
Ensure that the Finisher Transport Motor Pulley is fastened to the motor shaft.
Check the Compiler Drive Belt for proper tension or damage.
Check that the gears/ pulleys are properly fastened to the drive rolls.
The Exit Roll Belt is moving.
A
Finisher/Sorter
12-120, 12-121
1/05
8d-34
Reissue
DocuColor 12/DCCS50
A
Y
N
Check the gears and pulleys.
N
belts that would cause the copy to be slow to actuate the sensor.
Lower Exit Chute (PL 18.14)
Exit Roll Belt (PL 18.14)
Compiler Drive Belt (PL 18.9)
NOTE: The output of the Compiler Enter Sensor is Low when the sensor is blocked, and High
when the sensor is not blocked. Paper on the sensor moves the actuator away from the sensor, unblocking it.
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
Check the actuator for the Compiler Entrance Sensor for binding as it moves in and out of the
sensor. The actuator is binding.
Reissue
DocuColor 12/DCCS50
1/05
8d-35
Finisher/Sorter
12-121
12-170 RAP
The Compiler Paper Sensor detects a sheet of paper present 250 ms. after Eject drive is initiated.
Initial Actions
Replace the Compiler Paper Sensor (PL 18.16).
B
Check the actuator for the Compiler Paper Sensor for binding as it moves in and out of
the sensor. The actuator is binding.
Y
N
Check for obvious damage, missing and/or broken Drive Motor gear assemblies, or
slipping drive rolls that would cause the copy to be slow to actuate the sensor.
Obstructions in the Finisher paper path
Obstructions in the Compiler Tray
Paper Sensor are seated correctly and there are no obvious crimped or broken wires.
Procedure
There is a sheet of paper in the Compiler Tray.
Y
N
Enter dC330 012-252 Compiler Paper Sensor.Press Start.Manually actuate the Compiler
Paper Sensor. The display changes from Low to High to Low as the actuator moves
in and out of the sensor.
Y
N
Y
N
Y
N
Y
N
Y
N
Go to Flag 17 on BSD 12.1. Check the +5VDC wiring for an
open circuit.
Enter dC330 012-024 Eject Motor Forward. Press Start. The Eject Roll is rotating.
Y
N
The Eject Motor is rotating.
Y
N
Press Stop. Disconnect the Eject Motor Drive Belt. Press Start. The Eject Motor is
rotating.
Y
N
Go to Flag 8 and Flag 9 on BSD 12.14. Check the wires for an open circuit or a
short circuit to GND. If the wires are good, replace the Eject Motor (PL 18.19).
If the problem continues, replace the Finisher PWB (PL 18.4).
Check the Eject Roll and Bearing (PL 18.19) for damage or contamination.
Ensure that the Eject Motor Drive Belt PL 18.19 is clean and undamaged.
Ensure that the Pulley is fastened to the Exit Roll shaft (PL 18.19).
Check that the teeth in the Eject Motor pulley are clean and undamaged(PL 18.19).
Check the Eject Clamp Pinch Rolls (PL 18.20) and Eject Roll PL 18.19 for glazing or contamination.

Y
N
Go to Flag 4 on BSD 12.11. Check the harness for an open circuit. If the
wire is good, replace the Finisher PWB (PL 18.4)
Replace the Compiler Paper Sensor (PL 18.16). If the problem continues,
Y
N
Go to Flag 4 on BSD 12.11. Check the wire for a short circuit to GND. If the wire
is good, replace the Finisher PWB (PL 18.4)
A
B
Finisher/Sorter
12-170
1/05
8d-36
Reissue
DocuColor 12/DCCS50
12-180 RAP
12-181 RAP
The Compiler Entrance Sensor detects a sheet of paper present in standby or at initialization.
The Compiler Paper Sensor detects a sheet of paper present at power up or at Job Complete.
Initial Actions
Initial Actions
Check the Finisher Transport paper path for uncleared jams or obstructions. If no obstruction or
paper is found, continue with this RAP.
Check the Compiler Tray for uncleared jams or obstructions. If no obstruction or paper is found,
continue with this RAP.
Procedure
Procedure
Y
N
Y
N
Y
N
Y
N
Y
N
Enter dC330 012-252 Compiler Paper Sensor. Press Start. Manually actuate the Compiler
Paper Sensor. The display changes from Low to High to Low as the actuator moves in
Y
N
Y
N
Y
N
Y
N
Y
N

Y
N

Y
N
Replace the Compiler Paper Sensor (PL 18.16). If the problem continues, replace

Y
N

Y
N
Check the Compiler Entrance Sensor Actuator for binding as it moves in and out of the sensor.
Reissue
DocuColor 12/DCCS50
Check the actuator for the Compiler Paper Sensor for binding as it moves in and out of the sensor. If the actuator is binding, replace the Compiler Paper Sensor (PL 18.16).
1/05
8d-37
Finisher/Sorter
12-180 , 12-181
12-240 RAP
The Control Logic does not detect one of the following conditions:
End Wall Open (H) +5 VDC, from the End Wall Open Sensor, within 300msec after the
signal, End Wall Motor Open.
End Wall Open (L) +5 VDC, from the End Wall Open Sensor, within 300msec after the signal, End Wall Motor Close.
A
Press Stop. Press the C button. Enter dC330 012-036 Compiler Tray Solenoid Down. Press
Start. The Compiler Tray Solenoid energizes.
Y
N
The solenoid is always in the energized position.
Y
N
Press Stop. There is + 24 VDC from P/J1041-2 to GND.
Y
Initial Actions
Press Start. There is less than 1.0 VDC from P/J1041-2 to GND.
Y
N
Replace the Finisher PWB.
Procedure
NOTE: The output of the End Wall Open Sensor is Low when the sensor is blocked, and High
when the sensor is not blocked.
Open the Stapler Door and cheat the interlock. Enter dC330 012-270 End Wall Open Sensor.
Press Start.
Block and unblock the End Wall Open Sensor with a piece of paper. The display changes
from High to Low to High as the paper moves in and out of the sensor.
Y
N
Y
N
Y
N
Y
N
Y
N
Check the alignment of the solenoid. Check for binding of the linkage. If the checks
are good, replace the Compiler Tray Solenoid (PL 18.15).
Disconnect P/J1082. The solenoid deenergizes.
Y
N
Replace the Compiler Tray Solenoid (PL 18.15).
Go to Flag 8 on BSD 12.11. Check the harness for a short circuit. If the circuit is good,
Press Stop. Press the C button. Enter dC330 012-030 End Wall Motor Open. Press Start.
The End Wall moves to the open position.
Y
N
The End Wall can be manually moved to the open position.
Y
N
Check for binding of the linkage, or damage to the End Wall.
Connect the DMM between P/J1083-1 (+) and P/J1083-2 (-). set the meter for negative
Peak Hold. Press Start. A pulse of -20 VDC or greater is recorded.
Y
N
Go to Flag 12 and Flag 13 on BSD 12.12. Check the harness for an open circuit or a
short circuit. If the wires are good, replace the Finisher PWB (PL 18.4)

Y
N
Replace the End Wall Open Sensor (PL 18.16). If the problem continues, replace the
Y
N
N
Go to Flag 7 and Flag 8 on BSD 12.11. Check the wires for an open circuit. If
the circuit is good, replace the Compiler Tray Solenoid (PL 18.15).
Replace the End Wall Motor (PL 18.15).

Press the C button. Enter dC330 012-031 End Wall Motor Close. Press Start. The End Wall
moves to the closed position.
Y
N
Replace the Finisher PWB (PL 18.4). If the problem persists, replace the End Wall Motor
(PL 18.15).
Go to Flag 8, Flag 9, Flag 12, and Flag 13 on BSD 12.12. Check the circuit for an intermittent
connection.
Replace the End Wall Open Sensor (PL 18.16).
A
Finisher/Sorter
12-240
1/05
8d-38
Reissue
DocuColor 12/DCCS50
12-243 RAP
12-244 RAP
The Staple Ready Sensor does not detect the Staple sheet in the Ready position just prior to
stapling, or within 13 dummy staplings at Stapler initialization.
The Staple Head Home Sensor does not detect the Stapler in the home position within 600 ms
from the start of Stapler Motor reverse.
Initial Actions
Initial Actions
Refer to BSD 12.13 for the following procedure:
Ensure that connector P/J1092 is seated correctly to the Stapler Assembly, that connector P/J1044 is seated correctly to the Finisher PWB and that there are no obvious
crimped or broken wires on either connector.
Ensure that the Staple Cartridge contains staples and that it is correctly installed in the
Stapler Assembly.
Check for staple jams.
Procedure
Procedure
Remove, then reinstall, the Staple Cartridge. Enter dC330 012-273 Staple Ready Sensor.
Press Start. The display indicates Low.
Y
N
Go to Flag 7 on BSD 12.13. Check the wires for an open circuit or a short circuit to GND.
If the wires are good, go to Flag 4 on BSD 12.13. Check the wire for an open circuit. If the
wire is good, replace the Stapler Assembly (PL 18.17).
The Stapler Assembly appears to be operating correctly. If the problem continues, replace the
Staple Cartridge and test the system. If the problem continues, replace the Stapler Assembly
(PL 18.17).
Remove the Stapler Cover Assembly (REP 15.3.3). Remove the Staple Cartridge. Push the
Staple Assembly toward the rear of the Finisher until the semicircular cam on the front of the
assembly is facing forward. Rotate the cam in a clockwise direction until the flat portion of the
cam is facing up. Enter dC330 012-273 Staple Ready Sensor. Press Start. The display indicates High.
Y
N
Disconnect P/J1092 from the Stapler. The display indicates High.
Y
N
Go to Flag 2 on BSD 12.13. Check the wire for a short circuit to GND. If the wire is
good, replace the Finisher PWB (PL 18.4).
Replace the Stapler Assembly (PL 18.17).
Rotate the cam in a clockwise direction until the flat portion of the cam is facing down. The
display changes to Low.
Y
N
Disconnect P/J1092 from the Stapler. +5 VDC is measured between J1092-9 and
GND.
Y
N
Go to Flag 7 on BSD 12.13. Check the wires for an open circuit or short circuit to GND. If
the wires are good, replace the Stapler Assembly (PL 18.17).
Replace the Stapler Assembly (PL 18.17). If the problem continues, replace the Finisher PWB
(PL 18.4).
Reissue
DocuColor 12/DCCS50
1/05
8d-39
Finisher/Sorter
12-243, 12-244
12-245 RAP
This fault is declared when either of the following occur:
The Stapler is not detected at the Front Corner position within 2000msec (1000ms if shifting from Front Straight to Front Corner), after the Stapler Position Motor was energized to
move the Stapler to the front.
The Stapler remains at the Front Corner position xxx msec after Stapler Position Motor
On
C
Go to Flag 10 on BSD 12.12. Check for an open circuit or a short circuit to GND. If
the wires are good, replace the Stapler Position Motor (PL 18.17). If the problem
continues, replace the Finisher PWB (PL 18.4).
Remove the Stapler Cover Assembly (REP 15.3.3). Ensure that the Stapler is in the front
position and that the Stapler Front Corner Sensor is blocked (manually move the Stapler
toward the front if necessary). Enter dC330 012-269 Stapler Front Corner Sensor. Press
Start. The display indicates High.
Y
N
good, replace the Stapler Front Corner Sensor (PL 18.18). If the problem continues,
Initial Actions
Move the Stapler to the rear, to unblock the Stapler Front Corner Sensor. The
display
changes to Low.
Y
N
Disconnect P/J1057 from the Stapler Front Corner Sensor. +5 VDC is measured
between J1057-1 and J1057-3.
Y
N
Go to Flag 6 on BSD 12.12. Check the wires for an open circuit or a short circuit
to GND. If the wires are good, replace the Finisher PWB (PL 18.4).
Obstructions in the Stapler Rail Assembly (PL 18.18) that would prevent movement of the
Stapler
Bent or out of position End Wall
Bent or out of position Compiler Tray
Clean the Stapler Front Corner Sensor
Ensure that connectors P/J1043 and P/J1035 on the Finisher PWB, P/J1089 on the Stapler Position Motor, and P/J1057 on the Stapler Front Corner Sensor and seated correctly and there are no obvious crimped or broken wires.
replace the Stapler Front Corner Sensor (PL 18.18). If the problem continues,
replace the Finisher PWB.
Procedure
Open the Stapler Cover.
isher).
Y
N
The Stapler is in the home position (at the front of the Fin-
Manually move the Stapler toward the front and rear of the Finisher to ensure that it
moves smoothly and that there are no obstructions in the Stapler travel. Correct any
problems found.
NOTE: In the following step, dC330 [12-076] should move the Stapler toward the front of
the Finisher in small steps. Each time Start is pressed, the Stapler should move.
Cheat the Stapler Door Interlock Switch. Enter dC330 012-030 End Wall Motor Open.
Press Start. Press Clear then enter 012-036 Compiler Tray Solenoid Down. Press Start.
Press Clear then enter 012-076 Staple Move Motor Top Front. Press Start. The Stapler
Position Motor moves the Stapler toward the front of the Finisher each time the
Start button is pressed.
Y
N
Check the Stapler Drive Belt (PL 18.17), the Stapler Rail Belt (PL 18.18), and Pulleys
to ensure they are in place and are not loose or broken. The Belts and Pulleys are
OK.
Y
N
Replace any defective components as required.
Remove the IOT Connector Cover (REP 15.3.8). +24 VDC is measured from P/
J1089-2 to GND and from P/J1089-5 to GND.
Y
N
Go to Flag 11 on BSD 12.12. Check for an open circuit. If the problem continues, replace the Finisher PWB (PL 18.4).
A
B
C
Finisher/Sorter
12-245
Replace the Stapler Front Corner Sensor (PL 18.18).
NOTE: In the following step, dC330 [12-078] should move the Stapler toward the rear of the
Finisher in small steps. Each time Start is pressed, the Stapler should move.
Remove the Stapler Cover Assembly (REP 15.3.3). Cheat the Stapler Door Interlock Switch.
Enter dC330 012-030 End Wall Motor Open. Press Start. Press Clear then enter 012-036
Compiler Tray Solenoid Down. Press Start. Press Clear then enter 012-078 Staple Move
Motor Top Rear. Press Start. The Stapler Position Motor moves the Stapler toward the
rear of the Finisher each time the Start button is pressed.
Y
N
Check the Stapler Drive Belt (PL 18.17), the Stapler Rail Belt (PL 18.18), and Pulleys to
ensure they are in place and are not loose or broken. The Belts and Pulleys are OK.
Y
N
Replace any defective components as required.
Remove the IOT Connector Cover (REP 15.3.8). +24 VDC is measured from P/J10892 to GND and from P/J1089-5 to GND.
Y
N
Go to Flag 11 on BSD 12.12. Check for an open circuit.
D
1/05
8d-40
E
Reissue
DocuColor 12/DCCS50
E
Go to Flag 10 on BSD 12.12. Check for an open circuit or a short circuit to GND. If the
wires are good, replace the Stapler Position Motor (PL 18.17). If the problem continues,
Ensure that the Stapler is in the front position and that the Stapler Front Corner Sensor is
blocked (manually move the Stapler toward the front if necessary). Enter dC330 012-269 Stapler Front Corner Sensor. Press Start. The display indicates High.
Y
N
Go to Flag 7 on BSD 12.12. Check the wire for a short circuit to GND. If the wire is good,
replace the Stapler Front Corner Sensor (PL 18.18). If the problem continues, replace the
Move the Stapler to the rear, to unblock the Stapler Front Corner Sensor. The
display
changes to Low.
Y
N
Disconnect P/J1057 from the Stapler Front Corner Sensor. +5 VDC is measured
between J1057-1 and J1057-3.
Y
N
Go to Flag 6 on BSD 12.12. Check the wires for an open circuit or a short circuit to
GND. If the wires are good, replace the Finisher PWB (PL 18.4).
Go to Flag 7 on BSD 12.12. Check the wire for an open circuit. If the wire is good, replace
the Stapler Front Corner Sensor (PL 18.18). If the problem continues, replace the Finisher
PWB.
12-246 RAP
This fault is caused by one of the following conditions:
During Initialization, the Control Logic does not detect the Stacker Offset Home Sensor in
the home position (High) within 500ms of the start of Offset Home recovery operation.
During Set Eject, the Control Logic does not detect the Stacker Offset Home Sensor in
the offset position (Low) within 300ms from the start of the offset cycle.
During Set Eject, the Control Logic does not detect the Stacker Offset Home Sensor in
the home position (High) within 300ms of the command to return to the home position.
Initial Actions
Refer to BSD 12.1 and BSD 12.14 for this procedure.
Procedure
Enter dC330 012-027 Eject Clamp/Offset Motor F/R. Press Start. The Eject Roll and Clamp
move to the offset position and back to home.
Y
N
Switch off the power. Remove the rear covers. Manually rotate the shaft of the Eject
Clamp/Offset Motor (PL 18.21) clockwise. The shaft moves freely.
Y
N
Disassemble the gear cluster (PL 18.21) connected to the Eject Clamp/Offset Motor.
Manually rotate the motor shaft The shaft moves freely.
Y
N
Replace the Eject Clamp/Offset Motor (PL 18.21).
moves smoothly and that there are no obstructions in the Stapler travel. Correct any problems found.
Replace the Stapler Front Corner Sensor (PL 18.18).
Check the gears for damage or dirt that may cause binding
Check the Eject Roll (PL 18.19) for damage or binding.
Check the Pinch Roll/Compiler Cover/Set Separator area for binding (PL
18.20).
Ensure that the Offset Lever and Cam Follower (PL 18.19) are correctly
installed, and that the Cam follower is positioned in the spiral groove in the Offset Cam (PL 18.21).
The Eject Shaft moves front/rear as the motor shaft is rotated

Y
N
18.20).
Go to Flag 10 and Flag 11 on BSD 12.14. Check the wires for an open circuit or a short
circuit to GND. If the wires are good, replace the Eject Clamp/Offset Motor (PL 18.21).
A
Reissue
DocuColor 12/DCCS50
1/05
8d-41
Finisher/Sorter
12-245 , 12-246
A
NOTE: The output of the Stacker Offset Home Sensor is Low when the sensor is blocked, and
High when the sensor is not blocked.
Press the C button. Enter dC330 012-277 Offset Home Sensor. Press Start. Manually rotate
the shaft of the Eject Clamp/Offset Motor (PL 18.21) in the clockwise direction (as viewed from
the rear). The display changes from High to Low as the motor shaft rotates.
Y
N
Unfasten the bracket for the Stacker Offset Home Sensor (refer to REP 15.2.18). Block
and unblock the sensor with a sheet of paper The display changes from High to Low
to High as the sensor is blocked and unblocked.
Y
N
Y
N
Y
N
Y
N
Y
N
open circuit.
Y
N
Replace the Offset Home Sensor (PL 18.19). If the problem continues, replace
Y
N
Go to Flag 2 on BSD12.14. Check the wire for a short circuit to ground. If the
Replace the Stacker Offset Home Sensor (PL 18.19).
Check the actuator on the Offset Cam (PL 18.21) for damage. Ensure that the Sensor is
installed so that the actuator passes through the center of the sensor.
12-248 RAP
The Stapler Front Straight Sensor does not detect the presence of the Stapler within 1200
msec. after the Stapler Position Motor was energized to move the Stapler.
Initial Actions
Stapler
Clean the Stapler Front Straight Sensor
Ensure that connector P/J1035 on the Finisher PWB and P/J1059 on the Stapler Front
Straight Sensor and seated correctly and there are no obvious crimped or broken wires.
Procedure
Remove the Stapler Cover Assembly (REP 15.3.3). Manually move the Stapler toward the rear
of the Finisher until it has cleared the Stapler Front Straight Sensor and the sensor is not
blocked. Enter dC330 012-278 Stapler Front Straight Sensor. Press Start. The display indicates Low.
Y
N
Go to Flag 3 and Flag 5 on BSD 12.12. Check the wires for an open circuit or a short circuit to GND. If the wires are good, go to Flag 4 on BSD 12.12. Check the wire for an open
circuit. If the wire is good, replace the Stapler Front Straight Sensor (PL 18.18). If the
problem continues, replace the Finisher PWB.
Block the Stapler Front Straight Sensor. The display changes to High.
Y
N
replace the Stapler Front Straight Sensor (PL 18.18). If the problem continues, replace the
Replace the Stapler Front Straight Sensor (PL 18.18).
Go to Flag 1 and Flag 2 on BSD 12.14. Check the wiring for a loose connection or an intermittent short circuit.
Finisher/Sorter
12-246 , 12-248
1/05
8d-42
Reissue
DocuColor 12/DCCS50
12-249 RAP
12-251 RAP
The Stapler Rear Straight Sensor does not detect the presence of the Stapler within 1600
msec. after the Stapler Position Motor was energized to move the Stapler.
When either of the following occur:
Initial Actions
The Eject Paddle Home Sensor does not detect the Eject Paddle in the Home position
within 400msec of the signal, Eject Paddle Motor On.
The Eject Paddle remains at the Home position 200msec after the signal, Eject Paddle
Motor On.
Initial Actions
Stapler
Clean the Stapler Rear Straight Sensor
Ensure that connector P/J1035 on the Finisher PWB and P/J1060 on the Stapler Rear
Straight Sensor and seated correctly and there are no obvious crimped or broken wires.
Procedure
Remove the Stapler Cover Assembly (REP 15.3.3). Manually move the Stapler to the rear of
the Finisher until it has cleared the Stapler Rear Straight Sensor and the sensor is not blocked.
Enter dC330 012-279 Stapler Rear Straight Sensor. Press Start. The display indicates
Low.
Y
N
Go to Flag 1 and Flag 5 on BSD 12.12. Check the wires for an open circuit or a short circuit to GND. If the wires are good, go to Flag 2 on BSD 12.12. Check the wire for an open
circuit. If the wire is good, replace the Stapler Rear Straight Sensor (PL 18.18). If the problem continues, replace the Finisher PWB.
Block the Stapler Rear Straight Sensor. The display changes to High.
Y
N
replace the Stapler Rear Straight Sensor (PL 18.18). If the problem continues, replace the
Replace the Stapler Rear Straight Sensor (PL 18.18).
Procedure
Enter dC330 012-053 Eject Paddle Motor. Press Start. The Eject Paddle rotates.
Y
N
Remove the Belt from the Eject Paddle Motor (PL 18.19). Enter dC330 012-053 Eject
Paddle Motor. Press Start. The Eject Paddle Motor rotates.
Y
N
Go to Flag 12 and Flag 13 on BSD 12.14. Check the wires for an open circuit. If the
wires are good, replace the Eject Paddle Motor (PL 18.19). If the problem continues,
Check the Eject Roll (PL 18.19) for damage, binding or misalignment
NOTE: The output of the Eject Paddle Home Sensor is Low when the sensor is blocked, and
High when the sensor is not blocked.
Enter dC330 012-241 Eject Paddle Home Sensor. Press Start. Manually actuate the Eject
Paddle Home Sensor. The display changes from High to Low to High as the actuator
moves in and out of the sensor.
Y
N
Y
N
Y
N
Y
N
Y
N
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
8d-43
C
Finisher/Sorter
12-249 , 12-251
C
Replace the Eject Paddle Home Sensor (PL 18.19). If the problem continues,
12-253 RAP
When one of the following occur:

Y
N
Replace the Eject Paddle Home Sensor (PL 18.19).
Check the actuator for the Eject Paddle Home Sensor for binding as it moves in and out of the
sensor. Ensure that the actuator is secured to the shaft.
Go to Flag 5 and Flag 6 on BSD 12.14. Check for an intermittent short circuit or loose connections. If the problem continues, replace the Eject Paddle Home Sensor (PL 18.19).
The Tamper Home Sensor detects that the Tamper remained in the Home position
800msec after Tamper Motor On.
The Tamper is not detected in the Home position after the Tamper cycle is complete.
Initial Actions
NOTE: It is much easier to access the Tamper components if the Stacker Assembly is
removed. Refer to REP 15.2.2 for this procedure.
Procedure
CAUTION
Do not continue to press the Start button after the Tamper reaches either the fully-forward or
fully-rearward position.
Push the Tamper towards the rear of the Finisher. Enter dC330 012-060 Tamper Motor Low
Front. Press Start. The Tamper moves toward the front each time the Start button is
pressed.
Y
N
There is 24 VDC from P/J1087- 3 to GND and from P/J1087-6 to GND.
Y
N
Go to Flag 6 on BSD 12.11. Check for an open circuit.
Go to Flag 5 on BSD 12.11. Check for an open circuit or a short circuit to GND. If the wires
are good, Replace the Tamper Motor (PL 18.16). If the problem continues, replace The
Enter dC330 012-062 Tamper Motor Low Rear. Press Start. The Tamper moves toward the
rear each time the Start button is pressed.
Y
N
Enter dC330 012-061 Tamper Motor Top Front. Press Start. The Tamper moves toward the
front each time the Start button is pressed.
Y
N
Enter dC330 012-063 Tamper Motor Top Rear. Press Start. The Tamper moves toward the
rear approximately 30-50 mm each time the Start button is pressed.
Y
N
A
Finisher/Sorter
12-251 , 12-253
1/05
8d-44
Reissue
DocuColor 12/DCCS50
A
Enter dC330 012-064 Tamper Motor Middle Front. Press Start. The Tamper moves toward
the front each time the Start button is pressed.
Y
N
Enter dC330 012-065 Tamper Motor Middle Rear. Press Start. The Tamper moves toward
the rear each time the Start button is pressed.
Y
N
are good, Replace the Tamper Motor (PL 18.16). If the problem continues, replace the
Enter dC330 012-265 Tamper Home Sensor. Press Start. Push the Tamper to the rear of the
Compiler Tray. The display is High.
Y
N
The Actuator is blocking the Tamper Home sensor.
Y
N
Check that the Tamper, Belt, Sensor, and Motor are correctly mounted (PL 18.16).
Y
N
Go to Flag 2 on BSD 12.11. Check for a short circuit. If the wire is good, replace the
12-254 RAP
This fault is declared if one of the following occurs:
The Stack Height Sensor does not detect the Tray descending, upon initialization.
The Stack Height Sensor does not detect the Tray ascending within 5000msec from the
start of tray-ascend.
Initial Actions
Refer to BSD 12.1 and 12.15 for the following procedure
Procedure
Remove the Front and Rear Lower Covers. Manually rotate the Stacker Motor shaft counterclockwise until the Stacker Tray is at the top of its range of travel. Enter dC330 012-041 Stacker
Motor Down and press Start. The Stacker Tray moves down.
Y
N
Remove the Stacker Motor Belt. Enter dC330 012-041 Stacker Motor Down and press
Start. The Stacker Motor rotates.
Y
N
Go to Flag 15 and Flag 16 on BSD 12.15 Check for an open circuit or a short to
GND. If the wires are good, replace the Stacker Motor (PL 18.26) If the problem continues, replace the Finisher PWB (PL 18.4).
Ensure that the gears in the Stacker Motor Assembly are installed correctly, and are free
from damage.
Ensure that the Front and Rear Stacker Tray Drive Belts are installed correctly (refer to
REP 15.2.9).
Replace the Tamper Home Sensor (PL 18.16).
Enter dC330 012-250 Stack Height Sensor. Press Start. The display is High.
Y
N
Remove the Compiler Cover Sensor (REP 15.2.22). Check that the Actuator is positioned
correctly, and is blocking the sensor.
If the actuator is functioning correctly, Disconnect P/J1073. The display changes to
High.
Y
N
Go to Flag 2 on BSD 12.15. Check for a short circuit to GND. If the wire is good,
Push the Tamper toward the front. The display changes to Low
Y
N
Y
N
Y
N
Y
N
Replace the Stack Height Sensor (PL 18.20).
Go to Flag 1 on BSD 12.11. Check for an open circuit

Replace the Tamper Home Sensor (PL 18.16).
Go to Flag 1 and Flag 2 on BSD 12.11. Check the circuit of the Tamper Home Sensor for loose
connections or an intermittent short circuit.
Raise the Actuator. The display changes to Low.

Y
N
Y
N
Y
N
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
8d-45
C
Finisher/Sorter
12-253 , 12-254
C
12-255 RAP

Y
N
Replace the Stack Height Sensor (PL 18.20). If the problem continues, replace the Finisher PWB (PL 18.4).
Go to Flag 1 and Flag 2 on BSD 12.15. Check for loose connections or an intermittent short circuit to GND. If the problem continues, replace the Stack Height Sensor (PL 18.20).
The Stacker Upper Limit Sensor detects the Stacker Tray at the upper limit during ascension,
or does not detect a change of state during descension
Initial Actions
Refer to BSDs 12.1 and 12.15 for the following procedure.
Procedure
Remove the Rear Lower Cover. The Stacker Upper Limit Sensor is blocked by the Actuator.
Y
N
Enter dC330 012-259 Stacker Upper Limit Sensor.Press Start. Manually actuate the
Stacker Upper Limit Sensor. The display changes from Low to High to Low.
Y
N
Y
N
Y
N
Y
N
Y
N
open circuit.
Y
N
Replace the Stacker Upper Limit Sensor (PL 18.27). If the problem continues,
Y
N
Go to Flag 4 and Flag 7 on BSD12.15. Check the wire for a short circuit to
GND. If the wire is good, replace the Finisher PWB (PL 18.4)
Replace the Stacker Upper Limit Sensor (PL 18.27).
Go to Flag 3 and Flag 4 on BSD 12.15. Check for a loose connection or an intermittent
short circuit to GND. If the wires are good, replace the Stacker Upper Limit Sensor (PL
18.27).
Enter dC330 012-041 Stacker Motor Down and press Start. The Stacker Tray moves down.
Finisher/Sorter
12-254, 12-255
1/05
8d-46
Reissue
DocuColor 12/DCCS50
N
Remove the Stacker Motor Belt. Enter dC330012-041 Stacker Motor Down and press
Y
N
from damage.
REP 15.2.9).
The problem appears to be intermittent. Go to Flag 3, Flag 4, Flag 7, Flag 15, and Flag 16 on
BSD 12.15. Check the circuits of the Stacker Motor and the Stacker Upper Limit Sensor for a
loose connection or an intermittent short circuit to GND.
12-256 RAP
The Stacker Lower Limit Sensor detects the Stacker Tray at the lower limit during ascension, or
does not detect a change of state during ascension.
Initial Actions
Refer to BSD 12.1 and 12.15 for the following procedure
Procedure
Remove the Rear Lower Cover. The Stacker Lower Limit Sensor is blocked by the Actuator.
Y
N
Enter dC330 012-260 Stacker Lower Limit Sensor. Press Start. Manually actuate the
Stacker Lower Limit Sensor. The display changes from Low to High to Low.
Y
N
Y
N
Y
N
Y
N
Y
N
open circuit.
Y
N
Replace the Stacker Upper Limit Sensor (PL 18.27). If the problem continues,
Y
N
Go to Flag 6 and Flag 7 on BSD12.15. Check the wire for a short circuit to
GND. If the wire is good, replace the Finisher PWB (PL 18.4)
Replace the Stacker Lower Limit Sensor (PL 18.27).
Go to Flag 5 and Flag 6 on BSD 12.15. Check for a loose connection or an intermittent
short circuit to GND. If the wires are good, replace the Stacker Lower Limit Sensor (PL
18.27).
Enter dC330 012-040 Stacker Motor Up and press Start. The Stacker Tray moves up.
Reissue
DocuColor 12/DCCS50
1/05
8d-47
Finisher/Sorter
12-255, 12-256
N
Remove the Stacker Motor Belt. Enter dC330 012-040 Stacker Motor Up and press
Y
N
from damage.
REP 15.2.9).
BSD 12.15. Check the circuits of the Stacker Motor and the Stacker Lower Limit Sensor for a
loose connection or an intermittent short circuit to GND.
12-264 RAP
The Eject Clamp Sensor does not detect the Eject Clamp in the open position within 500msec
from the start of Eject Roll Up.
Initial Actions
Procedure
Enter dC330 012-026 Eject Clamp/Offset Motor Up/Down. Press Start. The Eject Clamp
opens and/or closes.
Y
N
Clamp/Offset Motor (PL 18.21) counterclockwise. The shaft moves freely.
Y
N
Y
N
18.20).
The Eject Clamp opens and/or closes as the motor shaft is rotated
Y
N
18.20).
Go to Flag 10 and Flag 11 on BSD 12.14. Check the wires for an open circuit or a short
circuit to GND. If the wires are good, replace the Eject Clamp/Offset Motor (PL 18.21).
Remove the rear covers. Enter dC330 012-240 Eject Clamp Sensor. Press Start. Manually
display
rotate the shaft of the Eject Clamp/Offset Motor (PL 18.21) counterclockwise. The
changes from High to Low as the motor shaft is rotated.
Y
N
The display is a constant Low.
Y
N
A
Finisher/Sorter
12-256, 12-264
1/05
8d-48
B
Reissue
DocuColor 12/DCCS50
B
Y
N
Y
N
Y
N
12-265 RAP
The Eject Clamp Sensor does not detect the Eject Clamp in the closed position within
500msec from the start of Eject Roll Down.
Initial Actions
Procedure
Y
N
Replace the Eject Clamp Sensor (PL 18.19). If the problem continues, replace the
Enter dC330 012-026 Eject Clamp/Offset Motor Up/Down. Press Start. The Eject Clamp
opens and/or closes.
Y
N
Clamp/Offset Motor (PL 18.21) counterclockwise. The shaft moves freely.
Y
N
Y
N

Y
N
Replace the Eject Clamp Sensor (PL 18.19).

BSD 12.14. Check the circuits of the Eject Clamp/Offset Motor (PL 18.21) and the Eject Clamp
Sensor (PL 18.19) for a loose connection or an intermittent short circuit to GND
18.20).
The Eject Clamp opens and/or closes as the motor shaft is rotated
Y
N
18.20).
Go to Go to Flag 10 and Flag 11 on BSD 12.14. Check the wires for an open circuit or a
short circuit to GND. If the wires are good, replace the Eject Clamp/Offset Motor (PL
18.21).
Remove the rear covers. Enter dC330 012-240 Eject Clamp Sensor. Press Start. Manually
rotate the shaft of the Eject Clamp/Offset Motor (PL 18.21) counterclockwise. The
display
changes from High to Low as the motor shaft is rotated.
Y
N
The display is a constant Low.
Y
N
A
Reissue
DocuColor 12/DCCS50
1/05
8d-49
B
Finisher/Sorter
12-264, 12-265
B
Y
N
Y
N
Y
N
12-266 RAP
The Compiler Cover Safety Switch is closed within 60msec since the completion of Eject Roll
Up.
Initial Actions
Ensure that the Compiler Cover Moves freely.
Go to Flag 3 and Flag 7 on 12.14. Check the harness for an open circuit.
Procedure

Y
N
Replace the Eject Clamp Sensor (PL 18.19). If the problem continues, replace the
Enter dC330 012-306 Compiler Cover Safety Sw. Press Start. The display is Low.
Y
N
Remove the Stapler Cover Assembly. The actuator on the Compiler cover presses
down on the metal leaf of the Compiler Safety Switch.
Y
N
There is 24 VDC from J1099-2 to GND.
Y
N

Y
N
Disconnect P/J1099. There is 24 VDC from J1099-2 to GND.

Y
N
Replace the Compiler Cover Safety Switch (PL 18.15).
Replace the Eject Clamp Sensor (PL 18.19).
Go to Flag 1 and Flag 2 on BSD 12.2. Check for a short circuit between the two
wires. If the wires are OK, replace the Finisher PWB (PL 18.4).
The problem appears to be intermittent. Go to Flag 3, Flag 4, Flag 10, and Flag 11 on BSD
12.14. Check the circuits of the Eject Clamp/Offset Motor (PL 18.21) and the Eject Clamp Sensor (PL 18.19) for a loose connection or an intermittent short circuit to GND.
Check for damage or incorrect installation of the Compiler Cover (REP 15.2.22). Ensure
that the metal leaf of the Compiler Cover Safety Switch (PL 18.15) is not bent.
The problem may be intermittent. Go to Flag 1 and Flag 2 on BSD 12.2. Check the circuit for
loose connections. Ensure that the Compiler cover is correctly installed. If the problem persists replace the Compiler Cover Safety Switch (PL 18.15).
Finisher/Sorter
12-265, 12-266
1/05
8d-50
Reissue
DocuColor 12/DCCS50
12-302 RAP
12-303 RAP
The Compiler Cover Interlock Switch detects the Compiler Cover open.
The Compiler Cover was detected in the up position during the period between Eject Roll
Down and Eject Roll Up.
Initial Actions
Initial Actions
Refer to BSD 12.2 for this procedure.

Ensure that the Compiler Cover moves freely.
Procedure
Procedure
Enter dC330012-300 Compiler Cover Intlk Sw. Press Start. Raise and lower the Compiler
Cover. The display changes from Low to High to Low.
Y
N
Y
N
There is less than 1.0 VDC from P/J1033-5 to GND.
Y
N
Go to Flag 5 and Flag 6 on BSD 12.3. Check for an open circuit. If the problem
persists, replace the Compiler Cover Interlock Switch (PL 18.15).
Enter dC330 012-306 Compiler Cover Safety Sw. Press Start. Press down on the Compiler
cover. The display changes from Low to High.
Y
N
Remove the Stapler Cover Assembly. The actuator on the Compiler cover presses
down on the metal leaf of the Compiler Safety Switch.
Y
N
There is 24 VDC from J1099-2 to GND.
Y
N
Disconnect P/J1099. There is 24 VDC from J1099-2 to GND.
Y
N

Disconnect P/J1098. Enter dC330 012-300 Compiler Cover Intlk Sw. The display is
High.
Y
N
Go to Flag 1 and Flag 2 on BSD 12.2. Check for an open circuit. If the wires are OK,
Check for damage or incorrect installation of the Compiler Cover (REP 15.2.22). Ensure
that the metal leaf of the Compiler Cover Safety Switch (PL 18.15) is not bent.

The problem may be intermittent. Go to Flag 5 and Flag 6 on BSD 12.3. Check for a loose connection. If the problem persists, replace the Compiler Cover Interlock Switch (PL 18.15).
Reissue
DocuColor 12/DCCS50
The problem may be intermittent. Go to Flag 1 and Flag 2 on BSD 12.2. Check the circuit for
loose connections. Ensure that the Compiler cover is correctly installed. If the problem persists replace the Compiler Cover Safety Switch (PL 18.15).
1/05
8d-51
Finisher/Sorter
12-302, 12-303
12-305 RAP
12-306 RAP
The Stacker Tray could not be lowered to the correct height, relative to the ejected sheets,
within 250msec during the height adjustment operation.
The Stapler Door Interlock Switch detects the Stapler Door open.
Initial Actions
Initial Actions

Check that the actuator for the Stack Height Sensor is free to move.
Ensure that the Stapler Door is closed. Check for damage to the actuator, or an incorrectly
installed door. If the fault remains when the door is closed, continue with this RAP.
Procedure
Procedure
Enter dC330 012-250 Stack Height Sensor. Press Start. The display is High.
Y
N
Remove the Compiler Cover (REP 15.2.22). Check that the Actuator is positioned correctly, and is blocking the sensor.
If the actuator is functioning correctly, Disconnect P/J1073. The display changes to
High.
Y
N
Close the Stapler Door. Enter dC330 012-304 Staple Door INTLK Switch. Press Start.
display is Low.
Y
N
Open the Stapler Door. Use the Interlock Cheater to actuate the Interlock Switch.
display is Low.
Y
N
Y
N
Replace the Stack Height Sensor (PL 18.20).
The
The
Go to Flag 3 and Flag 4 on BSD 12.3. Check for an open circuit. If the wires are
good, replace the Stapler Door Interlock Switch (PL 18.11).
Raise the Actuator. The display changes to Low.

Y
N
Y
N
Y
N
Y
N
Check the Stapler Door (PL 18.2) for damage.

Open the Stapler Door. The display is High.
Y
N
There is less than 1 VDC from P/J1033-5 to GND.
Y
N
Go to Flag 3 and Flag 4 on BSD 12.3. Check for a short circuit. If the wires are good,
replace the Stapler Door Interlock Switch (PL 18.11)

Y
N
The problem may be intermittent. Check the Stapler Door for warping or damage. Ensure that
the actuator lines up with the switch.
Go to Flag 3 and Flag 4 on BSD 12.3. Check for loose connections or an intermittent short circuit to GND. If the wires are good, replace the Stapler Door Interlock Switch (PL 18.11)
Replace the Stack Height Sensor (PL 18.20). If the problem continues, replace the Finisher PWB (PL 18.4).
Go to Flag 1 and Flag 2 on BSD 12.15. Check for loose connections or an intermittent short circuit to GND. If the problem continues, replace the Stack Height Sensor (PL 18.20).
Finisher/Sorter
12-305, 12-306
1/05
8d-52
Reissue
DocuColor 12/DCCS50
12-400/12-538 RAP
12-531 RAP
12-400: The Low Staple Sensor detects the Stapler is nearly empty.
This fault is declared if Control Logic detects more than 100 stapled sets in the Stacker Tray.
12-538: The Stapler is empty. This fault is declared if 30 sets are stapled after 12-400 is
declared.
NOTE: The actual number of stapled sets allowed in the Stacker is determined by NVM location 790-032. a value of 0 (default) allows 100 sets to accumulate before declaring the fault. A
value of 1 limits the number of sets to 60.
Initial Actions
Initial Actions
Procedure
Ensure that the Stacker Tray is empty. If the fault is declared with an empty Stacker Tray, continue with this RAP.
There are at least three sheets of staples in the Staple Cartridge.

Y
N
Replace the Staples.
Procedure
Enter dC330 012-272 Low Staple Switch. Press Start. The display is Low.
Y
N
Y
N
Go to Flag 3 on BSD 12.13. Check for an open circuit. If the wire is good, Replace
the Stapler (PL 18.17).
The problem may be intermittent. Go to Flag 3 on BSD 12.13. Check for a loose connection. If
the wire is good, Check for damage to the Staple Cartridge. if the problem persists, replace the
Stapler Assembly (PL 18.17).
Enter dC330 012-253 Stacker Paper Sensor. Press Start. Manually actuate the Stacker Paper
Sensor. The display changes from Low to High to Low as the actuator moves in and out
of the sensor.
Y
N
Y
N
Y
N
+5 VDC is measured from P/J1038 -1 to P/J1038-3.
Y
N
Y
N
Y
N
Replace the Stacker Paper Sensor (PL 18.27). If the problem continues, replace the
Y
N
Replace the Stacker Paper Sensor (PL 18.27).
The problem may be intermittent. Remove the Stacker Tray Bottom Cover. Check the actuator
of the Stacker Paper Sensor for damage or binding.
Reissue
DocuColor 12/DCCS50
1/05
8d-53
Finisher/Sorter
12-400/12-538, 12-531
If the actuator is OK, go to Flag 8 and Flag 9 on BSD 12.15. Check for a loose connection or an
intermittent short circuit. If the wires are good, replace the Stacker Paper Sensor (PL 18.27).
12-536 RAP
The Staple Cartridge Set Switch does not detect the presence of a Staple Cartridge.
Initial Actions
A loaded Staple Cartridge is installed in the Stapler.
Connectors P/J1044 on the Finisher PWB and P/J1092 on the Stapler are seated correctly, and there are no obvious crimped or broken wires.
Procedure
Enter dC330 012-274 Cartridge Set Switch. Press Start. The display is Low.
Y
N
Y
N
Go to Flag 1 on BSD 12.13. Check for an open circuit. If the wire is good, replace the
The problem may be intermittent. Go to Flag 1 on BSD 12.13. Check for a loose connection. If
the wire is good, Check for damage to the Staple Cartridge. if the problem persists, replace the
Finisher/Sorter
12-531, 12-536
1/05
8d-54
Reissue
DocuColor 12/DCCS50
12-537 RAP
12-570 RAP
Control Logic does not detect the signal Staple Head Home (L) within 450msec since the start
of Staple Head Close operation.
This fault is declared if one of the following occur:
Initial Actions
Check for staple jams.
Procedure
Remove the Stapler Cover Assembly (REP 15.3.3). Remove the Staple Cartridge. Push the
Staple Assembly toward the rear of the Finisher until the semicircular cam on the front of the
assembly is facing forward. Manually rotate the cam in a clockwise direction until the flat portion of the cam is facing up. Enter dC330 012-273 Staple Ready Sensor. The display indicates High.
Y
N
Disconnect P/J1092 from the Stapler. The display indicates High.
Y
N
good, replace the Finisher PWB (PL 18.4).
Replace the Stapler Assembly (PL 18.17).
Rotate the cam in a clockwise direction until the flat portion of the cam is facing down. The
display changes to Low.
Y
N
Disconnect P/J1092 from the Stapler. +5 VDC is measured between J1092-9 and
GND.
Y
N
Stacker Full (H) is detected during the Stacker Tray height adjustment (descending).
Stacker Full (Mixed Size) (H) is detected during the Stacker Tray height adjustment
(descending) while ejecting mixed-size sets.
A mixed-size set is ejected after Stacker Full (Mixed Size) (H) is detected.
Initial Actions
Ensure that the Stacker Tray is empty. If the fault is declared with an empty Stacker Tray, proceed with this RAP.
Procedure
Enter dC330 012-253 Stacker Paper Sensor. Press Start. Manually actuate the Stacker Paper
Sensor. The display changes from Low to High to Low as the actuator moves in and out
of the sensor.
Y
N
Y
N
Y
N
+5 VDC is measured from P/J1038 -1 to P/J1038-3.
Y
N
Y
N
Y
N
Go to Flag 7 on BSD 12.13. Check the wires for an open circuit or short circuit to GND. If
the wires are good, replace the Stapler Assembly (PL 18.17).
Replace the Stacker Paper Sensor (PL 18.27). If the problem continues, replace the
Replace the Stapler Assembly (PL 18.17). If the problem continues, replace the Finisher PWB
(PL 18.4).

Y
N
Replace the Stacker Paper Sensor (PL 18.27).
Press the C button. Enter dC330 012-210 Stacker Full Sensor. Press Start. The display is
Low.
Reissue
DocuColor 12/DCCS50
1/05
8d-55
Finisher/Sorter
12-537, 12-570
N
Go to Flag 10, Flag 11 and Flag 14 on BSD 12.15. Check for an open circuit. If the wires
are good, replace the Stacker Full (Mixed Size) Sensor (PL 18.27).
Press the C button. Enter dC330 012-212 Stacker Full (Mixed Sets) Sensor. Press Start. The
display is Low.
Y
N
are good, replace the Stacker Full Sensor (PL 18.27).
The problem appears to be intermittent. Go to Flag 8, Flag 9,Flag 10, Flag 11, Flag 12, Flag 13,
and Flag 14 on BSD 12.15. Check the circuits of the Stacker Sensor s for a loose connection or
an intermittent short circuit to GND
12-571 RAP
Control Logic detected the signal Stacker Full (Mixed Set) (H) while mixed-size sets were
present in the Stacker Tray.
Initial Actions
Ensure that the Stacker Tray is empty. If the fault is declared with an empty Stacker Tray, proceed with this RAP.
Procedure
Enter dC330 012-253 Stacker Paper Sensor. Press Start. The display is Low.
Y
N
Go to Flag 8 and Flag 9 on BSD 12.15. Check for an open circuit. If the wires are good,
replace the Stacker Paper Sensor (PL 18.27).
Press the C button. Enter dC330 012-210 Stacker Full Sensor. Press Start. The display is
Low.
Y
N
are good, replace the Stacker Full (Mixed Size) Sensor (PL 18.27).
BSD 12.15. Check the circuits of the Stacker Sensors for a loose connection or an intermittent
short circuit to GND
Finisher/Sorter
12-570, 12-571
1/05
8d-56
Reissue
DocuColor 12/DCCS50
12-580 RAP
This fault is declared if Control Logic detects the Unload While Run Switch activated while a job
is being printed.
Ensure that connectors P/J1039 on the Finisher PWB and P/J1075 on the Unload While Run
Switch are seated correctly and there are no obvious crimped or broken wires.
Procedure
The Unload While Run LED is always lit.
Y
N
Press the Unload While Run Switch several times. The Unload While Run LED
switches on and off.
Y
N
Enter dC330 012-291 Unload While Run Switch. Press Start. Press the Unload
While Run Switch several times. The display alternates from High to Low.
Y
N
Disconnect P/J1075 from the Unload While Run Switch. There is +5VDC
from J 1075-3 to GND
Y
N
Go to Flag 4 on BSD 12.2. Check for a short circuit to GND. If the wire is
OK, replace the Finisher PWB (PL 18.4).
C
Go to Flag 4 on BSD 12.2. Check for an open circuit. If the wire is OK, replace the
Unload While Run Switch (PL 18.15).
The problem may be intermittent. Go to Flag 3, Flag 4, Flag 5, and Flag 6on BSD 12.2.
Check for an intermittent short circuit or a loose connection. If the problem is unresolved,
replace the Unload While Run Switch (PL 18.15).
Initial Actions
Enter dC330 012-099 Unload while Run LED. The LED remains lit.
Y
N
Go to Flag 4 on BSD 12.2. Check for a short circuit to GND. If the wire is OK, replace the
Unload While Run Switch (PL 18.15). If the problem is unresolved, replace the Finisher
PWB (PL 18.4).
Go to Flag 4 on BSD 12.2. Check for an open circuit. If the wire is OK, replace the Unload
While Run Switch (PL 18.15).
Go to Flag 5 on BSD 12.2. Check for a short circuit to GND. If the wire is OK, replace the Finisher PWB (PL 18.4).
Go to Flag 4 on BSD 12.2. Check for an open circuit. If the wire is OK, replace
the Unload While Run Switch (PL 18.15).
Y
N
the Finisher PWB (PL 18.4)
Enter dC330 012-099 Unload while Run LED. Press Start There is less than 1
VDC from P/J1075-2 to GND.
Y
N
Replace the Unload While Run Switch (PL 18.15).
Enter dC330 012-291 Unload While Run Switch. Press Start. Press the Unload While
Run Switch several times. The display alternates from High to Low.
Y
N
Disconnect P/J1075 from the Unload While Run Switch.There is +5VDC from J
1075-3 to GND
Y
N
Go to Flag 4 on BSD 12.2. Check for a short circuit to GND. If the wire is OK,
A
B
C
Reissue
DocuColor 12/DCCS50
1/05
8d-57
Finisher/Sorter
12-580
Finisher/Sorter
12-580
1/05
8d-58
Reissue
DocuColor 12/DCCS50
REP 15.1.1 Decurler
REP 15.1.2 Decurler Rolls 1 and 2

Removal

Removal
WARNING
WARNING
To avoid personal injury or shock, disconnect the Finisher Cable Connector. Switch off
1.
Remove the Decurler Door Assembly (REP 15.3.4).
1.
2.
Remove the Decurler Rear Cover (REP 15.3.13).
2.
3.
Remove the Decurler Inner Cover (REP 15.3.14).
3.
4.
Remove the Decurler Top Cover (REP 15.3.12).
4.
5.
Remove the Decurler (Figure 1).
5.
1.
1. Remove shouldered screws (2).
2.
3.
Remove the Decurler.
Figure 1 Remove the Decurler
Replacement

6.

Reinstall the Decurler in the reverse order of disassembly.

Reissue
DocuColor 12/DCCS50
1/05
8d-59
Finisher/Sorter
REP 15.1.1, REP 15.1.2

7.

8.

Finisher/Sorter
REP 15.1.2
1/05
8d-60
Reissue
DocuColor 12/DCCS50
Figure 5 Install the Rolls
Replacement
1.
Install the Rolls with the marks towards the rear of the Finisher (Figure 5).
1.
Roll 1 has one mark.
2.
Roll 2 has two marks.
Reissue
DocuColor 12/DCCS50
1/05
8d-61
Finisher/Sorter
REP 15.1.2
REP 15.1.3 Reflector and Cam

6. Remove the cam.

Removal
WARNING
1.
2.
3.

2. Release the harness from the Clamps (4).
5. Remove the spring from the Bracket.
Figure 2 Remove the Cam
Replacement
1.
Reinstall the Cam (Figure 3).
2.
Reinstall the remaining components in the reverse order of disassembly.
1. Align the hole on the Cam with the hole on the Gear.

4.
Remove the cam (Figure 2).

1. Remove the shoulder screw.
3. Remove the reflector.
Finisher/Sorter
REP 15.1.3
1/05
8d-62
Reissue
DocuColor 12/DCCS50
REP 15.1.4 Decurler Stepper Motor

Removal
WARNING
1.
2.
3.
Remove the Decurler Stepper Motor (Figure 1).

1.
Disconnect the connector from the Decurler Control PWB.
2.
3.
Remove the Decurler Stepping Motor.
Figure 3 Reinstall the Cam
Figure 1 Remove the Decurler Stepper Motor
Replacement
Reinstall the Decurler Stepper Motor in the reverse order of disassembly.
Reissue
DocuColor 12/DCCS50
1/05
8d-63
Finisher/Sorter
REP 15.1.3, REP 15.1.4
REP 15.1.5 Entrance Lower Chute and Pinch Roll

Removal
WARNING
1.
2.
3.
4.
5.
Remove the Entrance Lower Chute (Figure 1).

1. Remove screws (4).
2. Disconnect P/J664 and P/J665.
3. Remove the Entrance Lower Chute.
Figure 2 Remove the Pinch Rolls
Replacement
Reinstall the Entrance Lower Chute and Pinch Roll in the reverse order of disassembly.
Figure 1 Remove the Entrance Lower Chute

6.
Remove the Pinch Rolls (Figure 2).

1. Remove Pinch Rolls (5) from the Entrance Lower Chute.
Finisher/Sorter
REP 15.1.5
1/05
8d-64
Reissue
DocuColor 12/DCCS50
REP 15.1.6 Exit Lower Baffle and Pinch Roll
REP 15.1.7 Decurler PWB

Removal

Removal
WARNING
WARNING
1.
1.
2.
Decurler Inner Cover (REP 15.3.14).
3.
Decurler Rear Cover (REP 15.3.13).
4.
Remove the Exit Lower Baffle (Figure 1).

NOTE: Observe the ESD procedures when removing the Decurler PWB.
2.
Remove the Decurler PWB (Figure 1).

1. Disconnect the PWB connectors (4).
2. Remove the Exit Lower Baffle.
3. Remove the PWB.
3. Remove Pinch Rolls.
Figure 1 Remove the Decurler PWB
Figure 1 Remove the Exit Lower Baffle
Replacement
Reinstall the Exit Lower Baffle and Pinch Roll in the reverse order of disassembly.
Reissue
DocuColor 12/DCCS50
Replacement
Reinstall the Decurler PWB in the reverse order of disassembly.
1/05
8d-65
Finisher/Sorter
REP 15.1.6, REP 15.1.7
REP 15.1.8 Cam Drive Shaft
2. Remove the Gear.

3. Remove the Cam Drive Shaft.

Removal
WARNING
1.
2.
Decurler Rear Cover (REP 15.3.13).
3.
Decurler Top Cover (REP 15.3.12).
4.
Decurler Inner Cover (REP 15.3.14).
5.
Remove the Reflector and Cam (REP 15.1.3).
6.
Remove the Gear and Decurler Cam Clutch (Figure 1).

1. Disconnect the connector from Clutch.
2. Remove E-clip.
3. Remove the Gear.
4. Remove the Decurler Cam Clutch.
6. Remove the Bearing.
Figure 2 Remove the Cam Drive Shaft

8.
Remove the Bearing from the Shaft (Figure 3).

1. Remove E-Clip
2. Remove Bearing.
Figure 1 Remove the Gear and Decurler Cam Clutch

7.
Remove the Cam Drive Shaft (Figure 2).

1. Remove the E-Clip.
Finisher/Sorter
REP 15.1.8
1/05
8d-66
Reissue
DocuColor 12/DCCS50
REP 15.1.9 Torque Limiter Gear and Stopper

Removal
WARNING
1.
2.
3.
Remove the Torque Limiter Gear (Figure 1).

1. Remove E-Clip.
2. Remove the Stopper.
3. Remove the Torque Limiter Gear.
Figure 3 Remove the Bearing
Replacement
Reinstall the Cam Drive Shaft in the reverse order of disassembly.
Figure 1 Remove the Torque Limiter Gear
Replacement
Reinstall the Torque Limiter Gear and Stopper in the reverse order of disassembly.
Reissue
DocuColor 12/DCCS50
1/05
8d-67
Finisher/Sorter
REP 15.1.8, REP 15.1.9

Removal
WARNING
1.
2.
At the front of the Finisher, remove the Bearing (Figure 1).

Figure 2 Remove the Decurler Drive Roll 2
Replacement
1.
Install the Bearing at the gear end of the shaft, into the frame, prior to installing the Drive
Roll.
2.
Reinstall the remaining components in the reverse order of disassembly.

3.
At the rear of the Finisher, remove the Decurler Drive Roll 2 (Figure 2).
1.
Remove the E-Clip.
2.
Remove the gear.
3.
Remove the Bearing and Drive Roll from the rear of the Finisher.
Finisher/Sorter
REP 15.1.10
1/05
8d-68
Reissue
DocuColor 12/DCCS50

Removal
WARNING
1.
Remove the Decurler Door (REP 15.3.4).
2.
3.
4.
5.
6.
Remove the Front Lever (PL 18.7).
7.
Remove the Bearing from the roll at the front of the Finisher (Figure 1).
Figure 2 Remove the Decurler Drive Roll 1
Replacement
Reinstall the Decurler Drive Roll 1 in the reverse order of disassembly.

8.
Remove the Decurler Drive Roll 1 at the rear of the Finisher (Figure 2).
1.
Disengage the Drive Roll from the frame.
2.
Remove the E-Clip.
3.
Remove the gear.
4.
Remove the bearing and then remove the Drive Roll.
Reissue
DocuColor 12/DCCS50
1/05
8d-69
Finisher/Sorter
REP 15.1.11
REP 15.1.12 Decurler Entrance Roll
3. Remove the Torque Limiter.


Removal
WARNING
1.
2.
3.
4.
5.
Remove the Sensor Bracket (Figure 1).

2. Release the harness from the Clamps (4).
5. Remove the spring from the Bracket.
7.
Remove the Decurler Entrance Roll at the front of the Finisher (Figure 3).
1. Remove the C-Clip.
2. Remove the Bushing.
3. Remove the Decurler Entrance Roll.
Figure 1 Remove the Sensor Bracket

6.
Remove the Torque Limiter Gear at the rear of the Finisher (Figure 2).
Finisher/Sorter
REP 15.1.12
1/05
8d-70
Reissue
DocuColor 12/DCCS50
REP 15.1.13 Decurler Exit Roll

Removal
WARNING
1.
2.
3.
4.
5.
Remove the Torque Limiter, from the roll, at the rear of the Finisher (Figure 1).
3. Remove the Torque Limiter Gear.
Figure 3 Remove the Decurler Entrance Roll
Replacement
Reinstall the Decurler Entrance Roll in the reverse order of disassembly.

6.
Remove the Decurler Exit Roll at the front of the Finisher (Figure 2).
1. Disengage the Exit Roll from the frame.
3. Remove the Bearing, then remove the roll.
Reissue
DocuColor 12/DCCS50
1/05
8d-71
Finisher/Sorter
REP 15.1.12, REP 15.1.13
REP 15.1.14 Entrance Upper Baffle and Pinch Roll

Removal
WARNING
1.
Remove the Mailbox Door Assembly (REP 15.3.5).
2.
Remove the Entrance Chute Upper Baffle and Pinch Roll (Figure 1).
1.
Remove the screw.
2.
Remove the Entrance Upper Baffle.
3.
Remove the appropriate Pinch Roll(s).
Figure 2 Remove the Decurler Exit Roll
Replacement
Reinstall the Decurler Exit Roll in the reverse order of disassembly.
Figure 1 Remove the Entrance Chute Upper Baffle and Pinch Roll
Replacement
Reinstall the Entrance Chute Upper Baffle and Pinch Roll in the reverse order of disassembly.
Finisher/Sorter
REP 15.1.13, REP 15.1.14
1/05
8d-72
Reissue
DocuColor 12/DCCS50
REP 15.1.15 Finisher Transport Motor
REP 15.1.16 Finisher Drive Belt

Removal

Removal
WARNING
WARNING
1.
Remove the Rear Upper Cover (REP 15.3.7).
1.
2.
Remove the Rear Lower Cover (REP 15.3.15).
2.
3.
Remove the Finisher Transport Motor (Figure 1).
3.
Remove the Finisher Drive Belt (Figure 1).
1.
Disconnect the connector P/J1084.
1.
2.
Remove the three screws securing the motor.
2.
Disconnect the connector P/J1084.

Disengage the wire harnesses from the harness holders.
3.
Pull the motor straight out to remove.
3.
Remove the three screws securing the motor bracket.
4.
Remove the bracket with the motor.
5.
Remove the E-clip and the Decurler Gear.
6.
Remove the two screws securing the belt idler bracket.
7.
Remove the Finisher Drive Belt.
Figure 1 Remove the Finisher Transport Motor
Replacement
Reinstall the Finisher Transport Motor in the reverse order of disassembly.
Figure 1 Remove the Finisher Drive Belt
Replacement
1.
Reissue
DocuColor 12/DCCS50
1/05
8d-73
Reinstall the shaft and the one-way pulleys onto the belt idler bracket, ensuring that the
Finisher Drive Belt and Mailbox Drive Belt are installed onto the correct one-way pulley.
Finisher/Sorter
REP 15.1.15, REP 15.1.16
2.
REP 15.1.17 Single Catch Tray (SCT) Assembly
Route the Finisher Drive Belt onto the gears per the illustration (Figure 2).

Removal
WARNING
1.
2.
Remove the Single Catch Tray (SCT) Assembly (Figure 1).

1.
Remove the SCT Exit Cover.
2.
Remove one screw from the bottom of the tray.
3.
Lift up the tray, tilt out, and move the tray slightly away from the Finisher.
4.
Disconnect the sensor connector.
5.
Disengage the wire harness from the harness holders on the tray and remove the
tray.
Figure 2 Install the Finisher Drive Belt

3.
Reinstall the belt idler bracket.
4.
Reinstall the E-clip and the gear.
5.
Reinstall the bracket with the motor.

NOTE: In the following step, ensure that the wires are secured away from belts, pulleys,
and all moving components.
6.
Reinstall the wire harnesses into the harness holders and reconnect the connector P/
J1084.
Figure 1 Remove the Single Catch Tray (SCT) Assembly
Replacement
Reinstall the Single Catch Tray (SCT) Assembly in the reverse order of disassembly.
Finisher/Sorter
REP 15.1.16, REP 15.1.17
1/05
8d-74
Reissue
DocuColor 12/DCCS50
REP 15.1.18 SCT Static Eliminator
REP 15.1.19 SCT Exit Sensor

Removal

Removal
WARNING
WARNING
1.
1.
2.
Remove the SCT Static Eliminator (Figure 1).
2.
Remove the SCT Exit Sensor (Figure 1).
1.
1.
2.
Remove the Static Eliminator.
2.
Remove the SCT Cover.

Disconnect the Sensor Connector.
3.
Remove the SCT Exit Sensor.
Figure 1 Remove the SCT Static Eliminator
Figure 1 Remove the SCT Exit Sensor
Replacement
Align the Static Eliminator strip with the top of the SCT Exit Upper Chute, from which you
removed the old Static Eliminator, and stick the strip in place.
Reissue
DocuColor 12/DCCS50
Replacement
Reinstall the SCT Exit Sensor in the reverse order of disassembly.
1/05
8d-75
Finisher/Sorter
REP 15.1.18, REP 15.1.19
REP 15.1.20 SCT Pinch Roll

Removal

Removal
WARNING
WARNING
1.
1.
2.
Remove the SCT Pinch Roll (Figure 1).
2.
1.
3.
2.
Remove the Mailbox Rear Lower Cover.
4.
Remove the Stapler Door Assembly (REP 15.3.2).
3.
Remove the four screws securing the SCT Exit Upper Chute, in order to provide
access to the Pinch Rolls.
5.
Remove the wire harness from the Finisher Transport Motor Bracket (PL 18.9 item 10).
6.
Remove the Finisher Transport Motor Bracket from the Finisher (3 screws).
4.
Remove the appropriate Pinch Roll(s).
7.
Remove the Transport Roll 1 (Figure 1).

1. On the rear of the Finisher Transport Roll shaft 1, remove the E ring, Stopper Collar,
Friction Clutch, Pulley and the Bearing.
2. On the front of the Finisher Transport Roll shaft 1, remove the E ring and Bearing.
3. Remove the Finisher Transport Roll from the front of the Finisher.
Replacement
1.
Install the Finisher Transport Roll 1 into the frame in reverse order of removal.
Figure 1 Remove the SCT Pinch Roll
Replacement
Reinstall the SCT Pinch Roll in the reverse order of disassembly.
Finisher/Sorter
REP 15.1.20, REP 15.1.21
1/05
8d-76
Reissue
DocuColor 12/DCCS50

Removal
WARNING
1.
2.
3.
Remove the MailBox Door Assembly (REP 15.3.5).
4.
Remove the Transport Roll 2 (Figure 1).

1.
Remove the E ring and Collar from the Idler Pulley that is being driven by the Finisher Transport Roll 2.
2.
Remove the E ring, Idler Pulley and Bearing from the rear of the Finisher Transport
Roll shaft.
3.
Remove the E ring and Bearing from the front of the Finisher Transport Roll 2 shaft.
4.
Remove the screws (4) securing the Entrance Lower Chute to the frame (PL 18.14
item 25). Do not remove the Entrance Lower Chute. This will provide enough room
to allow the Finisher Transport Roll 2 shaft to be removed.
5.
Remove the Finisher Transport Roll 2 from the front of the Finisher.
Replacement
1.
Install the Finisher Transport Roll 2 into the Finisher frame.
2.
Install the Bearing and E ring onto the front end of the Finisher Transport Roll 2 shaft.
3.
Install the Bearing, Idler Pulley, and E ring onto the rear of the Finisher Transport Roll 2
shaft. Ensure the Finisher Drive Belt is installed on the Pulley.
4.
Reinstall the Entrance Lower Chute to the frame using the screws (4).
5.
Install the Collar and E ring on the Idler Pulley that is driven by the Finisher Transport Roll
2.
6.
Install the Rear Upper Cover.
7.
Install the Rear Lower Cover.
8.
Install the Mailbox Door Assembly.
9.
Install the Stapler Cover.
Figure 1 Remove the Transport Roll 1
Reissue
DocuColor 12/DCCS50
1/05
8d-77
Finisher/Sorter
REP 15.1.21, REP 15.1.22
Figure 1 Remove the Transport Roll 2
Finisher/Sorter
REP 15.1.22
1/05
8d-78
Reissue
DocuColor 12/DCCS50
REP 15.2.1 Compiler Tray Solenoid
Replacement

Removal
1.
Reconnect P/J1082.
2.
Route the wire harness through the harness clips and lock the clips.
WARNING
1.
Move the Stapler to the rear end of the Stapler track.
2.
Switch off the printer power and disconnect the AC Power Cord.
3.
Slide the solenoid Link onto the End Wall Shaft.
4.
Slide the End Wall Motor Link onto the End Wall Motor Shaft, and use a K Clip to secure
the Link to the shaft.
5.
Install the End Wall Spring.
6.
Install the Compiler Tray Solenoid Plunger into the Solenoid and secure the solenoid with
the screws (2).
3.
Remove the Stapler Cover Assembly (REP 15.3.3).
7.
Install the wire harness bracket to the Compiler Tray Solenoid with the screw (1).
4.
Remove the wire harness from the harness clamps.
8.
Reinstall the Stapler Cover Assembly.
5.
Remove the lower screw that secures the wire harness holder to the Compiler Tray Solenoid (PL 18.15 item 6).
6.
Remove the Compiler Tray Solenoid (Figure 1).

1.
Disconnect the Compiler Tray Solenoid Connector P/J1082.
2.
Remove the End Wall Spring (PL 18.15 item 2).
3.
Remove the K Clip securing the End Wall Motor Link to the End Wall Motor, and
remove the Link.
4.
Remove the two screws securing the Compiler Tray Solenoid to the Finisher frame.
Remove the Compiler Tray Solenoid.
5.
Slide the solenoid plunger Link off the End Wall Shaft, and remove the solenoid
plunger and Link.
Figure 1 Remove the Compiler Tray Solenoid
Reissue
DocuColor 12/DCCS50
1/05
8d-79
Finisher/Sorter
REP 15.2.1
REP 15.2.2 Stacker Tray Assembly
3.
Tighten the two middle screws.

Removal
4.
Reconnect P/J1090, P/J1071, P/J1067 and P/J1064 (Figure 1).
5.
Secure the wire harness into the harness clips.
WARNING
1.
6.
Install the Front Wheel Caster Cap.
7.
8.
Install the Stapler Cover Assembly.
2.
3.
4.
Remove the front wheel Caster Cap (PL 18.4 item 8).
5.
Disconnect P/J1090, P/J1071, P/J1067 and P/J1064 and remove the wire harness from
the harness clips.
6.
Remove the Stacker Tray Assembly (Figure 1).

1.
Remove the screws (5) securing the Stacker Tray Assembly to the Finisher frame
front and rear.
2.
Lift the Stacker Tray Assembly off the screws and remove the assembly from the
frame.
Figure 1 Remove the Stacker Tray Assembly
Replacement
1.
Reinstall the Stacker Tray Assembly by hooking the keyhole screw holes at the middle of
the Assembly over the two screws on the frame.
2.
Use two screws to secure the bottom of the Assembly to the frame.
Finisher/Sorter
REP 15.2.2
1/05
8d-80
Reissue
DocuColor 12/DCCS50
REP 15.2.4 Stacker Full Sensors
3.

Removal
4.
Reconnect P/J1062 to the Stacker Full (Mixed Sizes) Sensor.
5.
Reinstall the Sensor Bracket on the Stacker Tray frame, ensure the Limit Actuator tab is
aligned properly in the Sensor Bracket. Use screws (2) to secure the Bracket.
6.
Reinstall the Rear Lower Cover.
WARNING
1.
2.
3.
Remove the Stacker Tray Full Sensors (Figure 1).

1.
Remove the screws (2) securing the Sensor Bracket to the Stacker Tray frame, and
remove the Bracket.
2.
Disconnect P/J1062 from the Stacker Full (Mixed Sizes) Sensor. Press in and
release the Stacker Full (Mixed Sizes) Sensor latches that are securing the Sensor
to the Sensor Bracket, and remove the Sensor.
3.
Disconnect P/J1063 from the Stacker Full Sensor. Press in and release the Stacker
Full Sensor latches that are securing the Sensor to the Sensor Bracket, and remove
the Sensor.
Position the Stacker Full (Mixed Sizes) Sensor into the Sensor cutout in the Sensor
Bracket.
Figure 1 Stacker Tray Full Sensors
Replacement
1.
Position the Stacker Full Sensor into the Sensor cutout in the Sensor Bracket.
2.
Reconnect P/J1063 to the Stacker Full Sensor.
Reissue
DocuColor 12/DCCS50
1/05
8d-81
Finisher/Sorter
REP 15.2.4
REP 15.2.5 Stacker Upper and Lower Limit Sensors
REP 15.2.6 Stacker Tray Paper Sensor

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
Remove the Stacker Tray Assembly (REP 15.2.2).
3.
Remove the Stacker Lower and Upper Limit Sensors (Figure 1).
3.
Remove the Stacker Tray Paper Sensor (Figure 1).
1.
Disconnect P/J1065 from the Stacker Upper Limit Sensor. Press in and release the
Sensor latches that are securing the Sensor to the Bracket, and remove the Sensor.
1.
Turn the Stacker Tray Assembly upside down. Remove the screws (3) that secure
the Bottom Cover to the bottom of the Tray.
2.
Disconnect P/J1066 from the Stacker Lower Limit Sensor. Press in and release the
Sensor latches that secures the Sensor to the Bracket, and remove the Sensor.
2.
Remove the Bottom Cover.
3.
Disconnect P/J1069 from the Sensor. Press in and release the Sensor latches that
are securing the Sensor to the Bracket, and remove the Sensor.
Figure 1 Stacker Limit Sensors

Figure 1 Remove the Stacker Tray Paper Sensor
Replacement
1.
Position the Stacker Lower Limit Sensor into the Sensor cutout in the Sensor Bracket.
Replacement
2.
Reconnect P/J1066 to the Stacker Lower Limit Sensor.
1.
3.
Position the Stacker Upper Limit Sensor into the Sensor cutout in the Sensor Bracket.
Position the Stacker Tray Paper Sensor and insert it into the Sensor cutout in the Sensor
Bracket.
4.
Reconnect P/J1065 to the Stacker Upper Limit Sensor.
2.
Reconnect P/J1069 to the Sensor.
5.
Reinstall the Sensor Bracket on the Stacker Tray Assembly, ensure the Limit Actuator tab
is aligned properly in the Sensor Bracket. Use screws (2) to secure the Bracket.
3.
Reinstall the Bottom Cover to the Tray, and use screws (3) to secure the Cover.
4.
Reinstall the Stacker Tray Assembly.
6.
Finisher/Sorter
REP 15.2.5, REP 15.2.6
1/05
8d-82
Reissue
DocuColor 12/DCCS50
REP 15.2.7 Stacker Motor
REP 15.2.8 Lower Exit Chute Assembly

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
Remove the Stacker Motor (Figure 1).
3.
1.
Remove the screws (3) securing the Motor to the Bracket, and remove the Motor.
4.
Remove the Compiler Cover Assembly (REP 15.2.22).
2.
Disengage the Drive Belt from the Motor Pulley.
5.
Remove the Eject Pinch Roll Shaft Assembly (REP 15.2.23).
3.
Disconnect P/J1090, remove the wire harness from the harness clips and remove
the Motor.
6.
Remove the Upper Exit Chute Assembly (REP 15.2.24).
7.
Remove the Exit Roll (REP 15.2.21).
8.
Remove the Compiler Paddle Shaft Assembly (Figure 1).

1.
Remove the E-ring securing the rear bearing to the Paddle Drive Shaft, and slide the
bearing off the Shaft.
2.
Remove the screws (2) securing the Lower Exit Chute Assembly to the rear of the
Finisher frame.
3.
Remove the screws (2) securing the Lower Exit Chute Assembly to the front of the
Finisher frame.
4.
Remove the Lower Exit Chute Assembly.
Figure 1 Remove the Stacker Motor
Replacement
1.
Engage the Drive Belt then use the screws (3) to secure the Motor.
2.
Reconnect P/J1090.
3.
Figure 1 Remove the Compiler Paddle Shaft Assembly
Reissue
DocuColor 12/DCCS50
1/05
8d-83
Finisher/Sorter
REP 15.2.7, REP 15.2.8
Replacement
REP 15.2.9 Stacker Tray Drive Belts
1.
Reinstall the Lower Exit Chute Assembly onto the Finisher frame.
2.
Use the screws (4) to secure the Lower Exit Chute Assembly to the Finisher frame.
3.
Slide the metal bearing onto the rear of the Paddle Drive Shaft, and use an E-ring to
secure the bearing to the rear of the Finisher.

Removal
4.
Reinstall the Exit Roll.
5.
Reinstall the Upper Exit Chute Assembly.
6.
Reinstall the Eject Pinch Roll Assembly.
7.
Reinstall the Compiler Cover Assembly.
8.
9.
WARNING
1.
2.
3.
Remove the Stacker Motor Bracket and the Sensor Bracket (Figure 1).
1.
Remove the screws (3) securing the Stacker Motor Bracket.
2.
Pull the Dog Clutch Gear away from the Dog Clutch Pulley then remove the Bracket.
3.
Remove the screws (2) securing the Sensor Bracket to the Tray Frame, and remove
the Sensor Bracket.
Figure 1 Remove the Stacker Motor Bracket

4.
Finisher/Sorter
REP 15.2.8, REP 15.2.9
1/05
8d-84
Remove the Front Stacker Tray Drive Belt (Figure 2).

1.
To remove the front Stacker Tray Drive Belt, raise the Stacker Tray to the top of the
stacker. Remove the screws (2) from the front Stacker Tray Drive Belt Clamp.
Remove the E-ring from the top front Pulley and remove the Flange.
2.
Support the Stacker Tray with one hand and pull the front Stacker Tray Drive Belt and
the Belt Clamp from the Tray bracket. Remove the Belt Clamp from the Front Belt,
and remove the Front Belt from the Stacker Tray Assembly.
Reissue
DocuColor 12/DCCS50
REP 15.2.10 Stacker Tray

Removal
WARNING
1.
2.
3.
Removing the Stacker Motor Bracket and Sensor Bracket (Figure 1).
1. Remove the screws (3) that secures the Stacker Motor Bracket and set the
Bracket to one side.
2. Remove the screws (2) the secures the Sensor Bracket and set the Bracket to one
side.
3. Disconnect the Stacker Tray in line connector P/J1070 from the Sensor Bracket
and remove the wire harness from the harness clamps.
4. Pull the Dog Clutch Gear away from the Dog Clutch Pulley then remove the
Stacker Motor Bracket.
Figure 2 Remove the Front Stacker Tray Drive Belt

3.
To remove the Rear Stacker Tray Drive Belt, raise the Stacker Tray to the top of the
stacker. Remove the screws (2) from the Rear Stacker Tray Drive Belt Clamp (Figure 2).
4.
Remove the E-ring from the top rear Pulley and remove the Flange.
5.
Support the Stacker Tray with one hand and pull the Rear Belt and the Belt Clamp from
the Tray bracket.
6.
Remove the Belt Clamp from the Rear Belt.
7.
Remove the Rear Belt from the Stacker Tray Assembly.
Replacement
1.
Install the front and rear Belts onto the top pulleys and install the Pulley Flanges on the
front and rear pulley and secure with E-rings (2).
2.
Reinstall the Stacker Motor Bracket. ensure that the rear Stacker Tray Drive Belt is routed
under the Worm Wheel, and secure the Stacker Motor Bracket with screws (3).
3.
Reinstall the Sensor Bracket onto the Stacker Frame, ensure the Actuator tab is aligned
properly in the Sensor Bracket. Also ensure that the rear Drive Belt Clamp properly
engages the Sensor Actuator. Use the screws (2) to secure the Bracket.
4.
Install the Belts Clamps (2) onto the front and rear Stacker Tray Drive Belts.
5.
Ensure the Stacker Tray is level with the Stacker Tray Assembly and install the Belt
Clamps into the Stacker Tray brackets.
6.
Adjust the Stacker Tray Level (ADJ 15.3.2).
7.
Install the Stacker Tray Assembly.
8.
9.
Reissue
DocuColor 12/DCCS50
Figure 1 Removing the Stacker Motor Bracket and Sensor Bracket

4.
Removing the Stacker Drive Belt Clamps (Figure 2).

1. Remove the screws (2) from the Front Drive Belt Clamp and the Rear Drive Belt
Clamp.
1/05
8d-85
Finisher/Sorter
REP 15.2.9, REP 15.2.10
Figure 2 Removing the Stacker Drive Belt Clamps

5.
Figure 3 Remove the Stacker Tray
Replacement
Remove the Stacker Tray (Figure 3).

1. Support the Stacker Tray with one hand and pull the front and rear Belt Clamps
from the Tray brackets.
2. With one end of the Tray Carriage at the bottom of the Carriage track, raise the
opposite end of the Tray Carriage out of the slots in the Front and Rear Tray Frames,
and remove the Stacker Tray.
Finisher/Sorter
REP 15.2.10
1.
Reinstall the Stacker Tray into the slots in the Front and Rear Tray Frames.
2.
Install the Drive Belts and Belt Clamps into the Stacker Tray Brackets.
3.
Reinstall the Sensor Bracket onto the Stacker Frame, ensure the Actuator tab is aligned
properly in the Sensor Bracket. Also ensure that the rear Drive Belt Clamp properly
engages the Sensor Actuator. Use the screws (2) to secure the Sensor Bracket.
4.
Connect the Stacker Tray in line connector P/J1070 from the Sensor Bracket and install
the wire harness into the harness clamps.
5.
Adjust the Stacker Tray Level (ADJ 15.3.2).
6.
7.
8.
1/05
8d-86
Reissue
DocuColor 12/DCCS50
REP 15.2.11 Tamper Motor
Replacement

Removal
1.
Install the Tamper Motor onto the Compiler Bin and secure it with two screws.
2.
Reinstall the Tamper Motor Drive Belt over the Tamper Motor Pulley.
3.
Reinstall the Tie Plate and secure it to the Finisher Frame with the screws (4).
4.
Connect connector P/J1087 and install the Tamper Motor wiring harness into the cable
ties.
5.
WARNING
1.
2.
Lower the Stacker Elevator so the tray is at the lowest possible position.
3.
Disconnect the Finisher from the Printer.
4.
5.
6.
7.
Remove the screws (4) from the Tie Plate and remove the Tie Plate from the Finisher
Frame.
8.
Remove the Tamper Motor (Figure 1).

1.
Remove the Drive Belt from the Tamper Motor Pulley.
2.
Disconnect connector P/J1087 and remove the Tamper Motor wiring harness from
all cable ties.
3.
Accessing the rear of the Tamper Motor, remove the two screws that secure the
Motor to the Compiler Bin and remove the Tamper Motor.
6.
7.
8.
Connect the Finisher to the Printer.
Figure 1 Remove the Tamper Motor
Reissue
DocuColor 12/DCCS50
1/05
8d-87
Finisher/Sorter
REP 15.2.11
REP 15.2.12 Tamper Home Sensor
2.
Connect P/J1045 to the Sensor.

Removal
3.
Reinstall the Tamper Home Sensor Bracket onto the Compiler and use the screw (1) to
secure the Bracket.
4.
Reinstall the Tie Plate and use the screws (4) to secure it to the frame.
WARNING
5.
6.
7.
1.
8.
2.
3.
4.
5.
6.
Remove the screws (4) securing the Tie Plate to the Finisher Frame. Remove the Tie
Plate.
7.
Remove the Tamper Home Sensor (Figure 1).

1.
Loosen the screw (1) securing the Tamper Home Sensor Bracket to the Compiler
and remove the Bracket along with the Tamper Home Sensor.
2.
Disconnect P/J1045 from the Sensor.
3.
Press in and release the Sensor latches that are securing the Sensor to the Bracket,
and remove the Sensor.
Figure 1 Remove the Tamper Home Sensor
Replacement
1.
Position the Tamper Home Sensor into the Sensor cutout in the Sensor Bracket.
Finisher/Sorter
REP 15.2.12
1/05
8d-88
Reissue
DocuColor 12/DCCS50
REP 15.2.13 Compiler Paper Sensor
3.

Removal
4.
5.
Reinstall the Compiler Paper Sensor Bracket onto the Compiler and use the screw (1) to
secure the Bracket.
WARNING
6.
7.
8.
1.
2.
3.
4.
5.
6.
Remove the screws (4) securing the Tie Plate to the Finisher frame. Remove the Tie
Plate.
7.
Remove the Compiler Paper Sensor (Figure 1).

1.
Press in and release the Sensor latches that are securing the Sensor Bracket.
2.
Figure 1 Remove the Compiler Paper Sensor
Replacement
1.
Position the Compiler Paper Sensor into the Sensor cutout in the Sensor Bracket.
2.
Connect P/J1048 to the Sensor.
Reissue
DocuColor 12/DCCS50
1/05
8d-89
Finisher/Sorter
REP 15.2.13
REP 15.2.14 End Wall Open Sensor
2.
Position the End Wall Open Sensor into the Sensor cutout in the Sensor Bracket.

Removal
3.
4.
WARNING
1.
2.
3.
4.
5.
6.
Remove the screws (4) securing the Tie Plate to the Finisher frame (Figure 1). Remove
the Tie Plate.
7.
Remove the End Wall Open Sensor (Figure 1).

1.
Remove the screw (1) securing the Compiler Paper Sensor Bracket to the Compiler.
Remove the Bracket along with the Compiler Paper Sensor.
2.
3.
Press in and release the Sensor latches that are securing the Sensor to the Bracket.
Remove the Sensor.
5.
6.
7.
Figure 1 Remove the End Wall Open Sensor
Replacement
1.
Finisher/Sorter
REP 15.2.14
1/05
8d-90
Reissue
DocuColor 12/DCCS50
REP 15.2.15 Tamper Motor Drive Belt
Replacement

Removal
1.
Position the Tamper Motor Drive Belt so the ribs are on the inside of the Belt loop.
2.
Slip the Belt over the Tension Pulley.
3.
Insert the Belt between the top and bottom of the Belt Holder, and tighten the screw on
the Belt Holder.
4.
Reinstall the Tamper Motor.
WARNING
1.
2.
Lower the Stacker Elevator so the Stacker Tray is at the lowest possible position.
3.
4.
5.
6.
7.
Remove the screws (4) securing the Tie Plate to the Finisher Frame. Remove the Tie
Plate.
8.
Remove the Tamper Motor (REP 15.2.11).
9.
Remove the Tamper Motor Drive Belt (Figure 1).
5.
Tighten the Belt Tension Screw.
6.
7.
8.
9.
10. Connect the Finisher to the Printer.
1.
Loosen, do not remove, the screw (1) on the Belt Holder, and slip the Belt out of the
holder.
2.
Loosen the screw that secures the Belt Tension Pulley.
3.
Slip the Belt off of the Tension Pulley, and remove the Belt.
Figure 1 Remove the Tamper Motor Drive Belt
Reissue
DocuColor 12/DCCS50
1/05
8d-91
Finisher/Sorter
REP 15.2.15
REP 15.2.16 End Wall Motor
Replacement

Removal
1.
Reinstall the End Wall Motor onto the Motor Bracket.
2.
Reconnect the End Wall Motor Wire Harness.
3.
Reinstall the End Wall Motor Bracket onto the Finisher frame, making sure the End Wall
Link is captured inside the End Wall Motor yoke.
WARNING
1.
2.
3.
Remove the End Wall Motor (Figure 1).

1.
4.
Connect the End Wall Motor Connector P/J1083.
5.
Use the screws (2) to secure the End Wall Motor Bracket to the Finisher frame.
6.
Reinstall the End Wall Spring, with one end of the Spring attached to the End Wall
7.
Remove the screws (2) securing the Harness Holder to the Finisher frame and push
the wire harness to one side.
2.
Remove the End Wall Spring.
3.
Remove the screws (2) securing the End Wall Motor Bracket to the finisher frame.
Remove the Bracket along with the attached End Wall Motor.
4.
Release the end Wall Motor wire harness from the harness clips.
5.
Disconnect the End Wall Motor wire harness at the back of the motor or disconnect
P/J1083.
6.
Remove the screws (2) securing the End Wall Motor to the Bracket, and remove the
Motor.
Figure 1 Remove the End Wall Motor
Finisher/Sorter
REP 15.2.16
1/05
8d-92
Reissue
DocuColor 12/DCCS50
REP 15.2.17 Eject Clamp Sensor

Removal
4.
Reinstall the wire harnesses to the wire clamps that are attached to the Eject Bracket.
5.
WARNING
1.
2.
3.
Remove the Eject Clamp Sensor (Figure 1).

1.
Remove the wire harnesses from the wire clamps that are attached to the Eject
Bracket.
2.
Remove the screw (1) securing the Eject Clamp Sensor Bracket to the Eject Bracket,
and remove the Sensor Bracket, along with Sensor.
3.
4.
Press in and release the Sensor latches that secure the Sensor to the Bracket, and
remove the Sensor.
Figure 1 Remove the Eject Clamp Sensor
Replacement
1.
Position the Eject Clamp Sensor into the Eject Clamp Sensor Bracket.
2.
3.
Reinstall the Eject Clamp Sensor Bracket onto the Eject Bracket. Use the screw (1) to
secure the Sensor Bracket.
Reissue
DocuColor 12/DCCS50
1/05
8d-93
Finisher/Sorter
REP 15.2.17
REP 15.2.18 Stacker Offset Home Sensor
5.

Removal
WARNING
1.
2.
3.
Remove the Stacker Offset Home Sensor (Figure 1).

1.
Remove the screws (2) securing the Offset Home Sensor Bracket to the Finisher
frame, and remove the Bracket.
2.
Free the two wire harnesses from the wire clamp that is attached to the Bracket. Disconnect P/J1051 from the Stacker Offset Home Sensor.
3.
remove the Sensor.
Figure 1 Remove the Stacker Offset Home Sensor
Replacement
1.
Position the Stacker Offset Home Sensor into the cutout in the Sensor Bracket.
2.
Reconnect P/J1051 to the Stacker Offset Home Sensor.
3.
Secure the two wire harnesses in the wire clamp that is attached to the Bracket.
4.
Reinstall the Stacker Offset Home Sensor Bracket onto the Finisher frame. Use two
screws to secure the Bracket to the frame.
Finisher/Sorter
REP 15.2.18
1/05
8d-94
Reissue
DocuColor 12/DCCS50
REP 15.2.19 Eject Bracket Assembly
2.

Removal
3.
Hook the Tension Spring onto the Eject Bracket Assembly.
4.
Reinstall the Harness Bracket Assembly to the Finisher frame, and use the screws (3) to
secure the Bracket.
WARNING
5.
Ensure that P/J1055 to the Eject Paddle Sensor did not accidentally become disconnected when the Harness Bracket Assembly was moved.
6.
Reinstall the Stacker Offset Home Sensor.
1.
7.
Reconnect P/J1086 and replace the harness in the harness clamps.
2.
Move the Finisher away from the Printer.
8.
Reinstall the Eject Clamp Sensor.
3.
9.
4.
Remove the Eject Clamp Sensor (REP 15.2.17).
10. Reconnect the Finisher to the Printer.
5.
Remove the Stacker Offset Home Sensor (REP 15.2.18).
6.
Use the screws (4) to secure the Assembly.
Remove the Eject Bracket Assembly (Figure 1).

1.
Disconnect P/J1086 and free the harness from all cable clamps.
2.
Remove the screws (3) securing the Harness Bracket Assembly to the Finisher
frame, and remove the Assembly.
3.
Unhook the Tension Spring from the Eject Bracket Assembly.
4.
Remove the screws (4) securing the Eject Bracket Assembly to the finisher frame,
and remove the Assembly.
Figure 1 Remove the Eject Bracket Assembly
Replacement
1.
Reinstall the Eject Bracket Assembly onto the Finisher frame. Ensure the cam follower pin
on the Offset Lever is correctly positioned in the cam in the Exit Bracket Assembly.
Reissue
DocuColor 12/DCCS50
1/05
8d-95
Finisher/Sorter
REP 15.2.19
REP 15.2.20 Eject Paddle Motor and Drive Belt

Removal
WARNING
1.
2.
Roll the finisher away from the printer until it stops.
3.
4.
5.
6.
Remove the Eject Bracket Assembly (REP 15.2.19).
7.
Remove the Eject Paddle Motor and Drive Belt (Figure 1).
1.
Disconnect P/J1088.
2.
Disconnect P/J1055.
3.
Remove the screws (2) securing the Motor Bracket to the finisher frame, and pull the
Bracket away from the Finisher frame.
4.
Free the Eject Paddle Drive Belt from the Motor Pulley, and remove the Motor
Bracket.
5.
Remove the E-ring securing the Shaft Pulley to the Motor Shaft, and remove the Pulley.
6.
Remove the screws (2) securing the Eject Paddle Motor to the Motor Bracket, and
remove the Motor.
7.
Remove the Eject Paddle Motor Drive Belt from the Eject Pulley.
Finisher/Sorter
REP 15.2.20
Figure 1 Remove the Eject Paddle Motor and Drive Belt
Replacement
1.
Reinstall the Eject Paddle Motor onto the Motor Bracket, and use the screws (2) to secure
the Motor.
2.
Slide the Shaft Pulley, with the lip facing away from the Motor onto the Motor Shaft. Use
the E-ring to secure the Pulley onto the Shaft.
3.
Reinstall the Motor Bracket onto the Finisher frame, by first slipping the Eject Paddle Drive
Belt over the Shaft Pulley. Use the screws (2) to secure the Motor Bracket to the Finisher
frame.
4.
Reconnect P/J1088 and P/J1055.
5.
If removed, reinstall the Finisher PWB Cover and the Harness Cover.
6.
Reinstall the Eject Bracket Assembly.
7.
8.
9.
1/05
8d-96
Reissue
DocuColor 12/DCCS50
REP 15.2.21 Eject Shaft Assembly

Removal
WARNING
1.
2.
Roll the Finisher away from the Printer.
3.
4.
5.
6.
7.
8.
9.
10. Remove the Eject Paddle Motor (REP 15.2.20).

11. Remove the Eject Shaft Assembly (Figure 1).
1.
Remove the screws (4) securing the Frame tie plate, and remove the plate.
2.
Remove the E-ring securing the Set Clamp Actuator to Shaft 1, and remove the
Actuator, Pulley, and rear metal bearing.
3.
Remove the E-ring securing the front metal bearing for Shaft 1, and remove the front
bearing.
4.
Remove the E-ring securing the Offset Lever to Shaft 2, and remove the Offset
Lever.
5.
Remove the E-ring securing the Eject Gear to Shaft 2, and remove the Eject Gear.
6.
Remove the screw (1) securing the rear plastic bearing to Shaft 2, and slide the front
bearing off of the Shaft.
7.
Remove the screw (1) securing the front plastic bearing to Shaft 2, and slide the front
bearing off of the Shaft.
8.
Remove Shaft 1 and Shaft 2 (the Eject Shaft Assemblies) as a unit.

Figure 1 Remove the Eject Shaft Assembly
Replacement
1.
Reissue
DocuColor 12/DCCS50
Reinstall the Eject Shaft Assemblies into the Finisher frame.
2.
Slide the front and the rear metal bearings over the ends of Shaft 1.
3.
Position the Compiler Bin so the arms at the front and rear of the Bin line up with Shaft 1.
4.
Slide the front and the rear metal bearings into the bearing cutouts in the Finisher frame,
and through the arms of the Compiler Bin.
5.
use an E-ring to secure the front metal bearing to the front end of Shaft 1.
6.
Slide the Pulley and the Set Clamp Actuator over the rear end of Shaft 1, and use an Ering to secure them to the Shaft.
7.
Slide the front plastic bearing onto the front end of Shaft 2, and use the screw (1) to
secure the bearing to the Finisher frame.
1/05
8d-97
Finisher/Sorter
REP 15.2.21
8.
Slide the rear plastic bearing onto the rear end of Shaft 2, and use the screw (1) to secure
the bearing to the Finisher frame.
9.
Slide the Eject Gear onto the rear end of Shaft 2, and use an E-ring to secure the Gear to
the Shaft.
10. Slide the Offset Lever over the rear end of Shaft 2, and use an E-ring to secure the Offset
Lever.
REP 15.2.22 Compiler Cover Assembly

Removal
WARNING
11. Reinstall the Eject Paddle Motor.
12. Reinstall the Eject Bracket Assembly.
1.
13. Reinstall the Stacker Offset Home Sensor.
2.
14. Reinstall the Eject Clamp Sensor.
3.
15. Reinstall the Eject Roll Chute, and use the screws (4) to secure the Chute.
4.
16. Reinstall the Harness Cover.
5.
Remove the Eject Cover (PL 18.15 item 10).
17. Reinstall the Compiler Cover Assembly.
6.
Remove the Compiler Cover Assembly (Figure 1).
18. Reinstall the Rear Lower Cover.
1.
Remove the E-ring securing the Offset Lever to the rear of the Eject Pinch Roll Shaft.
Slide the Offset lever off the Eject Pinch Roll Shaft (rotate the Offset Cam if necessary).
2.
Remove the screw securing the Lever to the Eject Pinch Roll Shaft. Remove the
Lever.
3.
Remove the screw (1) securing the rear Pinch Roll Bearing to the finisher frame, and
slide the Bearing to the rear.
4.
Remove the screw securing the front Pinch Roll Bearing to the Finisher frame, and
slide the Bearing to the front.
5.
Lift the Compiler Cover Assembly and the Pinch Roll Assembly and remove the
Compiler Cover Assembly from the finisher frame.
Finisher/Sorter
REP 15.2.21, REP 15.2.22
1/05
8d-98
Reissue
DocuColor 12/DCCS50
REP 15.2.23 Eject Pinch Roll Shaft Assembly

Removal
WARNING
1.
2.
3.
4.
5.
Remove the Eject Pinch Roll Shaft Assembly (Figure 1).

1.
Remove the front and rear bearings from the Eject Pinch Roll Shaft.
2.
Disconnect P/J1075 from the Stack Height Sensor.
3.
Slide the Eject Pinch Roll Shaft Assembly to the rear and remove it from the Finisher.
Figure 1 Remove the Compiler Cover Assembly
Replacement
1.
Reinstall the Compiler Cover Assembly by first sliding the Stack Height Actuator and the
Pinch Rolls through the cutout in the Assembly.
2.
Hook the two arms of the Compiler Cover Assembly over the Pinch Roll Shaft.
3.
Slide the front Pinch Roll Bearing to the rear so the arms of the Compiler Cover Assembly
ride on the Bearing. Use the screw (1) to secure the Bearing to the Finisher frame.
4.
Slide the rear Pinch Roll Bearing to the front so the arms of the Compiler Cover Assembly
ride on the Bearing. Use the screw (1) to secure the Bearing to the Finisher frame.
5.
Insert the Lever on the shaft and secure with the screw (1).
6.
Insert the Offset Lever into the Offset Cam and onto the Eject Pinch Roll Shaft. Use the Ering to secure the lever.
7.
Raise and lower the Compiler Cover Assembly to make sure it moves freely, and the
Stack Height Actuator and Pinch Rolls also move freely.
8.
9.
10. Reinstall the Stapler Cover Assembly.
Reissue
DocuColor 12/DCCS50
Figure 1 Remove the Eject Pinch Roll Shaft Assembly
Replacement
1.
Insert the rear of the Eject Pinch Roll Shaft Assembly into the bearing hole at the rear of
the Finisher.
2.
Insert the front of the Eject Pinch Roll Shaft Assembly into the bearing hole at the rear of
the Finisher.
3.
Reconnect P/J1075 to the Stack Height Sensor.
1/05
8d-99
Finisher/Sorter
REP 15.2.22, REP 15.2.23
REP 15.2.24 Upper Exit Chute Assembly
4.
Slide the front and rear bearings over the ends of the Eject Pinch Roll Shaft.
5.
6.
Raise and lower the Compiler Cover Assembly to make sure it moves freely, and the
Stack Height Actuator and Pinch Rolls also move freely.
7.
8.

Removal
WARNING
1.
2.
3.
4.
5.
6.
Remove the Upper Exit Chute Assembly (Figure 1).

1.
Remove the screw (1) securing the Finisher Interlock Switch Bracket to the front of
the Finisher frame, and remove the Bracket to gain access one of the Upper Exit
Chute Assembly screws.
2.
Remove the screws (2) securing the Upper Exit Chute Assembly to the front Finisher
frame.
3.
Remove the screws (2) securing the Upper Exit Chute Assembly to the rear Finisher
frame.
4.
Rotate the Upper Exit Chute Assembly and remove the Assembly from the Finisher.
Figure 1 Remove the Upper Exit Chute Assembly
Finisher/Sorter
REP 15.2.23, REP 15.2.24
1/05
8d-100
Reissue
DocuColor 12/DCCS50
Replacement
1.
Reinstall the Upper Exit Chute Assembly into the Finisher frame. Use the screws (4) to
secure the front and rear of the Upper Exit Chute Assembly.
2.
Reinstall the finisher Interlock Switch Bracket to the front of the Finisher frame, and use
one screw to secure the Bracket.

Removal
WARNING
3.
Reinstall the Eject Pinch Roll Shaft Assembly.
4.
Reinstall the Exit Chute Assembly.
5.
1.
2.
3.
6.
7.
4.
5.
6.
7.
Remove the Exit Roll (Figure 1).

1.
Remove the E-ring securing the Paddle Shaft Drive Gear, that is located just below
the Exit Shaft Pulley, and remove the Drive Gear.
2.
Loosen the screws (2) that secure the Transport Motor Drive Belt Tension Assembly.
Push the idler pulley up to release the tension. Tighten the screws (2).
3.
Remove the screw securing the Exit Shaft Pulley to the Shaft, and remove the Pulley.
4.
Remove the E-ring securing the front and rear Exit Shaft bearings, and remove the
bearings.
5.
Slide the Exit Roll out of the Finisher frame.
Figure 1 Remove the Exit Roll
Reissue
DocuColor 12/DCCS50
1/05
8d-101
Finisher/Sorter
REP 15.2.24, REP 15.2.25
Replacement
REP 15.2.26 Compiler Paddle Shaft Assembly
1.
Reinstall the Exit Roll.
2.
Reinstall the Exit Roll front and rear bearings into the bearing cutouts at the front and rear
of the finisher frame. Use an E-ring at both ends of the Shaft.

Removal
3.
Reinstall the Exit Shaft Pulley onto the Exit Shaft, and use one screw to secure the Pulley
to the Shaft.
4.
Ensure the Transport Motor Drive Belt is properly installed on all pulleys.
5.
Loosen the screws that secures the Belt Tension Assembly.
1.
Allow the assembly to properly tension the belt, then tighten the two screws.
2.
7.
Reinstall the Paddle Shaft Drive Gear and use the E-ring to secure the Gear to the Shaft.
3.
8.
Reinstall the Upper Exit Chute Assembly.
4.
5.
6.
7.
Remove the Exit Roll (REP 15.2.21).
8.
Remove the Compiler Paddle Shaft Assembly (Figure 1).
6.
9.
WARNING
1.
Remove the E-ring securing the rear bearing to the Paddle Drive Shaft, and slide the
bearing off the Shaft.
2.
Remove the screws (2) securing the Lower Exit Chute Assembly to the rear of the
Finisher frame.
3.
Remove the screws (2) securing the Lower Exit Chute Assembly to the front of the
Finisher frame.
4.
Remove the Lower Exit Chute Assembly and place it on a stable work surface.
5.
Remove the E-rings from both ends of the Paddle Shaft.
6.
Slide the Paddle Drive Belt off of the Paddle Drive Pulley.
7.
Slide the Paddle Drive Pulley off of the Paddle Shaft.
8.
Remove the screw securing the front Paddle Bearing, and slide the bearing off of the
Shaft.
9.
Remove the screw securing the rear Paddle Bearing, and remove the bearing, Drive
Belt, Drive Shaft, and Paddle Shaft from the Lower Exit Chute Assembly.
10. Slide the Paddle Shaft out of the rear bearing.
Finisher/Sorter
REP 15.2.25, REP 15.2.26
1/05
8d-102
Reissue
DocuColor 12/DCCS50
7.
Use an E-ring to secure the front of the Paddle Shaft to the front bearing.
8.
Reinstall the Lower Exit Chute Assembly onto the Finisher frame.
9.
Use the screws (4) to secure the Lower Exit Chute Assembly to the Finisher frame.
10. Slide the metal bearing onto the rear of the Paddle Drive Shaft, and use an E-ring to
secure the bearing to the rear of the Finisher.
11. Reinstall the Exit Roll.
12. Reinstall the Upper Exit Chute Assembly.
13. Reinstall the Eject Pinch Roll Assembly.
Figure 1 Remove the Compiler Paddle Shaft Assembly
Replacement
1.
Reinstall the Drive Belt onto the Drive Pulley.
2.
Slide the end of the Paddle Shaft into the rear bearing.
3.
Install the Compiler Paddle Shaft Assembly, along with the attached rear Paddle Bearing,
onto the Lower Exit Chute Assembly. Use the screw (1) to secure the rear bearing to the
Exit Chute.
4.
Reinstall the front Paddle Bearing by sliding the bearing over the front end of the Paddle
Shaft.
5.
Slide the Paddle Drive Pulley, with a lip facing in, onto the rear of the Paddle Shaft, and
use an E-ring to secure the drive Pulley to the Shaft.
6.
Slide the Drive Belt onto the Paddle Drive Pulley.
Reissue
DocuColor 12/DCCS50
1/05
8d-103
Finisher/Sorter
REP 15.2.26
REP 15.2.27 Paddle Drive Belt
Replacement

Removal
1.
Slip the Paddle Drive Belt over the Paddle Gear.
2.
Press the Paddle onto the Paddle Cover Assembly.
3.
Reinstall the Sensor Bracket Assembly onto the Paddle Cover Assembly, and use the
screw (1) to secure the Bracket.
4.
Reinstall the Drive Gear onto the other end of the Belt, and position the Gear in the Paddle Cover Assembly.
1.
5.
2.
Slide the Paddle Cover Assembly onto the Eject Pinch Roll Shaft. Use an E-ring to secure
the Paddle Cover Assembly to the Eject Pinch Roll Shaft.
3.
6.
4.
Slide the Front Pinch Roll Cover onto the Eject Pinch Roll Shaft, and use the screws (2) to
secure the Cover to the Shaft.
5.
7.
6.
Remove the Paddle Drive Belt (Figure 1).
8.
1.
Remove the two screws securing the Front Pinch Roll Cover to the Eject Pinch Roll
Shaft, and slide the Cover off of the Shaft.
9.
Raise and loser the Compiler Cover Assembly to make sure it moves freely, and the Stack
Height Actuator and Pinch Rolls also move freely.
2.
Remove the E-ring securing the Paddle Cover Assembly to the Eject Pinch Roll
Shaft, and slide the Cover Assembly off of the Shaft.
3.
Remove the screw securing the Sensor Bracket to the Paddle Cover Assembly, and
remove the Bracket.
4.
Remove the Paddle out of the Paddle Cover Assembly.
5.
Remove the Paddle Drive Belt.
WARNING
Figure 1 Remove the Paddle Drive Belt
Finisher/Sorter
REP 15.2.27
1/05
8d-104
Reissue
DocuColor 12/DCCS50
REP 15.2.28 Stacker Height Sensor
5.

Removal
6.
Check that the Stack Height Actuator and Pinch Rolls moves freely.
7.
8.
WARNING
Raise and lower the Compiler Cover Assembly to make sure it moves freely.
1.
2.
3.
4.
5.
6.
Remove the Stacker Height Sensor (Figure 1).

1.
Release the latches that are securing the Stack Height Sensor to the Sensor
Bracket, and remove the Sensor.
Figure 1 Remove the Stacker Height Sensor
Replacement
1.
Position the Stack Height Sensor into the Sensor cutout in the Sensor Bracket.
2.
Raise and lower the Stack Height Sensor Actuator to make sure the Actuator arm moves
freely between the arms of the Stack Height Sensor.
3.
Reinstall the eject Pinch Roll Shaft Assembly.
4.
Reissue
DocuColor 12/DCCS50
1/05
8d-105
Finisher/Sorter
REP 15.2.28
REP 15.2.29 Unload While Run Switch
REP 15.2.30 Compiler Entrance Sensor

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
Remove the Unload While Run Switch (Figure 1).
3.
1.
Remove the screw (1) securing the Switch Bracket to the Finisher frame, and
remove the Bracket.
4.
Remove the Compiler Entrance Sensor (Figure 1).

1.
Disconnect the Compiler Entrance Sensor Connector P/J1052.
2.
Disconnect P/J1075 from the Switch.
2.
Remove the screws (2) securing the Compiler Entrance Sensor Bracket.
3.
Remove the screw (1) securing the Switch to the Bracket, and remove the Switch.
3.
Pull the Sensor Bracket up and remove the Compiler Enter Sensor.
Figure 1 Remove the Unload While Run Switch
Figure 1 Remove the Compiler Entrance Sensor
Replacement
Replacement
1.
Reinstall the Unload While Run Switch onto the Switch Bracket.
1.
Install the Compiler Entrance Sensor bracket into place.
2.
With the screw (1) secure the Switch to the Bracket.
2.
3.
Reconnect P/J1075 to the Switch.
Route the Compiler Entrance Sensor harness through the opening in the frame and connect P/J1052 connector.
4.
Reinstall the Bracket to the Finisher frame, and use the screw (1) to secure it to the frame.
3.
Install the screws (2) and secure the Compiler Entrance Sensor Bracket.
5.
4.
Finisher/Sorter
REP 15.2.29, REP 15.2.30
1/05
8d-106
Reissue
DocuColor 12/DCCS50
REP 15.2.31 Eject Paddle Home Sensor
3.

Removal
4.
5.
WARNING
6.
Reinstall the Upper Rear Cover.
7.
Reconnect the Finisher to the Printer.
1.
2.
Roll the Finisher away from the printer until it stops.
3.
4.
5.
6.
7.
Remove the Eject Paddle Motor (REP 15.2.20).

NOTE: Do not remove the Motor from the Bracket.
8.
Remove the Eject Paddle Home Sensor (Figure 1).

1.
remove the Sensor.
Figure 1 Remove the Eject Paddle Home Sensor
Replacement
1.
Position the Eject Paddle Home Sensor into the cutout in the Motor Bracket.
2.
Reinstall the Eject Paddle Motor.
Reissue
DocuColor 12/DCCS50
1/05
8d-107
Finisher/Sorter
REP 15.2.31
REP 15.2.32 Eject Motor

Removal
WARNING
1.
2.
3.
4.
Remove the Eject Motor (Figure 1).

1.
Free the wire harnesses that run the length of the Harness Bracket.
2.
Remove the screws (3) securing the Harness Bracket to the Finisher frame, and
remove the Bracket.
3.
Disconnect P/J1091.
4.
Remove the screws (2) securing the Eject Motor Bracket to the Finisher frame.
5.
Slip the Motor shaft pulley free of the Eject Motor Drive Belt, and remove the Bracket
and Motor. Remove the screws (2) securing the Eject Motor to the Motor Bracket,
and remove the Motor.
2.
Reinstall the Motor Bracket onto the Finisher frame, making sure to loop the free end of
the Eject Motor Drive Belt over the Motor shaft pulley. Use the screws (2) to secure the
Eject Motor Bracket to the Finisher frame, but do not tighten the screws at this time.
3.
Push down slightly on the Eject Motor, to apply tension to the Drive Belt, and hold the
Motor down while tightening the screws (2) securing the Bracket to the frame.
4.
Reconnect P/J1091.
5.
Reinstall the Harness Bracket to the Finisher frame, and use the screws (3) to secure it to
the frame.
6.
Route the wire harnesses through the clips that run the length of the Harness Bracket.
7.
8.
Reconnect the Finisher to the Printer.
Figure 1 Remove the Eject Motor
Replacement
1.
Position the Eject Motor against the Eject Motor Bracket. Use the screws (2) to secure the
Motor to the Bracket.
Finisher/Sorter
REP 15.2.32
1/05
8d-108
Reissue
DocuColor 12/DCCS50
REP 15.2.33 Eject Clamp/Offset Motor

Removal
WARNING
1.
2.
3.
4.
5.
6.
7.
Remove the Eject Clamp/Offset Motor (Figure 1).

1.
Remove the E ring securing the One Way Gear to the Offset Cam Assembly, and
remove the Gear.
2.
Remove the E ring securing the Rear Offset Cam Assembly Bearing, and remove
the Bearing.
3.
Remove the Offset Cam Assembly from the Eject Bracket.
4.
Remove the E ring securing the Drive Gear, and remove the Gear.
5.
Remove the two Idler Gears.
6.
Remove the screws (3) securing the Eject Clamp Offset Motor, and remove the
Motor from the Eject Bracket Assembly.
Figure 1 Remove the Eject Clamp/Offset Motor
Replacement
1.
Reinstall the Eject Clamp Offset Motor into the Eject Bracket Assembly, and use the
screws (3) to secure the Motor.
2.
Reinstall the two idler Gears.
3.
Reinstall the Drive Gear, and use an E ring to secure the Gear.
4.
Reinstall the Offset Cam Assembly, with the Actuator toward the inside wall of the Eject
Bracket, into the Eject Bracket Assembly.
5.
Reinstall the bearings to both ends of the Offset Cam Assembly Shaft.
6.
Reinstall an E ring to the short end of the Offset Cam Assembly Shaft.
7.
Reinstall the One Way Gear to the end of the Offset Cam Assembly Shaft, and use an E
ring to secure the Gear to the Shaft.
8.
9.
10. Reinstall the Eject Clamp Sensor.

Reissue
DocuColor 12/DCCS50
1/05
8d-109
Finisher/Sorter
REP 15.2.33
Finisher/Sorter
REP 15.2.33
1/05
8d-110
Reissue
DocuColor 12/DCCS50
REP 15.3.1 Finisher
REP 15.3.2 Stapler Door Assembly

Removal

Removal
WARNING
WARNING
1.
1.
2.
Move the Finisher away from the printer.
2.
Remove the Stapler Door Assembly (Figure 1).
3.
Disconnect the Finisher (Figure 1).
1.
Open the Stapler Door.
1.
Remove the thumb screw from the end of the Docking Rail Assembly, and pull the
Finisher free from the Docking Rail Assembly.
2.
Remove the C-Clip securing the top hinge.
3.
Lift and remove the Stapler Door.
2.
Disconnect the Finisher IOT Connector from the rear of the printer.
3.
Roll the Finisher away from the printer.
Replacement
1.
Replacement
1.
Reinstall the Stapler Door in the reverse order of removal.
Move the Finisher to within 12 inches (304.8 mm) of the printer.
2.
Reinstall the Docking Rail Assembly under the printer.
3.
Secure the Docking Rail Assembly with the thumb screw.
4.
Reconnect the Finisher IOT Connector to the printer.
5.
Push the Finisher in against the printer, making sure that the Docking pin on the printer is
aligned with the Docking Plate locating hole on the Finisher.
Figure 1 Remove the Stapler Door Assembly
Figure 1 Disconnect the Finisher
Reissue
DocuColor 12/DCCS50
1/05
8d-111
Finisher/Sorter
REP 15.3.1, REP 15.3.2
REP 15.3.3 Stapler Cover Assembly
REP 15.3.4 Decurler Door Assembly

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
Remove the Decurler Door Assembly (Figure 1).
3.
Remove the Stapler Cover Assembly (Figure 1).
1.
1.
Open the Stapler Door Assembly.
2.
Remove the C-clip securing the bottom hinge.
2.
Remove the three screws securing the Cover Assembly.
3.
Lift and remove the Decurler Door Assembly.
3.
Lift and pull to remove the Stapler Cover Assembly.
Replacement
1.
Open the Decurler Door Assembly.
Replacement
1.
Reinstall the Decurler Door Assembly in the reverse order of removal.
Reinstall the Stapler Cover Assembly in the reverse order of removal.
Figure 1 Remove the Decurler Door Assembly

Figure 1 Remove the Stapler Cover Assembly
Finisher/Sorter
REP 15.3.3, REP 15.3.4
1/05
8d-112
Reissue
DocuColor 12/DCCS50
REP 15.3.5 Mailbox Door Assembly
REP 15.3.6 Left Lower Cover

Removal
Parts List on 18.2

Removal
WARNING
WARNING
1.
1.
2.
Remove the Mailbox Door Assembly (Figure 1).
2.
Roll the Finisher away from the printer until the Finisher stops.
1.
3.
Remove the Left Lower Cover (Figure 1).
Open the Mailbox Door Assembly.
2.
Remove the C-clip securing the top hinge.
1.
Remove the two screws securing the Left Lower Cover.
3.
Lift and remove the Mailbox Door Assembly.
2.
Remove the Left Lower Cover.
Replacement
Replacement
1.
1.
Reinstall the Mailbox Door Assembly in the reverse order of removal.
Figure 1 Remove the Mailbox Door Assembly
Reissue
DocuColor 12/DCCS50
Replace the Left Lower Cover in the reverse order of removal.
Figure 1 Remove the Left Lower Cover
1/05
8d-113
Finisher/Sorter
REP 15.3.5, REP 15.3.6
REP 15.3.7 Rear Upper Cover
REP 15.3.8 IOT Connector Cover

Removal

Removal
WARNING
WARNING
1.
1.
2.
Remove the Rear Upper Cover (Figure 1).
2.
Remove the IOT Connector Cover (Figure 1).
1.
Remove the three screws securing the Rear Upper Cover.
1.
Remove the rear left Caster Cap.
2.
Pull out while lifting, to remove the Rear Upper Cover.
2.
Remove the one screw securing the cover.
3.
Disengage the wire harness and the IOT Connector support link from the cover to
remove the IOT Connector Cover.
Replacement
1.
Ensure that the tabs of the Rear Upper Cover are snapped onto the ledge of the Rear
Lower Cover before installing the three screws.
Replacement
1.
Replace the IOT Connector Cover in the reverse order of removal.
Figure 1 Remove the Rear Upper Cover

Figure 1 Remove the IOT Connector Cover
Finisher/Sorter
REP 15.3.7, REP 15.3.8
1/05
8d-114
Reissue
DocuColor 12/DCCS50
REP 15.3.9 Finisher PWB Cover
REP 15.3.10 Left Upper Cover

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
Remove the Left Upper Cover (Figure 1).
3.
Remove the Left Lower Cover (REP 15.3.6).
1.
Remove the two screws securing the cover.
4.
Remove the Finisher PWB Cover (Figure 1).
2.
Remove the Left Upper Cover.
1.
Remove the 12 screws securing the Finisher PWB Cover.
Replacement
2.
Remove the Finisher PWB Cover.
1.
Replace the Left Upper Cover in the reverse order of removal.
Replacement
1.
Replace the Finisher PWB Cover in the reverse order of removal.
Figure 1 Remove the Left Upper Cover

Figure 1 Remove the Finisher PWB Cover
Reissue
DocuColor 12/DCCS50
1/05
8d-115
Finisher/Sorter
REP 15.3.9, REP 15.3.10
REP 15.3.11 Top Cover
REP 15.3.12 Decurler Top Cover

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
Remove the Top Cover (Figure 1).
3.
Remove the Decurler Top Cover (Figure 1).
1.
Open the Mailbox Door.
1.
2.
Loosen the one screw at the front of the cover.
2.
Remove the one screw on the rear side of the cover.
3.
Loosen the screw at the rear and the screw at the top inside.
3.
Remove the Decurler Top Cover.
4.
Lift to remove the Top Cover.
Replacement
1.
Remove the two screws on the left side of the cover.
Replacement
1.
Replace the Decurler Top Cover in the reverse order of removal.
Replace the Top Cover in the reverse order of removal.
Figure 1 Remove the Decurler Top Cover

Figure 1 Remove the Top Cover
Finisher/Sorter
REP 15.3.11, REP 15.3.12
1/05
8d-116
Reissue
DocuColor 12/DCCS50
REP 15.3.13 Decurler Rear Cover
REP 15.3.14 Decurler Inner Cover

Removal

Removal
WARNING
WARNING
1.
1.
2.
Move the Finisher away from the printer until the Finisher stops.
2.
3.
3.
Remove the Decurler Inner Cover (Figure 1).
4.
Remove the Decurler Rear Cover (Figure 1).
1.
Open the Decurler Door.
1.
Remove the three screws securing the Decurler Rear Cover.
2.
Remove the 6 Knob.
2.
Disengage the wire harness from the cover at the bottom, as you remove the
Decurler Rear Cover.
3.
Remove the two screws securing the Decurler Inner Cover.
4.
Disconnect the connector to the Decurler Door Interlock Switch as you remove the
Decurler Inner Cover.
Replacement
1.
Reinstall the Decurler Rear Cover in the reverse order of removal.
Replacement
1.
Reinstall the Decurler Inner Cover in the reverse order of removal.
Figure 1 Remove the Decurler Rear Cover

Figure 1 Remove the Decurler Inner Cover
Reissue
DocuColor 12/DCCS50
1/05
8d-117
Finisher/Sorter
REP 15.3.13, REP 15.3.14
REP 15.3.15 Rear Lower Cover
REP 15.3.16 Stapler Assembly

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
Remove the Rear Lower Cover (Figure 1).
3.
Reach in from the side and pull the Stapler Assembly to the front of the Finisher, if
required.
1.
Remove the three screws securing the Rear Lower Cover.
2.
Snap off the Rear Panel securing the wire harness to the cover.
3.
Lift up and remove the Rear Lower Cover.
4.
Replacement
1.
Place the cover back into position and secure it with the three screws.
2.
Align the wire harness into the cutout of the Rear Panel and snap the Rear Panel into
place.
Remove the Stapler Assembly (Figure 1).

1.
Disconnect P/J1092 from the Stapler Assembly.
2.
Release the harness clip from the side of the Stapler Assembly.
3.
Observe the orientation of the scribe lines so that the Stapler Assembly can be repositioned correctly during the replacement.
4.
Remove the two screws securing the Stapler Assembly to the Slider Bracket, and
remove the Stapler Assembly.
5.
Release the wire harness from the harness clip near the rear of the Stapler Assembly.
6.
Remove the screw to remove the green ground wire.
Figure 1 Remove the Rear Lower Cover
Figure 1 Remove the Stapler Assembly
Finisher/Sorter
REP 15.3.15, REP 15.3.16
1/05
8d-118
Reissue
DocuColor 12/DCCS50
Replacement
REP 15.3.17 Stapler Position Sensors
1.
Position the Stapler Assembly near the Slider Bracket.
2.
Route the wire harness through the harness clip near the rear of the Stapler Assembly.

Removal
3.
Install the screw to secure the green ground wire to the Stapler Assembly.
4.
Reinstall the Stapler Assembly onto the Slider Bracket, making sure to slide the rear tab
of the Stapler Assembly into the cutout on the Slider Bracket.
5.
Position the Stapler assembly to align with the scribe lines as observed during the
removal, and then use two screws to secure the Stapler Assembly to the Rail.
WARNING
1.
Disconnect the Finisher from the Printer (REP 15.3.1).
6.
Reinstall the harness clip to the side of the Stapler Assembly.
2.
7.
Reconnect P/J 1092 to the Stapler Assembly.
3.
Remove the Stapler Cover (REP 15.3.3).
8.
Reinstall the Stapler Cover Assembly (REP 15.3.3).
4.
Remove the Rear Lower Cover REP 15.3.15.
9.
Check the Staple Position Adjustment (ADJ 15.3.1).
5.
Remove the Stapler Assembly (REP 15.3.16).
6.
7.
At the rear of the Finisher, prepare to remove the Stapler Position Sensors by rotating the
Stapler Position Motor Drive Belt as you slip the Belt off of the Drive Pulley.
8.
Remove the Stapler Position Sensors (Figure 1).
Reissue
DocuColor 12/DCCS50
1/05
8d-119
1.
Disconnect the three connectors from the Stapler Sensors, and free the wire harnesses from the harness clip that is located on the Stapler Rail.
2.
Remove two screws at the rear of the Finisher and two screws at the front of the Finisher that secure the Stapler Rail to the Finisher frame, and remove the Rail.
3.
Place the Stapler Rail on a flat work surface.
4.
Remove the screw that secures the sensor bracket of the sensor you are changing.
Remove the Bracket along with the attached sensor.
5.
Press in and release the Sensor latch that is securing the Sensor to the Bracket, and
remove the Sensor.
Finisher/Sorter
REP 15.3.16, REP 15.3.17
2.
Reinstall the Sensor Bracket onto the Stapler Rail, and use one screw to secure the
Bracket to the Rail.
3.
Reinstall the Stapler Rail into the Finisher frame. Use four screws to secure the Rail to
the frame.
4.
Reconnect the three connectors to the three sensors.
5.
Route the wire harness through the harness clips that are located on the Stapler Rail.
6.
Rotate the Stapler Transport Motor Drive Belt as you slip the Belt onto the Drive Pulley.
7.
Reinstall the Stapler Assembly.
8.
9.
Reinstall the Stapler Cover.
10. Reconnect the Finisher to the Printer
Figure 1 Remove the Stapler Position Sensors
Replacement
1.
Position the Sensor into the Sensor cutout in the Sensor Bracket.
Finisher/Sorter
REP 15.3.17
1/05
8d-120
Reissue
DocuColor 12/DCCS50
REP 15.3.18 Stapler Rail Belt

Removal
WARNING
1.
2.
Disconnect the Finisher from the Printer (REP 15.3.1).
3.
Remove the Stapler Cover (REP 15.3.3).
4.
Remove the Rear Lower Cover REP 15.3.15.
5.
Remove the Stapler Assembly (REP 15.3.16).
6.
7.
At the rear of the Finisher, prepare to remove the Stapler Position Sensors by rotating the
Stapler Position Motor Drive Belt as you slip the Belt off of the Drive Pulley.
8.
Remove the Stapler Rail (Figure 1).

1. Disconnect the three connectors from the Stapler Sensors, and free the wire harnesses from the harness clip that is located on the Stapler Rail.
2. Remove two screws at the rear of the Finisher and two screws at the front of the
Finisher that secure the Stapler Rail to the Finisher frame, and remove the Rail.
3.
Place the Stapler Rail on a flat work surface.
Figure 1 Remove the Stapler Rail

9.
Remove the Stapler Rail Belt (Figure 2).

1.
Reissue
DocuColor 12/DCCS50
1/05
8d-121
Remove the two screws securing the Tension Cover to the Rail, and remove the
Cover.
Finisher/Sorter
REP 15.3.18
2.
Remove the ten screws securing the Upper Rail to the Lower Rail, and remove the
Upper Rail.
3.
Reinstall the Belt Clamp onto the Slider Bracket, and use one screw to secure the Clamp.
Ensure that the tension idler engages the belt.
3.
Remove the screw securing the Belt Clamp to the Slider Bracket.
4.
4.
Disengage the Belt from the Lower Rail.
Push out on the Tension Bracket so that the springs are stretched, and reinstall the Upper
Rail onto the Lower Rail.
5.
Remove the Belt from the Belt Clamp.
5.
Reach under the Lower Rail and position the Belt so the back (non-ribbed side) of the Belt
rides against the Tension Roll.
6.
Release the Tension Bracket.
7.
Use the remaining screws to secure the Upper Rail to the Lower Rail. Ensure that the belt
moves freely without binding.
8.
Reinstall the Tension Cover over the Tension Bracket, and use two screws to secure the
Cover to the Upper Rail.
9.
Rotate the Drive Pulley to make sure that the Belt tracks correctly and that the Slider
Bracket moves smoothly along the Rail.
10. Reinstall the Stapler Rail into the Finisher frame. Use four screws to secure the Rail to
the frame.
11. Reconnect the P/J connectors to the sensors.
12. Route the wire harness through the harness clips that are located on the Stapler Rail.
13. Rotate the Stapler Transport Motor Drive Belt as you slip the Belt onto the Drive Pulley.
14. Reinstall the Stapler Assembly.
16. Reinstall the Stapler Cover.
Figure 2 Remove the Stapler Rail Belt
Replacement
1.
Ensure that the belt is positioned as shown in the illustration and reinstall the Belt Clamp
onto the Belt.
2.
Reinstall the Belt on the Lower Rail.
Finisher/Sorter
REP 15.3.18
1/05
8d-122
Reissue
DocuColor 12/DCCS50
REP 15.3.19 Stapler Position Motor
REP 15.3.20 Mailbox Drive Motor

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
3.
3.
4.
Remove the Stapler Position Motor (Figure 1).
1.
Disconnect the P/J1021 from the connector on the motor PWB.
1.
2.
Remove the two screws at the bottom of the motor bracket.
3.
While holding the motor bracket, remove the top screw from the bracket and remove
2.
Open the harness clamp securing the wire harness and disconnect the motor connector P/J1089.
Remove the two screws securing the motor to the motor bracket.
Remove the Mailbox Drive Motor (Figure 1).
3.
Disengage and remove the belt.
Replacement
4.
Remove the Stapler Position Motor.
1.
Engage the teeth of the motor gear onto the Mailbox Drive Belt and ensure that the motor
shaft is installed into the hole in the frame.
Replacement
1.
Install the Stapler Position Motor onto the motor bracket.
2.
Secure the motor bracket with the three screws.
2.
Place the drive belt onto the gear.
3.
Rotate the motor in order to ensure that the drives are engaged correctly.
3.
Bring the motor into position and engage the belt and the motor drive gear.
4.
Reconnect P/J1021.
4.
Secure the motor with the screws.
Figure 1 Remove the Mailbox Drive Motor

Figure 1 Remove the Stapler Position Motor
Reissue
DocuColor 12/DCCS50
1/05
8d-123
Finisher/Sorter
REP 15.3.19, REP 15.3.20
REP 15.3.21 Mailbox Drive Belt

Removal
WARNING
1.
2.
3.
Remove the SCT Exit Cover (PL 18.3).
4.
Remove the Mailbox Drive Motor (REP 15.3.20).
5.
Remove the Mailbox Drive Belt (Figure 1).

1.
Remove the two screws securing the Belt Idler Bracket.
2.
Remove the Mailbox Drive Belt.
Figure 2 Install the Mailbox Drive Belt

2.
Reinstall the Belt Idler Bracket and secure with the two screws.
3.
Reinstall the Mailbox Drive Motor (REP 15.3.20).
4.
Reinstall the SCT Exit Cover (PL 18.3).
5.
Reinstall the Rear Upper Cover (REP 15.3.7).
Figure 1 Remove the Mailbox Drive Belt
Replacement
1.
Route the Mailbox Drive Belt onto the gears per the illustration (Figure 2).
Finisher/Sorter
REP 15.3.21
1/05
8d-124
Reissue
DocuColor 12/DCCS50
REP 15.3.23 Docking Interlock Switch
REP 15.3.25 Decurler Door Interlock Switch

Removal

Removal
WARNING
WARNING
1.
1.
2.
Move the Finisher away from the printer until the Finisher stops.
2.
3.
3.
4.
4.
Remove the Decurler Door Interlock Switch (Figure 1).
5.
Remove the appropriate Docking Interlock Switch (Figure 1).
1.
Disconnect the connector, then push in the tabs to remove the Decurler Door Interlock Switch from the Decurler Inner Cover.
1.
Disconnect the Docking Switch Connector, P/J664 or P/J665.
2.
Remove the four screws securing the Entrance Lower Chute.
Replacement
3.
Disengage the switch harness from the harness clamps.
1.
4.
Remove the two screws to remove the appropriate Docking Interlock Switch.
Reinstall the Decurler Door Interlock Switch in the reverse order of removal.
Replacement
1.
Reinstall the Docking Interlock Switch in the reverse order of removal.
Figure 1 Remove the Decurler Door Interlock Switch
Figure 1 Remove the Docking Interlock Switches
Reissue
DocuColor 12/DCCS50
1/05
8d-125
Finisher/Sorter
REP 15.3.23, REP 15.3.25
REP 15.3.28 Finisher PWB
REP 15.3.29 Finisher PWB EPROM

Removal

Removal
WARNING
WARNING
1.
1.
2.
2.
Observe the ESD procedures.
3.
Remove the Left Lower Cover (REP 15.3.6).
3.
Remove the Finisher PWB (REP 15.3.28).
4.
Remove the EPROM.
NOTE: Observe the ESD procedures while removing the Finisher PWB.
4.
Replacement
Remove the Finisher PWB (Figure 1).
1.
1.
Remove the Finisher PWB Cover.
2.
Disconnect the 18 connectors from the Finisher PWB. Remove the harness from the
harness holder and move the harness lines away.
3.
Remove eight screws securing the Finisher PWB.
4.
Grasp the PWB at the bottom and move the bottom away first to remove the Finisher
PWB.
Reinstall the EPROM in the reverse order of removal.
Replacement
1.
Reinstall the Finisher PWB in the reverse order of removal.
Figure 1 Remove the Finisher PWB
Finisher/Sorter
REP 15.3.28, REP 15.3.29
1/05
8d-126
Reissue
DocuColor 12/DCCS50
REP 15.3.30 Vertical LED and Sensor
1. Remove the four screws securing the chute to the frame at the front and at the
rear.

Removal
2. Rotate the chute to the right side to access the screw securing the sensor.
WARNING
4. Remove the Vertical Sensor.
1.

a.
Rear Upper Cover (REP 15.3.7).
b.
SCT Exit Cover (PL 18.3).
c.
Top Cover (REP 15.3.11).
2.
Remove the Mailbox Door (REP 15.3.5).
3.
Remove the Vertical LED (Figure 1).

3. Remove the LED Sensor screw.
Figure 2 Remove the Vertical Sensor
Replacement
1.
Reinstall the Vertical LED and Sensor in the reverse order of disassembly.
Figure 1 Remove the Vertical LED

4.
Remove the Vertical Sensor (Figure 2).
Reissue
DocuColor 12/DCCS50
1/05
8d-127
Finisher/Sorter
REP 15.3.30

Removal
WARNING
1.
2.

a.
Rear Upper Cover (REP 15.3.7)
b.
Top Cover (REP 15.3.11)
c.
Left Upper Cover (REP 15.3.10)

2. Remove the Mailbox Drive Belt from the pulley.
Figure 2 Remove the Bin Tray Cover

4.
Remove the Panel Assembly (Numbered Panel) (PL 18.2 item 25).
5.

2. Lift up on Bin Tray 1 to snap the pawl free from the gate, then remove Bin Tray 1.

3.
Remove the Bin Tray Cover (Figure 2).

1. Remove the screw from the Vertical LED.
3. Remove the screws (3) from the Bin Tray Cover.
4. Remove the Bin Tray Cover.
Finisher/Sorter
REP 15.3.31
1/05
8d-128
Reissue
DocuColor 12/DCCS50
REP 15.3.32 Bin Trays 2 - 10

Removal
WARNING
NOTE: This page describes how to disassemble Bin Tray 2.
NOTE: To remove any Bin Tray (n), first remove Bin Trays 1 to (n-1).
1.
Remove the Bin Tray 1 (REP 15.3.31).
2.
Remove the Panel Assembly (Numbered Panel) (PL 18.2 item 25).
3.

1. Disconnect the connector (if required).
3. Lift up on Bin Tray 2 to snap the pawl free from the gate, then remove Bin Tray 2.
Replacement
1.
Reinstall the Bin Tray 1 in the reverse order of removal.
Figure 1 Remove the Bin Tray 2
Installation
1.
Reissue
DocuColor 12/DCCS50
1/05
8d-129
Reinstall the Bin Trays 2 - 10 in the reverse order of removal.
Finisher/Sorter
REP 15.3.31, REP 15.3.32
Finisher/Sorter
REP 15.3.31, REP 15.3.32
1/05
8d-130
Reissue
DocuColor 12/DCCS50
ADJ 15.3.1 Staple Position Adjustment
2.
Using the scribe lines as a reference, move the Stapler Assembly to achieve the
desired dimension. Dimension A changes in increments of approximately 4 mm. To
increase the dimension A, move the stapler in the direction of the (+) sign. To
decrease the dimension A, move the stapler in the direction of the (-) sign (Figure 2).
3.
Tighten the two screws.
Purpose
The purpose is to ensure that the staples are in the correct position.
Check
4.
1.
Run a copy set into the Finisher in the staple mode.
2.
Check the staple position (Figure 1).
Perform the check again.
Figure 2 Adjust the Staple position (Dimension A)

Figure 1 Check the Staple Position
3.
To change dimension A, perform Dimension A adjustment.
4.
To change dimension B, perform Dimension B adjustment.
Adjustment
Dimension B adjustment
WARNING
Adjustment
Dimension A adjustment
WARNING
1.
2.
3.
Adjust the position of the Compiler Tray (Figure 3).
1.
1.
Loosen the screw.
2.
Adjust the position of the Stapler Assembly (Figure 2).
2.
Using the scribe lines as a reference, move the Compiler Tray to achieve the desired
dimension. Dimension B changes in increments of approximately 6 mm. To increase
the dimension B, move the tray in the direction of the (+) sign. To decrease the
dimension B, move the tray in the direction of the (-) sign (Figure 3).
3.
Tighten the screw.
1.
Loosen the two screws.
Reissue
DocuColor 12/DCCS50
1/05
8d-131
Finisher/Sorter
ADJ 15.3.1
ADJ 15.3.2 Stacker Tray Level

Purpose
The purpose of this adjustment is to ensure the Stacker Tray Carriage is level with the frame of
the Stacker Tray Assembly.
Check
1.
Lower the Stacker Tray to the bottom of the Stacker Tray Assembly by supporting the
Stacker Tray with one hand then pull to separate the Dog Clutch Gear from the Dog
Clutch Pulley.
2.
Check that the Stacker Tray Carriage is touching the Stacker Tray Assembly Tie Plate on
the front and rear of the Assembly (Figure 1).
3.
If both ends of the Stacker Tray Carriage are touching the Tie Plate, the check is good.
Figure 3 Adjust the Staple position (Dimension B)

4.
Perform the check again.
Figure 1 Checking the Stacker Tray Carriage
Adjustment
NOTE: If entering this procedure from REP 15.2.9 Stacker Tray Drive Belts or REP 15.2.10
Stacker Tray, proceed to Step 4.
Finisher/Sorter
ADJ 15.3.1, ADJ 15.3.2
1.
2.
3.
Support the Stacker Tray with one hand and pull the Dog Clutch Gear away from the Dog
Clutch Pulley and lower the Tray to the bottom of the Stacker Tray Assembly (PL 18.22).
4.
Remove the screws (2) from the front Stacker Tray Drive Belt Clamp and remove the
Clamp (Figure 2).
1/05
8d-132
Reissue
DocuColor 12/DCCS50
5.
Adjust the Tray level by pulling the Belt Clamp off the front Drive Belt and reinstalling the
Clamp up or down the Belt to move the front end of the Stacker Tray Carriage up or down
in order to be level with the rear end of the Stacker Tray Carriage.
6.
Install the Drive Belt and Belt Clamp into the Tray bracket.
7.
Check the adjustment and repeat step 5 and step 6 if necessary.
8.
Install the screws (2) to secure the front Belt Clamp to the front Drive Belt.
9.
Return to REP 15.2.9 or REP 15.2.10 or reinstall the Stacker Tray Assembly (REP
15.2.2).

11. Install the Stapler Cover Assembly.
Figure 2 Leveling the Stacker Tray
Reissue
DocuColor 12/DCCS50
1/05
8d-133
Finisher/Sorter
ADJ 15.3.2
Finisher/Sorter
ADJ 15.3.2
1/05
8d-134
Reissue
DocuColor 12/DCCS50
PL 18.1 Finisher Accessory

Item
Part
Description
2
3
4
5
6
7
8
9
10
11
12
13
015K35862
003K91881
830E19412
029E21610
015K31860
015K31871
032E10210
14
15
16
17
Finisher Assembly (Not Spared)

(REP 15.3.1)
Docking Rail
Knob Screw
Docking Plate
Docking Pin
Vcci Bracket (Not Spared)
Thumb Screw (Not Spared)
Rail Bracket
Plate (Tray Module Left)
Guide (Tray Module Right)
Bracket (Mailbox Left) (P/O PL 18.1
Item 2)
Bracket (Mailbox Right) (P/O PL
18.1 Item 2)
Docking Rail (P/O PL 18.1 Item 2)
Rail Assembly (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
8d-135
Finisher/Sorter
PL 18.1
PL 18.2 Covers - Left, Front

Item
Part
Description
3
4
802E13930
048K77410
5
6
7
8
9
10
121E90490
802K14650
11
12
13
830E59990
048E65721
14
15
16
17
121E84720
802K14660
18
19
20
21
22
23
24
25
26
892E13300
891E73451
048E66520
048K77971
802K05082
048E66560
Finisher (REF: PL 18.4) (Not

Spared)
Finisher PWB Cover (Not Spared)
(REP 15.3.9)
Left Lower Cover (REP 15.3.6)
Decurler Door Assembly (REP
15.3.4)
Decurler Door (P/O PL 18.2 Item 4)
Magnet Plate (P/O PL 18.2 Item 4)
Hinge (P/O PL 18.2 Item 4)
Magnet Catch
Stapler Door Assembly (REP
15.3.2)
Stapler Cover (P/O PL 18.2 Item
10)
Magnet Plate
Stapler Cover Assembly (REP
15.3.3)
Stapler Cover (P/O PL 18.2 Item
13)
Magnet Catch
Mailbox Door Assembly (REP
15.3.5)
Mailbox Door (P/O PL 18.2 Item
17)
Wrench (P/O PL 18.2 Item 17)
Label
Label
Left Upper Cover (REP 15.3.10)
Top Cover (REP 15.3.11)
Panel Assembly
Panel
Finisher/Sorter
PL 18.2
1/05
8d-136
Reissue
DocuColor 12/DCCS50
PL 18.3 Covers - Right, Rear

Item
Part
Description
048E65740
3
4
5
6
7
802E13940
802E13950
802E13960
050K41310
9
10
11
12
13
14
130K60600
162K60401
830E34990
830E35000
15
16
17
18
048E66571
802E13990
802E14000
802E14010
Finisher (REF: PL 18.4) (Not

Spared)
Decurler Rear Cover (REP
15.3.13)
IOT Connector Cover (REP 15.3.8)
Rear Panel (Not Spared)
Rear Upper Cover (REP 15.3.7)
Rear Lower Cover (REP 15.3.15)
Single Catch Tray Assembly (REP
15.1.17)
Single Catch Tray (P/O PL 18.3
Item 7)
SCT Full Sensor
Wire Harness (Finisher PWB-IOT)
Support Link (Left)
Support Link (Right)
11)
Mailbox Rear Lower Cover
SCT Exit Front Cover
SCT Exit Cover
SCT Exit Rear Cover
Reissue
DocuColor 12/DCCS50
1/05
8d-137
Finisher/Sorter
PL 18.3
PL 18.4 Finisher Components

Item
Part
Description
1
2
3
4
160K67951
5
6
7
8
9
10
11
12
13
14
417W30349
021E96430
050K41320
121E87250
Stapler (Not Spared)

PWB Chassis (Not Spared)
Finisher PWB (REP 15.3.28)
Decurler (Not Spared) (REP
15.1.1)
Cabinet (Not Spared)
Nut (Not Spared) (4 Places)
Caster (4 Places)
Caster Cap (4 Places)
Stacker
Mailbox (Not Spared)
Front Bracket (Not Spared)
Rear Bracket (Not Spared)
Magnet Bracket (Not Spared)
Magnet Catch
Finisher/Sorter
PL 18.4
1/05
8d-138
Reissue
DocuColor 12/DCCS50
PL 18.5 Decurler Cover

Item
Part
Description
1
2
3
4
5
6
003K85570
003K83211
003E46501
003K85101
048K77420
110E97990
9
10
11
12
048E65730
809E02991
Knob Assembly
Knob
Handle
Hinge
Decurler Inner Cover (REP
15.3.14)
Decurler Inner Cover (P/O PL 18.5
Item 6)
Decurler Door Interlock Switch
(REP 15.3.25)
Decurler Top Cover (REP 15.3.12)
Spring
Label (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
8d-139
Finisher/Sorter
PL 18.5
PL 18.6 Decurler Chute, PWB

Item
Part
Description
5
6
7
054E14510
054K13920
059K08590
9
10
11
12
13
14
003E36290
105E09160
121E91450
160K67991
Entrance Lower Chute (Not

Spared)
Entrance Lower Chute (P/O PL
18.6 Item 1)
Wire Harness (Decurler PWB-Finisher PWB) (P/O PL 18.6 Item 1)
Docking Interlock Switch 1, Switch
2 (P/O PL 18.6 Item 1) (REP
15.3.23)
Chute
Exit Lower Baffle Assembly
Exit Lower Baffle (P/O PL 18.6
Item 6)
Pinch Roll (5 Places) (REP 15.1.6
REP 15.1.5)
Knob
Label (5) (P/O PL 18.6 Item 6)
Upper Chute (Not Spared)
Static Eliminator
Magnet Catch
Decurler PWB (REP 15.1.7)
Finisher/Sorter
PL 18.6
1/05
8d-140
Reissue
DocuColor 12/DCCS50
PL 18.7 Decurler Roll

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
006E61320
007E54990
007E55010
007E45131
007E55030
007E55040
015K28141
007E45091
008E93390
011K94401
011K94411
022K57120
15
022K57130
16
17
18
19
20
21
22
062E98711
121K83981
130E82530
809E14570
413W08350
413W75959
Cam Drive Shaft (REP 15.1.8)

Gear (32)
Gear (28/33)
Gear (32)
Gear (52/56)
Gear (20)
Idler Gear Assembly
Gear (32)
Screw (Not Spared)
Cam (REP 15.1.3)
Front Lever
Rear Lever
Decurler Roll 1 (Upper) (REP
15.1.2)
Decurler Roll 2 (Lower) (REP
15.1.2)
Reflector (REP 15.1.3)
Decurler Cam Clutch
Sensor Bracket (Not Spared)
Decurler Cam Position Sensor
Spring
Bearing
Bearing
Reissue
DocuColor 12/DCCS50
1/05
8d-141
Finisher/Sorter
PL 18.7
PL 18.8 Decurler Transport Roll

Item
Part
Description
1
2
007E54960
3
4
5
6
7
8
9
10
11
007E54980
007E54990
007E55000
007E45091
407W08220
007E54970
022E19660
022E19670
022K61500
12
13
14
022K51621
127K24901
15
16
17
18
413W08350
413W75959
19
20
003E48920
604K13030
Gear (38)
Torque Limiter Gear (Not Spared)
(REP 15.1.9)
Gear (16)
Gear (32)
Gear (16)
Gear (32)
Gear (20)
Gear (34)
Decurler Drive Roll 2 (REP 15.1.10)
Decurler Drive Roll 1 (REP 15.1.11)
Decurler Entrance Roll (REP
15.1.12)
Decurler Exit Roll (REP 15.1.13)
Motor Shaft (Not Spared)
Decurler Stepper Motor (REP
15.1.4)
Bearing
Bearing
Wheel (Not Spared)
Stopper (One-Way Clutch) (Not
Spared)
Stopper
Finisher/Sorter Mailbox Gear
Repair Kit
Finisher/Sorter
PL 18.8
1/05
8d-142
Reissue
DocuColor 12/DCCS50
PL 18.9 Mailbox - Stapler Entrance

Roll
Item
Part
Description
1
2
3
4
5
6
7
8
005E15360
007E62850
007E62860
009E72520
020E25141
020E33850
022K61450
022K61460
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
007E62870
015K44950
020K09460
020K98320
423W87254
007E62880
015K44960
007E62890
413W75959
499W14524
127K24952
27
28
29
30
31
007E62830
423W30754
Collar (Not Spared)

Friction Clutch
Decurler Gear
Idler Pulley
Spring
Idler Pulley
Pulley (21)
Finisher Transport Roll 1 (REP
15.1.21)
Finisher Transport Roll 2 (REP
15.1.21)
Motor Bracket (Not Spared)
Gear Pulley
Collar (Not Spared)
Transmission Gear Assembly
One Way Pulley (23)
One Way Pulley (26)
Finisher Drive Belt
Decurler Gear
Tension Pulley
Stopper Collar (Not Spared)
Decurler Gear
Bearing
Idler Pulley
Finisher Transport Motor (REP
15.1.15)
Collar (Not Spared)
Gear Pulley
Compiler Drive Belt
Plate (Not Spared)
Screw (Not Spared)
Reissue
DocuColor 12/DCCS50
1/05
8d-143
Finisher/Sorter
PL 18.9
PL 18.10 Mailbox Entrance Roll, Sct

Exit Roll
Item
Part
Description
1
2
3
4
5
005E15350
020E33840
022K61470
023E13160
6
7
8
9
10
11
12
13
015K48190
809E14980
022E83460
022K61490
127K37840
14
15
16
17
18
19
20
21
22
23
24
7E56970
413W75959
499W17061
499W14123
162K47500
Collar (Not Spared)

Friction Clutch
Pulley (23)
Mailbox Entrance Roll
Mailbox Drive Belt (Not Spared)
(REP 15.3.21)
Belt Tension Bracket
Tension Pulley (Not Spared)
Screw (Not Spared)
Spring
Idler Pulley
Stopper Collar (Not Spared)
SCT Exit Roll (REP 15.1.20)
Mailbox Drive Motor Assembly
(REP 15.3.20)
13)
Mailbox Drive Motor (P/O PL 18.10
Item 13)
Belt (P/O PL 18.10 Item 13)
Bearing
Idler Pulley
Pulley
Wire Harness (Motor Mailbox PWB)
Finisher/Sorter
PL 18.10
1/05
8d-144
Reissue
DocuColor 12/DCCS50
PL 18.11 Mailbox - Gate, PWB,

Interlock Switch
Item
Part
Description
1
2
3
4
5
012E09860
012E09870
110E97990
6
7
8
9
10
11
12
13
14
121E87250
050E16500
050E16510
160K67960
121K14541
Hinge (Not Spared)

Link (Finisher Gate)
Link (SCT Gate)
Switch Bracket (Not Spared)
Stapler Door Interlock Switch, Mailbox Door Interlock Switch
Magnet Catch (3 Places)
Mailbox Gate
E-Ring (Not Spared)
Finisher Gate
Mailbox PWB
Mailbox Solenoid, Finisher Gate
Solenoid
Reissue
DocuColor 12/DCCS50
1/05
8d-145
Finisher/Sorter
PL 18.11
PL 18.12 Mailbox - Stapler Entrance

Chute
Item
Part
Description
1
2
3
032E15690
054K16800
4
5
6
7
003E36290
059K00521
8
9
10
11
054K16810
054K16790
054K16820
12
13
891E73431
14
Chute Guide
Entrance Upper Baffle
Entrance Upper Baffle (P/O PL
18.12 Item 2)
Knob
Pinch Roll (8 Places)
Label 7 (P/O PL 18.12 Item 2)
Entrance Lower Chute (Not
Spared)
Finisher Entrance Baffle Assembly
Finisher Entrance Baffle 1
Finisher Entrance Baffle 2
Finisher Entrance Baffle 1 (P/O PL
18.12 Item 8)
Label 8 (P/O PL 18.12 Item 9)
Finisher Entrance Baffle 2 (P/O PL
18.12 Item 10)
Finisher/Sorter
PL 18.12
1/05
8d-146
Reissue
DocuColor 12/DCCS50
PL 18.13 Mailbox Chute

Item
Part
Description
2
3
162K60451
4
5
6
7
8
9
10
11
054K16780
022K43720
022K48240
127K31260
059K08590
12
13
14
15
130E80100
130K94740
105E98690
160K53431
16
17
SCT Exit Lower Chute (Not

Spared)
Bin Tray Lower Chute (Not Spared)
Wire Harness (Sensor-Mailbox
PWB)
Mailbox Transport Baffle Assembly
Knob (P/O PL 18.13 Item 4)
10-SCT Exit Upper Chute
Lower Baffle Pinch Rolls (4 Places)
(REP 15.1.20)
SCT Exit Sensor (REP 15.1.19)
Mailbox Entrance Sensor
Static Eliminator (REP 15.1.18)
Mailbox Vertical Sensor (REP
15.3.30)
Mailbox Transport Baffle (P/O PL
18.13 Item 4)
Reissue
DocuColor 12/DCCS50
1/05
8d-147
Finisher/Sorter
PL 18.13
PL 18.14 Stapler - Exit Chute

Item
Part
Description
1
2
3
4
5
6
006K83590
006K83620
007E45120
054K09360
7
8
9
054K09462
10
11
12
13
14
423W23354
054K16770
15
16
17
18
19
20
21
22
23
24
105K18810
407W08174
423W24953
020E33860
499W15121
130K94740
25
Collar (Not Spared)

Exit Roll (REP 15.2.25)
Reverse Paddle Drive Shaft
Gear Pulley
Screw (Not Spared)
Lower Exit Chute Assembly (REP
15.2.26)
Lower Exit Chute
Compiler Paddle (P/O PL 18.14
Item 6) (REP 15.2.26)
Paddle Drive Shaft (P/O PL 18.14
Item 6)
Compiler Paddle Belt
Upper Exit Chute Assembly (REP
15.2.24)
Upper Exit Chute (P/O PL 18.14
Item 14)
Plate Spring (P/O PL 18.14 Item
14)
Static Eliminator
Gear
Belt
Pulley
Pulley
Compiler Entrance Sensor (REP
15.2.30)
Tie Plate (Not Spared)
Finisher/Sorter
PL 18.14
1/05
8d-148
Reissue
DocuColor 12/DCCS50
PL 18.15 Stapler-Compiler
Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
009E72530
009E72550
012E94950
013E13600
038K83030
050K41330
12
13
14
054K09382
110K10710
15
110E94510
16
17
18
120E99661
110K08140
19
121K13070
20
127K23320
Spring
Spring
Link
Bearing
Support (Not Spared)
Harness Holder (Not Spared)
Registration Guide (Not Spared)
End Guide
Guide (Not Spared)
Eject Cover (Not Spared)
Compiler Tray Assembly (REF: PL
18.16)
Compiler Exit Cover (REP 15.2.22)
Switch Assembly
Switch Bracket (P/O PL 18.15 Item
13)
Compiler Cover Safety Switch (1
Place), Compiler Cover Interlock
Switch (2 Places)
Label (Not Spared)
Actuator
Unload While Run Switch (REP
15.2.29)
Compiler Tray Solenoid (REP
15.2.1)
End Wall Motor (REP 15.2.16)
Reissue
DocuColor 12/DCCS50
1/05
8d-149
Finisher/Sorter
PL 18.15
PL 18.16 Compiler Tray Components

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
038K83340
423W21053
015K28290
005E91640
009E72520
127K20871
004E08030
130E82530
19
130E82540
20
21
120E99480
Compiler Tray (Not Spared)

Tamper
Actuator (Not Spared)
Holder (Not Spared)
Belt Clip (Not Spared)
Tamper Drive Belt (REP 15.2.15)
Tension Pulley Assembly
Flange
Spring
Tamper Motor (REP 15.2.11)
Damper
Damper (Not Spared)
Tamper Home Sensor (REP
15.2.12)
Compiler Paper Sensor (REP
15.2.13), End Wall Open Sensor
(REP 15.2.16)
Actuator (Not Spared)
Finisher/Sorter
PL 18.16
1/05
8d-150
Reissue
DocuColor 12/DCCS50
PL 18.17 Stapler Accessory

Item
Part
Description
029K91881
3
4
050K41290
015K45020
5
6
7
127K18880
127K16600
9
10
423W46753
Stapler Assembly (REP

15.3.16,ADJ 15.3.1)
Stapler Housing (P/O PL 18.17
Item 1)
Staple Cartridge
Stapler Rail Assembly (REF: PL
18.18)
Harness Arm (Not Spared)
Stapler Position Motor Assembly
6)
Stapler Position Motor (REP
15.3.19)
Belt
Reissue
DocuColor 12/DCCS50
1/05
8d-151
Finisher/Sorter
PL 18.17
PL 18.18 Stapler Rail Component

Item
Part
Description
1
2
3
015K28452
5
6
7
8
9
10
11
005E91660
020E22210
020E22220
023E15560
12
13
14
130K55360
15
16
Stapler Rail
Slider (P/O PL 18.18 Item 1)
Upper Bracket (P/O PL 18.18 Item
1)
Lower Bracket (P/O PL 18.18 Item
1)
Flange
Pulley
Pulley
Belt Clamp (P/O PL 18.18 Item 1)
Stapler Rail Belt (REP 15.3.18)
Tension Pulley (P/O PL 18.18 Item
1)
Rear Spring (P/O PL 18.18 Item 1)
Front Spring (P/O PL 18.18 Item 1)
Stapler Position Sensor (Front Corner, Front Straight, Rear Straight) (3
Places) (REP 15.3.17)
Tension Cover (Not Spared)
Finisher/Sorter
PL 18.18
1/05
8d-152
Reissue
DocuColor 12/DCCS50
PL 18.19 Offset And Set Eject

Item
Part
Description
006K21000
006K83642
3
4
5
6
7
8
007E45170
011K93650
011K93870
013E85870
013P60796
015K89062
9
10
11
12
13
14
15
16
020E24820
059E92070
120E99651
127K20930
17
18
19
127K20900
127K29540
20
130E82540
21
22
23
24
25
130E82530
499W15123
423W25953
26
423W46753
Eject Clamp Pinch Roll And

Reverse Paddle (REF: PL 18.20)
Eject Paddle Eject Roll (REP
15.2.21)
Gear
Offset Lever
Eject Clamp Lever
Bearing
Bearing
Eject Clamp/Offset Cam (REF:PL
18.21)
Gear Pulley
Screw (Not Spared)
Cam Follower
Eject Paddle Actuator
Eject Motor Assembly
15)
Eject Motor (REP 15.2.32)
Eject Paddle Motor Assembly
Eject Paddle Motor (P/O PL 18.19
Item 18) (REP 15.2.20)
Eject Paddle Home Sensor (REP
15.2.31), Offset Home Sensor
(REP 15.2.18)
Eject Clamp Sensor (REP 15.2.17)
Pulley
Eject Paddle Drive Belt (REP
15.2.20)
Eject Motor Belt
Reissue
DocuColor 12/DCCS50
1/05
8d-153
Finisher/Sorter
PL 18.19
PL 18.20 Eject And Paddle

Components
Item
Part
Description
2
3
4
5
6
7
8
9
10
048K62471
022K61480
020E24800
033K92751
11
12
13
130K87332
130E82530
14
15
16
Pinch Roll Shaft (Not Spared)

(REP 15.2.23)
Pinch Roll Cover
Pinch Spring (Not Spared)
Shaft (Not Spared)
Eject Clamp Pinch Roll
Gear Pulley
Reverse Paddle Assembly
Paddle (P/O PL 18.20 Item 7)
Paddle Drive Belt (P/O PL 18.20
Item 7) (REP 15.2.27)
Stack Height Sensor Assembly
Stack Height Sensor (REP
15.2.28)
Lever (Not Spared)
Finisher/Sorter
PL 18.20
1/05
8d-154
Reissue
DocuColor 12/DCCS50
PL 18.21 Eject And Offset

Components
Item
Part
Description
2
3
4
5
6
7
008K91360
008K91370
007K83910
007E39910
407W07626
127K16360
8
9
10
11
12
012K93390
809E03071
809E03080
413W77559
Eject Bracket Assembly (Not

Spared) (REP 15.2.19)
Eject Clamp Cam
Offset Cam
One Way Gear
Gear
Gear
Eject Clamp/Offset Motor (REP
15.2.33)
Shaft (Not Spared)
Clamp Up Lever
Plate Spring
Spring
Bearing
Reissue
DocuColor 12/DCCS50
1/05
8d-155
Finisher/Sorter
PL 18.21
PL 18.22 Bin Tray 1

Item
Part
Description
1
2
3
160K53431
802K09190
4
5
6
7
8
9
10
038E88980
038E86180
038E21280
022K43710
120E13130
120E17020
050K36832
11
12
13
14
15
005E83570
013E89540
022E83451
16
17
18
830E32600
050E88781
413W77559
Vertical LED (REP 15.3.30)

Bin Tray 1 Cover Assembly
Bin Tray 1 Cover (P/O PL 18.22
Item 2)
Paper Guide
Paper Guide
Static Eliminator
Actuator
Actuator
Bin Tray 1 Assembly (REP
15.3.31)
Collar
Bearing
Roll
Tapping Screw (P/O PL 18.22 Item
10)
Support
Bin Tray
Bearing
Finisher/Sorter
PL 18.22
1/05
8d-156
Reissue
DocuColor 12/DCCS50
PL 18.23 Bin Tray 2/4/6/8

Item
Part
Description
050K36822
2
3
4
5
6
009E64140
013E89540
022E83451
7
8
9
10
038E88980
050E88781
050K33220
11
12
13
14
15
120E13130
120E17020
121E83120
413W77559
830E32600

15.3.32)
Spring
Bearing
Roll
1)
Paper Guide
Bin Tray
Gate
Static Eliminator (P/O PL 18.23
Item 1)
Actuator
Actuator
Gate Solenoid
Bearing
Support
Reissue
DocuColor 12/DCCS50
1/05
8d-157
Finisher/Sorter
PL 18.23
PL 18.24 Bin Tray 3/5/7/9

Item
Part
Description
050K36812
2
3
4
5
6
009E64140
013E89540
022E83451
7
8
9
10
11
038E88980
050E88781
050K33220
059K13261
12
13
14
15
16
120E13130
120E17020
121E83120
413W77559
830E32600

15.3.32)
Spring
Bearing
Roll
1)
Paper Guide
Bin Tray
Gate
Idler Roll
Static Eliminator (P/O PL 18.24
Item 1)
Actuator
Actuator
Gate Solenoid
Bearing
Support
Finisher/Sorter
PL 18.24
1/05
8d-158
Reissue
DocuColor 12/DCCS50
PL 18.25 Bin Tray 10

Item
Part
Description
050K36801
2
3
4
5
6
7
005E83570
009E64140
013E89540
022E83451
8
9
10
11
12
050E88781
050K33220
121E83120
413W77559
830E32600
Bin Tray 10 Assembly (REP

15.3.32)
Collar
Spring
Bearing
Roll
1)
Bin Tray
Gate
Gate Solenoid
Bearing
Support
Reissue
DocuColor 12/DCCS50
1/05
8d-159
Finisher/Sorter
PL 18.25
PL 18.26 Stacker Tray Drive

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
005E91640
020E24770
015K28070
006E70950
007E62840
809E26230
020E33820
802E13970
802E13980
127K29491
127K29500
18
19
20
21
22
23
24
007K85791
413W75959
499W14233
423W25954
020E33830
25
26
413W77559
423W90654
27
28
29
499W14432
809E27360
Front Frame (Not Spared)

Flange
Pulley
Tension Roll
Rear Frame
Shaft
Dog Clutch Gear
Dog Clutch Spring
Spacer (Not Spared)
Tie Plate (Not Spared)
Dog Clutch Pulley
Guide Tray (Not Spared)
Rear Inner Cover
Front Inner Cover
Stacker Motor Assembly
Stacker Motor (REP 15.2.7)
15)
Worm
Bearing
Pulley
Belt
Worm Wheel
Nylon Washer (P/O PL 18.26 Item
15)
Bearing
Stacker Tray Drive Belt (REP
15.2.9)
Pulley
Spring
Washer (Not Spared)
Finisher/Sorter
PL 18.26
1/05
8d-160
Reissue
DocuColor 12/DCCS50
PL 18.27 Stacker Tray

Item
Part
Description
1
2
019E31680
050K41330
3
4
5
6
7
048E45760
050E86731
130E82530
9
10
120E12360
11
12
13
809E02941
120E18280
Belt Clamp
Stacker Tray Assembly (REP
15.2.2,ADJ 15.3.2)
Tray Spacer (P/O PL 18.27 Item 2)
Carriage (P/O PL 18.27 Item 2)
Bottom Cover
Stacker Tray (REP 15.2.10)
Sensor Bracket (P/O PL 18.27
Item 2)
Stacker Upper Limit Sensor (REP
15.2.5), Stacker Full (Mixed Size)
Sensor (REP 15.2.4), Stacker Full
Sensor (REP 15.2.4), Stacker
Lower Limit Sensor (REP 15.2.5),
Stacker Paper Sensor (REP
15.2.10)
Actuator
Stacker Harness (P/O PL 18.27
Item 2)
Spring
Actuator
Reissue
DocuColor 12/DCCS50
1/05
8d-161
Finisher/Sorter
PL 18.27
Common Hardware
Item
Part
Description
C
G
H
J
K
L
M
N
P
R
S
T
X
Y
AB
AE
AF
AG
AH
AJ
AK
AL
AM
AN
AP
AQ
AR
AS
AT
AU
AV
AW
AX
AY
AZ
BA
BC
BD
BE
BH
BL
BM
BQ
BR
BS
BT
BU
BV
BW
112W27859
112W29751
113W15551
113W20457
113W20657
113W20857
113W21057
113W21257
113W21657
113W27456
113W28451
113W35657
113W36057
113W37457
113W38257
141W27351
141W27451
141W27851
141W35451
153W17655
153W17855
153W18055
153W18255
153W27655
158W27655
158W27855
158W28055
158W28255
158W28655
158W35655
158W35855
158W36255
158W36655
158W45055
252W26450
252W29350
252W31350
271W21650
271W28050
271W28250
271W28650
Screw
Screw
Screw
Screw (M3 X 4)
Screw (M3 X 6)
Screw (M3 X 8)
Screw (M3 X 10)
Screw (M3 X 12)
Screw (M2.5 X 14)
Screw (M3 X 16)
Screw (M3 X 4)
Screw (M3 X 4)
Screw (M3 X 14)
Screw (M4 X 6)
Screw
Screw
Screw (M4 X 45)
Setscrew (M3 X 3)
Setscrew (M3 X 4)
Setscrew (M3 X 8)
Setscrew (M4 X 4)
Screw (M3 X 6)
Screw (M3 X 8)
Screw (M3 X 8)
Screw (M3 X 10)
Screw (M3 X 12)
Screw (M3 X 16)
Screw (M4 X 12)
Screw (M4 X 16)
Screw (M4 X 8)
Screw (M4 X 12)
Screw (M4 X 16)
Screw (M5 X 10)
Washer (2.5)
Washer (6)
Nylon Washer (5)
Nylon Washer (8)
Nylon Washer (8)
Nylon Washer (10)
Dowel (2.5 X 16)
Dowel Pin (3 X 10)
Dowel Pin (3 X 12)
Dowel Pin (3 X 16)
Finisher/Sorter
Common Hardware
BX
BY
BZ
CA
CB
CC
CE
CF
CG
CH
CJ
CK
CL
CM
CP
CQ
CS
CT
CW
CX
CZ
DB
DC
DD
DF
DG
DH
DJ
DK
DL
DP
DQ
DR
DT
DU
DV
DW
DY
DZ
1/05
8d-162
271W28850
271W37150
285W16251
354W19251
354W21254
354W24254
354W27254
354W29254
220W24350
113W35857
113W15851
113W28056
141W27651
158W27650
153W16055
113W22557
113W35557
285W28651
285W29151
113W28856
113W20557
153W28050
Dowel Pin (3 X 20)

Dowel Pin (3 X 25)
Dowel Pin (4 X 25)
Dowel Pin (5 X 36)
Spring Pin (2 X 12)
Spring Pin (2 X 12)
E-clip (2.5)
E-clip (3)
Kl-clip (3)
E-clip (4)
Kl-clip (4)
E-clip (5)
E-clip (6)
Kl-clip (6)
Kl-clip (8)
Flange Nut (M4)
Spring Pin (1.6 X 10)
Screw (M4 X 8)
Screw (M2 X 8)
Screw (M3 X 10)
Setscrew (M3 X 6)
Screw (M3 X 6)
Screw (M3 X 6)
Setscrew (M4 X 5)
Screw (M3 X 25)
Screw (M4 X 5)
Screw (M4 X 16)
Spring Washer (12)
Spring Pin (3-16)
Spring Pin (3 X 25)
Screw (M4 X 8)
Screw (M3 X 20)
Dowel Pin Pin (3 X 22)
Screw (M3 X 5)
Capscrew (M3 X 8)
Screw (M3 X 10)
Screw (M3 X 8)
Reissue
DocuColor 12/DCCS50
Part Number Index

Part Number
Part List
007E62840
PL 18.26
Part Number
Part List
007E62850
PL 18.9
003E36290
PL 18.12
007E62860
PL 18.9
PL 18.6
007E62870
PL 18.9
003E46501
PL 18.5
007E62880
PL 18.9
003E48920
PL 18.8
007E62890
PL 18.9
003K83211
PL 18.5
007K83910
PL 18.21
003K85101
PL 18.5
007K85791
PL 18.26
003K85570
PL 18.5
008K91360
PL 18.21
003K91881
PL 18.1
008K91370
PL 18.21
004E08030
PL 18.16
008E93390
PL 18.7
005E15350
PL 18.10
009E64140
PL 18.23
005E15360
PL 18.9
005E83570
PL 18.22
PL 18.25
005E91640
PL 18.24
PL 18.25
009E72520
PL 18.16
PL 18.16
PL 18.9
PL 18.26
009E72530
PL 18.15
005E91660
PL 18.18
009E72550
PL 18.15
006K21000
PL 18.19
011K93650
PL 18.19
006E61320
PL 18.7
011K93870
PL 18.19
006E70950
PL 18.26
011K94401
PL 18.7
006K83590
PL 18.14
011K94411
PL 18.7
006K83620
PL 18.14
012E09860
PL 18.11
006K83642
PL 18.19
012E09870
PL 18.11
007E39910
PL 18.21
012K93390
PL 18.21
007E45091
PL 18.7
012E94950
PL 18.15
PL 18.8
013E13600
PL 18.15
007E45120
PL 18.14
013P60796
PL 18.19
007E45131
PL 18.7
013E85870
PL 18.19
007E45170
PL 18.19
013E89540
PL 18.22
007E54960
PL 18.8
PL 18.23
007E54970
PL 18.8
PL 18.25
007E54980
PL 18.8
007E54990
PL 18.7
015K28070
PL 18.26
PL 18.8
015K28141
PL 18.7
007E55000
PL 18.8
015K28290
PL 18.16
007E55010
PL 18.7
015K28452
PL 18.18
007E55030
PL 18.7
015K31853
PL 18.1
007E55040
PL 18.7
015K31860
PL 18.1
007E56970
PL 18.10
015K31871
PL 18.1
007E62830
PL 18.9
015K35862
PL 18.1
Reissue
DocuColor 12/DCCS50
PL 18.24
1/05
8d-163
Finisher/Sorter
Part Number Index
Part Number
Part List
Part Number
Part List
015K44950
PL 18.9
029E21610
PL 18.1
015K44960
PL 18.9
029K91881
PL 18.17
015K45020
PL 18.17
032E10210
PL 18.1
015K48190
PL 18.10
032E15690
PL 18.12
015K89062
PL 18.19
033K92751
PL 18.20
019E31680
PL 18.27
038E21280
PL 18.22
020K09460
PL 18.9
038K83030
PL 18.15
020E22210
PL 18.18
038K83031
PL 18.15
020E22220
PL 18.18
038K83340
PL 18.16
020E24770
PL 18.26
038E86180
PL 18.22
020E24800
PL 18.20
038E88980
PL 18.22
020E24820
PL 18.19
020E25141
PL 18.9
020E33820
PL 18.26
048E45760
PL 18.27
020E33830
PL 18.26
048K62471
PL 18.20
020E33840
PL 18.10
048E65721
PL 18.2
020E33850
PL 18.9
048E65730
PL 18.5
020E33860
PL 18.14
048E65740
PL 18.3
020K98320
PL 18.9
048E66520
PL 18.2
021E96430
PL 18.4
048E66560
PL 18.2
022E19660
PL 18.8
048E66571
PL 18.3
022E19670
PL 18.8
048K77410
PL 18.2
022K43710
PL 18.22
048K77420
PL 18.5
022K43720
PL 18.13
048K77971
PL 18.2
022K48240
PL 18.13
050E16500
PL 18.11
022K51621
PL 18.8
050E16510
PL 18.11
022K57120
PL 18.7
050K33220
PL 18.23
022K57130
PL 18.7
022K61450
PL 18.9
022K61460
PL 18.9
050K36801
PL 18.25
022K61470
PL 18.10
050K36812
PL 18.24
022K61480
PL 18.20
050K36822
PL 18.23
022K61490
PL 18.10
050K36832
PL 18.22
022K61500
PL 18.8
050K41290
PL 18.17
022E83451
PL 18.22
050K41310
PL 18.3
PL 18.24
050K41320
PL 18.4
PL 18.25
050K41330
PL 18.15
PL 18.24
PL 18.23
PL 18.25
PL 18.24
PL 18.23
PL 18.27
022E83460
PL 18.10
050E86731
PL 18.27
023E13160
PL 18.10
050E88781
PL 18.22
023E15560
PL 18.18
Finisher/Sorter
Part Number Index
PL 18.25
1/05
8d-164
Reissue
DocuColor 12/DCCS50

Part Number
Part List

Part Number
PL 18.24
Part List
PL 18.24
PL 18.23
PL 18.25
054K09360
PL 18.14
121K83981
PL 18.7
054K09382
PL 18.15
121E84720
PL 18.2
054K09462
PL 18.14
121E87250
PL 18.11
054K13920
PL 18.6
054E14510
PL 18.6
121E90490
PL 18.2
054K16770
PL 18.14
121E91450
PL 18.6
054K16780
PL 18.13
127K16360
PL 18.21
054K16790
PL 18.12
127K16600
PL 18.17
054K16800
PL 18.12
127K18880
PL 18.17
054K16810
PL 18.12
127K20871
PL 18.16
054K16820
PL 18.12
127K20900
PL 18.19
059K00521
PL 18.12
127K20930
PL 18.19
059K08590
PL 18.13
127K23320
PL 18.15
PL 18.6
127K24901
PL 18.8
059K13261
PL 18.24
127K24952
PL 18.9
059E92070
PL 18.19
127K29491
PL 18.26
062E98711
PL 18.7
127K29500
PL 18.26
105E09160
PL 18.6
127K29540
PL 18.19
105K18810
PL 18.14
127K31260
PL 18.13
105E98690
PL 18.13
127K37840
PL 18.10
110K08140
PL 18.15
130K55360
PL 18.18
110K10710
PL 18.15
130K60600
PL 18.3
110E94510
PL 18.15
130E80100
PL 18.13
110E97990
PL 18.11
130E82530
PL 18.16
PL 18.4
PL 18.5
PL 18.20
120E12360
PL 18.27
PL 18.7
120E13130
PL 18.22
PL 18.27
PL 18.24
PL 18.23
120E17020
PL 18.19
130E82540
PL 18.22
PL 18.16
PL 18.19
PL 18.24
130E82970
PL 18.6
PL 18.23
130K87332
PL 18.20
120E18280
PL 18.27
130K94740
PL 18.13
120E99480
PL 18.16
120E99651
PL 18.19
120E99661
PL 18.15
121K13070
PL 18.15
160K67951
PL 18.4
121K14541
PL 18.11
160K67960
PL 18.11
121E83120
PL 18.23
160K67991
PL 18.6
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PL 18.14
160K53431
PL 18.13
PL 18.22
1/05
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Finisher/Sorter
Part Number Index
Part Number
Part List
Part Number
Part List
162K47500
PL 18.10
802E13940
PL 18.3
162K60401
PL 18.3
802E13950
PL 18.3
162K60451
PL 18.13
802E13960
PL 18.3
407W07626
PL 18.21
802E13970
PL 18.26
407W08174
PL 18.14
802E13980
PL 18.26
407W08220
PL 18.8
802E13990
PL 18.3
413W08350
PL 18.7
802E14000
PL 18.3
PL 18.8
802E14010
PL 18.3
PL 18.10
802K14650
PL 18.2
PL 18.7
802K14660
PL 18.2
PL 18.26
809E02941
PL 18.27
PL 18.9
809E02991
PL 18.5
PL 18.8
809E03071
PL 18.21
PL 18.21
809E03080
PL 18.21
PL 18.24
809E14570
PL 18.7
PL 18.25
809E14980
PL 18.10
PL 18.23
809E26230
PL 18.26
PL 18.22
809E27360
PL 18.26
PL 18.26
830E19412
PL 18.1
417W30349
PL 18.4
830E32600
PL 18.22
423W21053
PL 18.16
PL 18.23
423W23354
PL 18.14
PL 18.25
423W24953
PL 18.14
423W25953
PL 18.19
830E34990
PL 18.3
423W25954
PL 18.26
830E35000
PL 18.3
423W30754
PL 18.9
830E59990
PL 18.2
423W46753
PL 18.17
891E73431
PL 18.12
PL 18.19
891E73451
PL 18.2
423W87254
PL 18.9
892E13300
PL 18.2
423W90654
PL 18.26
499W14123
PL 18.10
499W14233
PL 18.26
499W14432
PL 18.26
499W14524
PL 18.9
499W15121
PL 18.14
499W15123
PL 18.19
499W17061
PL 18.10
604K13030
PL 18.8
802K05082
PL 18.2
802K09190
PL 18.22
802E13930
PL 18.2
413W75959
413W77559
Finisher/Sorter
Part Number Index
PL 18.24
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P/JNo.
FigureNo.
ItemNo.
1.
To find the location of a connector in the Finisher, perform the following steps.
P/J659
Figure 6
a.
Refer to the Plug/Jack Index.
P/J660
Figure 6
11
Find the connector number in the P/J No column.
P/J661
Figure 6
Find the Figure number and Item number in that row.
P/J664
Figure 6
Go to the Diagram and find the Figure, then locate the Item number that identifies
the specific location of the Plug/Jack.
P/J665
Figure 6
P/J800/800B
Figure 5
P/J1001
Figure 3
15
P/J1002
Figure 3
16
P/J1004
Figure 3
P/J1005
Figure 3
P/J1006
Figure 3
P/J1007
Figure 3
18
P/J1008
Figure 3
P/J1009
Figure 3
P/J1010
Figure 3
17
P/J1011
Figure 3
10
P/J1012
Figure 3
11
P/J1013
Figure 3
12
P/J1014
Figure 3
14
P/J1017
Figure 2
P/J1018
Figure 1
P/J1019
Figure 1
14
P/J1020
Figure 5
P/J1021
Figure 3
P/J1022
Figure 3
P/J1023
Figure 3
P/J1024
Figure 3
P/J1025
Figure 3
13
P/J1026
Figure 4
13
P/J1027
Figure 4
11
P/J1028
Figure 4
14
P/J1029
Figure 4
15
P/J1030
Figure 4
16
P/J1031
Figure 4
17
P/J1032
Figure 4
12
P/J1033
Figure 4
10
P/J1034
Figure 4
P/J1035
Figure 4
P/J1037
Figure 4
P/J1038
Figure 4
18
P/J1039
Figure 4
b.
c.
d.
Refer to Figure 1 for an example of the Plug/Jack Index connector list.
Figure x
1056
Item number in the

a Plug/Jack.
P/J Number

can be located.
Plug/Jack Index
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P/JNo.
FigureNo.
ItemNo.
P/J651
Figure 6
P/J652
Figure 6
P/J653
Figure 6
P/J654
Figure 6
10
P/J656
Figure 6
P/J658
Figure 6
1/05
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P/JNo.
FigureNo.
ItemNo.
P/JNo.
FigureNo.
ItemNo.
P/J1040
Figure 4
P/J1084
Figure 5
P/J1041
Figure 4
P/J1086
Figure 5
21
P/J1042
Figure 4
P/J1087
Figure 5
23
P/J1043
Figure 4
P/J1088
Figure 5
22
P/J1044
Figure 4
P/J1089
Figure 5
14
P/J1045
Figure 2
P/J1090
Figure 5
15
P/J1046
Figure 2
P/J1091
Figure 5
24
P/J1047
Figure 5
11
P/J1092
Figure 1
12
P/J1048
Figure 2
P/J1093
Figure 5
13
P/J1049
Figure 5
12
P/J1094
Figure 1
P/J1050
Figure 5
19
P/J1096
Figure 1
P/J1051
Figure 5
P/J1098
Figure 1
P/J1052
Figure 1
P/J1099
Figure 1
P/J1053
Figure 1
P/J1054
Figure 5
P/J1055
Figure 5
P/J1056
Figure 5
20
P/J1057
Figure 1
11
P/J1058
Figure 5
25
P/J1059
Figure 1
15
P/J1060
Figure 1
16
P/J1061
Figure 5
10
P/J1062
Figure 2
12
P/J1063
Figure 2
11
P/J1064
Figure 5
17
P/J1065
Figure 2
P/J1066
Figure 2
10
P/J1067
Figure 5
18
P/J1069
Figure 2
13
P/J1070
Figure 2
P/J1071
Figure 5
16
P/J1073
Figure 2
P/J1074
Figure 1
P/J1075
Figure 1
P/J1076
Figure 5
P/J1078
Figure 2
P/J1079
Figure 2
P/J1080
Figure 5
P/J1081
Figure 5
P/J1082
Figure 1
13
P/J1083
Figure 1
10
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Figure 1 Compiler Plug/Jack Locations

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Finisher/Sorter
Figure 2 Stacker Plug/Jack Locations

Finisher/Sorter
1/05
8d-170
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Figure 3 Mail Box Plug/Jack locations

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Finisher/Sorter
Figure 4 Finisher PWB Plug/Jack Locations

Finisher/Sorter
1/05
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Figure 5 Finisher Rear (Inline) Plug/Jack Locations

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Finisher/Sorter
Figure 6 Decurler Plug/Jack Locations

Finisher/Sorter
1/05
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Finisher Wirenets
Figure 1 Wirenet Finisher/Mailbox Sorter +5VDC-1

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1/05
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Finisher/Sorter
Finisher Wirenets
Finisher/Sorter
Finisher Wirenets
1/05
8d-176
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1/05
8d-177
Finisher/Sorter
Finisher Wirenets
Figure 4 Wirenet Finisher/Mailbox Sorter +5VDC RTN-1
Finisher/Sorter
Finisher Wirenets
1/05
8d-178
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1/05
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Finisher/Sorter
Finisher Wirenets
Finisher/Sorter
Finisher Wirenets
1/05
8d-180
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Finisher/Sorter
Finisher Wirenets
Finisher/Sorter
Finisher Wirenets
1/05
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Finisher BSDs
Purpose
power.
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Finisher/Sorter
Finisher BSDs
Figure 1 BSD 12.1 Finisher/MBS DC Power and Interlock Switching (1 of 2)
Finisher/Sorter
Finisher BSDs
1/05
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Figure 2 BSD 12.1 Finisher/MBS DC Power and Interlock Switching (2 of 2)
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Finisher/Sorter
Finisher BSDs
Figure 3 BSD 12.2 Unload While Run and Compiler Cover Safety Switch
Finisher/Sorter
Finisher BSDs
1/05
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Figure 4 BSD 12. 3 Interlock Monitoring
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Finisher/Sorter
Finisher BSDs
Figure 5 BSD 12.4 Finisher-IOT CPU Communication
Finisher/Sorter
Finisher BSDs
1/05
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Figure 6 BSD 12.5 Transport Drives
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Finisher/Sorter
Finisher BSDs
Figure 7 BSD 12.6 Decurler Control (1 of 2)
Finisher/Sorter
Finisher BSDs
1/05
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Figure 8 BSD 12.6 Decurler Control (2 of 2)
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Finisher/Sorter
Finisher BSDs
Figure 9 BSD 12.7 Finisher Transportation (1 of 2)
Finisher/Sorter
Finisher BSDs
1/05
8d-192
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Figure 10 BSD 12.7 Finisher Transportation (2 of 2)
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Finisher/Sorter
Finisher BSDs
Figure 11 BSD 12.8 Bin Tray Transportation (1 of 2)
Finisher/Sorter
Finisher BSDs
1/05
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Figure 12 BSD 12.8 Bin Tray Transportation (2 of 2)
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Finisher/Sorter
Finisher BSDs
Figure 13 BSD 12.9 Bin Full Sensors
Finisher/Sorter
Finisher BSDs
1/05
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Figure 14 BSD 12.10 SCT Tray Control
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Finisher/Sorter
Finisher BSDs
Figure 15 BSD 12.11 Compiling
Finisher/Sorter
Finisher BSDs
1/05
8d-198
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Figure 16 BSD 12.12 Stapler Positioning (1 of 2)
Reissue
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Finisher/Sorter
Finisher BSDs
Figure 17 BSD 12.12 Stapler Positioning (2 of 2)
Finisher/Sorter
Finisher BSDs
1/05
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Figure 18 BSD 12.13 Stapler Control
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1/05
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Finisher/Sorter
Finisher BSDs
Figure 19 BSD 12.14 Offset and Eject (1 of 2)
Finisher/Sorter
Finisher BSDs
1/05
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Figure 20 BSD 12.14 Offset and Eject (2 of 2)
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Finisher/Sorter
Finisher BSDs
Figure 21 BSD 12.15 Stacker Tray Control (1 of 2)
Finisher/Sorter
Finisher BSDs
1/05
8d-204
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Figure 22 BSD 12.15 Stacker Tray Control (2 of 2)
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1/05
8d-205
Finisher/Sorter
Finisher BSDs
Finisher/Sorter
Finisher BSDs
1/05
8d-206
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1/05
8d-207
Finisher/Sorter
Finisher BSDs
Finisher/Sorter
Finisher BSDs
1/05
8d-208
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DocuColor 12/DCCS50
1/05
8d-209
Finisher/Sorter
Finisher BSDs
Finisher/Sorter
Finisher BSDs
1/05
8d-210
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8E Electronic Pre-Collation
Chain 3
OF3-1 EPC Fault Entry RAP ...........................................................................................
OF3-2 Operator Message RAP .......................................................................................
3-285 EPC Communications Fault RAP .........................................................................
8e-3
8e-3
8e-4
Chain 40
40-040 / 40-280 / 40-283 EPC PWB Failure RAP...........................................................
40-281 / 40-282 HDD Failure RAP..................................................................................
40-284 EPC Hard Drive Detection RAP..........................................................................
40-285 / 40-286 EPC Memory Failure RAP ....................................................................
40-287 EPC HDD Format Failure RAP ...........................................................................
8e-5
8e-5
8e-6
8e-6
8e-7
Repairs
REP 20.1 EPC PWB .......................................................................................................
REP 20.2 EPC Hard Drive ..............................................................................................
REP 20.3 EPC Scan Cable.............................................................................................
REP 20.4 EPC Print Cable..............................................................................................
REP 20.5 EPC Memory PWB .........................................................................................
8e-9
8e-10
8e-11
8e-12
8e-13
Parts Lists
EPC Module
PL 20.1 EPC Components ..............................................................................................
8e-15
8e-16
General Procedures
GP 1 EPC Initialization....................................................................................................
dC131 EPC NVM Read/Write .........................................................................................
8e-17
8e-17
Wiring Data
EPC Plug/Jacks
EPC Plug/Jack Locator Diagram.....................................................................................
8e-19
EPC BSDs
EPC BSDs (Chain 01).....................................................................................................
EPC BSDs (Chain 03).....................................................................................................
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8e-21
8e-22
1/05
8e-1
Electronic Pre-Collation (EPC)
1/05
8e-2
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OF3-1 EPC Fault Entry RAP
OF3-2 Operator Message RAP

Listing of operator message codes declared by EPC-enabled machines.
NOTE: Use this RAP if the IOT does not recognize the presence of the EPC unit. For Finisher
configurations, correct communications is determined by the presence of the Stapling and
More . . option under Copy Output, on the Basic Copying Tab.
Procedure
If one of the codes in Table 1 is displayed, perform the actions listed in the third column of the
row corresponding to the displayed code. Ensure that the customer understands the specifications and limitations of the copier (refer to the EPC Customer Supplement).
For other configurations, check for Additional Originals and Output Delivery options on the
Job Assembly Tab.
Use this RAP to determine where to start troubleshooting EPC failures when no fault code is
displayed on the copier UI.
Table 1 Operator Message/Fault Code Table

Fault
Code
Initial Actions
Check that NVM location 752-017 [EPC Option Config] is set to 1.
Procedure
Connect the PWS and launch the DC12/DCCS 50 Diagnostic Tool. A Fault Code is displayed in Active Faults or in Last 40 Faults.
Y
N
Go to the 3-285 RAP.
Fault Code 40-040 - go to the 40-040 / 40-280 / 40-283 RAP
Fault Code 40-281 - go to the 40-281 / 40-282 RAP
Fault Code 40-284 - go to the 40-284 RAP
Action
3-513 The paper in the tray selected by APS (Auto Paper

Select) cannot be output to the Stacker.
Cancel the job. Reload

appropriate paper in the
tray(s), and/or deselect APS
3-514 Paper too heavy to feed through Stacker.
Cancel the job. Reload correct paper in the tray(s).
3-515 One of the following occurs when the non-stapled

Press Start to continue
stacker output is selected with Mix Original Size spec- (forces the job to the Top
ified or with the addition of originals for platen copy
Tray), or select Job Cancel.
specified:
Paper in the tray selected by APS is different in

size from previously selected paper.
The fault is a 3-5XX-series fault.

Y
N
For the following faults, go to the associated RAP. If the fault does not appear on this list,
return to Section 2 in the main portion of this Service Manual to locate the fault.
Description
The paper in the tray selected by APS cannot be

output to the stacker.
The paper selected by APS is different in size

from the paper already output to the stacker.
3-516 One of the following occurs when stacker stapled output is selected with Mix Original Size specified or with
the addition of originals for platen copy specified:
Paper selected by the APS is different in size

from previously selected paper.
Press Start to continue, cancel Staple, (forces the job to

the Top Tray) or select Job
Cancel. Reload correct paper
in the tray(s) if indicated.
The paper in the tray selected by APS cannot be

output to the Stacker.
3-517 APS invert NG
Cancel the job. Reload

appropriate paper in the
tray(s), and/or deselect APS
3-545 Staple position is different than that specified.
Cancel Staple or select Job

Cancel.
Go to the OF3-2 RAP.
03-555 For the 2nd and subsequent originals, with APS or

Cancel Staple or select Job
AMS, cannot staple at the position specified, or staple Cancel.
position is different from that specified.
03-590 EPC memory full failure.
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Select Job Cancel or Continue. If the problem persists,

initialize the EPC (GP 1).
OF3-1, OF3-2
3-285 EPC Communications Fault RAP
Table 1 Operator Message/Fault Code Table

Fault
Code
Description
Control Logic was unable to communicate with the EPC PWB.
Action
Initial Actions
03-591 The number of originals exceeds the EPC controllable Select Job Cancel or Continue. If the code is displayed
number limit.
before the limit is actually
reached, initialize the EPC
(GP 1).
Refer to EPC BSDs (Chain 01) and EPC BSDs (Chain 03) for this procedure.
Check that the EPC Scan Cable and Print Cable are seated correctly.
Initialize the EPC (GP 1).
Procedure
There is +5VDC from pin 8 to pin 5 of P640 on the EPC PWB.
Y
N
Go to Flag 2 and Flag 3 on BSD 1.1 (EPC DC Power). check for an open circuit or an
open fuse F6. If the wires are OK, replace the IOT LVPS (PL 9.3).
Check the EPC Scan Cable and Print Cable for damage or poor connections. If the problem
continues, replace the following parts in the order listed until the problem is resolved:
EPC Print Cable (PL 20.1)
OF3-2, 3-285
1/05
8e-4
EPC Scan Cable (PL 20.1)
EPC PWB (PL 20.1)
VSEL Base TTL PWB (PL 9.2)
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40-040 / 40-280 / 40-283 EPC PWB Failure RAP
40-281 / 40-282 HDD Failure RAP
40-040: Control Logic detects that the IOT cannot retrieve image(s) from the EPC.
40-281: Control Logic detects an EPC Hard Drive read/write check error.
40-280: Control Logic has detected an Application Specific Integrated Circuit (ASIC) failure on
the EPC PWB.
40-282: Control Logic detects an unlogged bad sector on the EPC Hard Drive.
Procedure
40-283: Control Logic detects a file system failure in EPC NVM.
Switch off the power. Reseat the EPC Hard Drive Cable on the Hard Drive and on the EPC
PWB. Switch on the power. If the problem continues, initialize the EPC (GP 1). If the problem
continues, replace the EPC Hard Drive (PL 20.1).
Procedure
Switch the power off then on. If the problem continues, initialize the EPC (GP 1). If the problem
remains replace the EPC Memory PWB (PL 20.1). If the problem continues, replace the EPC
PWB (PL 20.1).
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40-040 / 40-280 / 40-283, 40-281 / 40-282
40-284 EPC Hard Drive Detection RAP
40-285 / 40-286 EPC Memory Failure RAP
Control Logic did not detect the presence of an EPC Hard Drive.
40-285: Page Buffer read/write check error
Initial Actions
40-286: DIMM Failure
Refer to EPC BSDs (Chain 01) and EPC BSDs (Chain 03) for this procedure.
Initial Actions
Switch the power off then on.
Procedure
Procedure
There is +5VDC from pin 4 to pin 3 of P656 on the EPC Hard Drive.
Y
N
Y
N
Y
N
Go to Flag 2 and Flag 3 on BSD 1.1 (EPC DC Power). Check for an open circuit
or an open fuse F6. If the wires are OK, replace the IOT LVPS (PL 9.3).
If the problem continues, reseat the Memory PWB (PL 20.1). If the problem persists, replace
the Memory PWB. If the fault remains, replace the EPC PWB (PL 20.1).
Replace the EPC PWB (PL 20.1).

Go to Flag 4 on BSD 1.1 (EPC DC Power). check for an open circuit.
There is +12VDC from pin 1 to pin 2 of P656 on the EPC Hard Drive.
Y
N
Y
N
Y
N
Go to Flag 1 and Flag 2 on BSD 1.1 (EPC DC Power). Check for an open circuit. If the wires are OK, replace the IOT LVPS (PL 9.3).
Replace the EPC PWB (PL 20.1).
Go to Flag 4 on BSD 1.1 (EPC DC Power). check for an open circuit.
Reseat the EPC Hard Drive Cable on the Hard Drive and on the EPC PWB. Switch the power
off then on. If the problem continues, replace the following parts in the order listed until the
problem is resolved:
EPC Hard Drive Cable (PL 20.1)
EPC Hard Drive (PL 20.1)
EPC PWB (PL 20.1)
40-284, 40-285 / 40-286
1/05
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40-287 EPC HDD Format Failure RAP

Control Logic detects EPC Hard Drive format failure.
Procedure
Switch the power off then on. If the problem continues, initialize the EPC (GP 1). If the fault
persists or is a recurring problem, replace the EPC Hard Drive (PL 20.1).
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40-287
40-287
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REP 20.1 EPC PWB

Removal
Disconnect the
Connectors (3)
Remove the screws (3)
Remove the
screws (12)
CAUTION
Use the ESD Kit and the established ESD procedures when replacing the EPC PWB. The EPC
PWB can be damaged by electrostatic discharge.
1.
For DCCS50:
Switch Off the power. Wait 30 seconds, then unplug the power cord. Disconnect the
IDFE DDI Cables.
For DC12 with attached Fiery or Splash DFE:
Perform the correct power down procedure. Disconnect the DFE DDI cables.
For DC12 without an attached DFE:
2.
Access the EPC PWB (Figure 1).
2
Remove the Memory PWB
Figure 2 Removing the EPC PWB
Replacement
1.
Loosen the screws

(6)
2.
Disconnect the
Connectors (2)
Lower the Cover
Figure 1 Accessing the EPC PWB

3.
Remove the EPC PWB (Figure 2).
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REP 20.1
REP 20.2 EPC Hard Drive

Removal
Disconnect the
Connectors (2)
CAUTION
Use the ESD Kit and the established ESD procedures when replacing the EPC PWB. The EPC
PWB can be damaged by electrostatic discharge.
1.
For DCCS50:
IDFE DDI Cables.
2.
Access the EPC Hard Drive (Figure 1).
3
Remove the EPC Hard Drive
2
Remove the
screws (4)
Figure 2 Removing the EPC Hard Drive.
Replacement
1
Loosen the screws (6)
1.
2.
2
Lower the Cover
Figure 1 Accessing the EPC Hard Drive

3.
Remove the EPC Hard Drive (Figure 2).
REP 20.2
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REP 20.3 EPC Scan Cable

Removal
1.
For DCCS50:
IDFE DDI Cables.
2.
3.
4.
Undock the Finisher or Mailbox/Sorter, if present.

Remove the following:
Exit Tray (PL 12.11)
IIT Rear Cover (PL 11.3)
IOT Rear Cover (PL 11.3)
2
Remove the Cover
Open the IIT (REP 3.1.2)
CAUTION
Take note of the routing for the Scan Cable, the Print Cable and the Ribbon Cable. These components must be reinstalled carefully to avoid damage.
5.
Remove the Scan Cable (Figure 1 and Figure 2):

Figure 1 Accessing the VSEL PWB
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REP 20.3
REP 20.4 EPC Print Cable
2
Disconnect the Scan Cable

Removal
1.
For DCCS50:
IDFE DDI Cables.
2.
3.
4.
Remove the Print Cable (Figure 1):
1
Disconnect the Flat
Cable
Figure 2 Removing the Scan Cable
Replacement
1.
Disconnect the
Connector
Figure 1 Removing the Print Cable
Replacement
1.
REP 20.3, REP 20.4
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REP 20.5 EPC Memory PWB

Removal
Remove the Memory PWB

CAUTION
Use the ESD Kit and the established ESD procedures when replacing the Memory PWB. The
Memory PWB can be damaged by electrostatic discharge.
1.
For DCCS50:
IDFE DDI Cables.
2.
Access the Memory PWB (Figure 1).
Figure 2 Removing the Memory PWB.
Replacement
1
Loosen the screws (6)
1.
2.
2
Lower the Cover
Figure 1 Accessing the Memory PWB

3.
Remove the Memory PWB (Figure 2).
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REP 20.5
REP 20.5
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PL 20.1 EPC Components

Item
Part
Description
962K22550
2
3
4
5
117E20391
162K63570
162K64021
160K76442
6
7
8
9
10
11
121K24580
133E69730
117E20380
802K31420
027E92270
12
13
14
EPC Enablement Harness (W/TAG

P38)
Scan Cable (W/TAG P38)
EPC LV Harness
EPC Hard Drive Cable
EPC PWB Assembly (Includes Item
7)
EPC Hard Drive
EPC Memory PWB
Print Cable
EPC IOT Rear Cover (W/TAG P38)
Thumbscrews
EPC Hard Drive Bracket (Not
Spared)
Clamp (Scan Cable) (Not Spared)
Clamp (Print Cable) (Not Spared)
EPC Mounting Plate (Not Spared)
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PL 20.1
Part Number Index

Part Number
Part List
027E92270
PL 20.1
117E20380
PL 20.1
117E20391
PL 20.1
121K24580
PL 20.1
133E69730
PL 20.1
160K76442
PL 20.1
162K63570
PL 20.1
162K64021
PL 20.1
802K31420
PL 20.1
962K22550
PL 20.1
Part Number Index
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GP 1 EPC Initialization
dC131 EPC NVM Read/Write
Perform this procedure whenever the EPC PWB or the EPC Hard Drive is replaced, or when
directed to do so by another procedure.
Procedure
NOTE: Currently, EPC NVM locations can only be accessed through the UI Diagnostic Mode.
Procedure
1.
1.
Enter the UI Diagnostic Mode (refer to How to Enter/Exit the UI (IOT) Diagnostics).
2.
From the Diagnostics Setup Screen, select NVM Read/Write.
2.
From the Diagnostics Setup Screen, select NVM Read / Write (dC131 NVM UI Diagnostics).
3.
Press the Enter Number button on the display.
3.
Check that NVM location 752-017 [EPC Option Config] is set to 1.
4.
Enter the Chain-Link number of the location you wish to view. Refer to Table 1.
4.
Set the value for location 757-020 [Dustoff Init] to 6789.
5.
Close the NVM Read/Write screen.
Enter the UI Diagnostic Mode
CAUTION
6.
From the Diagnostics Setup Screen, select NVM Initialize.
7.
Select EPC. Initialize the EPC NVM.
5.
Press the Start button. The display will shows the current value of the displayed location.
8.
Exit NVM Initialize. Select NVM Read/Write.
6.
9.
Set the value for location 757-102 [HDD Control] to 22184.
To change the value enter the new number using the ten-key pad and press the Start button.
7.
After the operation, return to the Diagnostics Setup Screen by selecting Close on the
UII screen.
10. Exit the UI Diagnostic Mode.
Table 1 EPC NVM List

Chain-Link
Number
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Name
Default
Range
Description
757-010
SW Set Version
0 -65535 NOTE: Octal value
757-011
PRODUCT CODE 1
0-255
757-012
PRODUCT CODE 2
0-255
757-013
PRODUCT CODE 3
0-255
757-014
PRODUCT CODE 4
0-255
757-015
PRODUCT CODE 5
0-255
757-016
PRODUCT CODE 6
0-255
757-017
PRODUCT CODE 7
0-255
757-018
PRODUCT CODE 8
0-255
757-020
DUSTOFF_INIT
0-65535 0 = Disable
6789 = Enable
757-102
HDD Control
0-65535 22184 = formatting and initialization command (GP 1)
GP 1, dC131
GP 1, dC131
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EPC Plug/Jack Locator Diagram
Figure 1 EPC Assembly

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EPC BSDs (Chain 01)
Figure 1 BSD 1.1 EPC DC Power

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EPC BSDs (Chain 01)
EPC BSDs (Chain 03)
Figure 1 BSD 3.1 EPC System Interconnections
EPC BSDs (Chain 03)
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9 Installation
Edit Pad Installation Instructions
Edit Pad Installation ........................................................................................................
9-3
Edit Pad-to-IOT Mounting Kit Installation Instructions

Edit Pad-to-IOT Mounting Kit Installation ........................................................................
9-9

High Capacity Feeder (HCF) Installation ........................................................................
9-13
Convenience Stapler Installation Instructions

Convenience Stapler Installation.....................................................................................
9-25

Foreign Interface Install Instructions ..............................................................................
9-35
Electronic Pre-Collation (EPC) Kit Installation

Electronic Pre-Collation (EPC) Enablement Kit Installation ............................................
Electronic Pre-Collation (EPC) Kit Installation ................................................................
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Installation Instructions
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Edit Pad Installation

Procedure
NOTE: Ensure that TAG P30, 7.06.3 IOT SW or higher is installed in the machine.
TAG P24 must also be installed in the machine. It will be added as part of this procedure if not
already installed.
1.
Power OFF the machine and disconnect the power plug.
2.
Remove the IIT Rear Cover and the IOT Rear Cover. (PL 11.3)
3.
Remove the IOT Control PWB Assy Cover. (PL 9.2)
4.
Disconnect the Flat Cable (FPC-IOT). (PL 9.2)
5.
Remove the (3) screws and lower the IOT Control PWBA Assy.
6.
Remove the (2) screws securing the Ground Strips. (Figure 1)
Figure 2 Connect the Connectors

8.
Loosen the screws (4) securing the Extension Plate to allow assembly of the Edit Pad
Harness Connector. Ensure that the connector orientation is correct. Secure the connector with the (2) screws removed in step (7). (Figure 2)
9.
Tighten the screws securing the Extension Plate.
10. Connect the connector from the Edit Pad Harness P594 (4 pin) to J594 on the machine
harness. P594 is located in the harness bundle that is clamped to the right rear vertical
frame rail. (Figure 2)
11. Remove the Right Upper Cover. Route the Edit Pad Harness (yellow wires), with connector J491, under the Extension Plate and along the machine harness (yellow & blue wires)
on the right side. (PL 11.2) (Figure 3)
7.
Remove (2) screws securing the port cover on the Extension Plate. (save the screws)
(Figure 1)
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Figure 3 Route the Edit Pad Harness
Figure 4 Route the Edit Pad Harness
12. Remove the (2) screws securing the UI Assy and slide it forward to gain access to the harness below. REP 9.5.1.
14. If TAG P24 is marked off go to step 21.
13. Route the Edit Pad Harness up through the harness clamps behind the UI Assy.
(Figure 4)
16. Remove the UI Assy Bottom Plate to gain access to the UI PWB. (PL 9.5)
15. Disconnect connectors P/J490, P/J492 and P/J493 from the UI Assy.
17. Disconnect connectors P/J486, P/J484, P/J482A and J482B from the UI PWB.
18. Replace the UI PWB with the UI PWB supplied in kit 600K83650. (PL 9.5)
19. Reconnect connectors P/J486, P/J484, P/J482A and J482B to the UI PWB.
20. Reinstall the UI Assy Bottom Plate.
21. Connect Connectors P/J490, P/J492 and P/J493.
22. Connect Connector J491 on the Edit Pad Harness to P491 on the UI PWB.
23. Reinstall the UI Assy and secure with (2) screws. REP 9.5.1
24. Disconnect the Video Cable and the Black Cable. Remove the CCD Cable Cover (2
screws) and disconnect the CCD Cable. (Figure 5)
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Figure 5 Disconnect the Cables
Figure 6 Remove Screws and Disconnect the Connectors
25. Remove the (6) screws securing the IPS Drawer. (Figure 6)
26. Disconnect (5) connectors. (2) red and (3) white (Figure 6)
27. Slide open the IPS PWB Drawer to gain access to the PWBs. (Figure 7)
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Figure 7 Open the IPS PWB Drawer
Figure 8 Install the Stand-offs
28. Remove the (3) screws securing the Post IPS PWB. (save the screw) Install the (3)
mounting stand-offs, supplied in the kit, in the screw holes. (Figure 8)
29. Install the IPS-EDIT PWB, supplied in the kit, on the mounting stand-offs and secure with
the screws removed in step 28. (Figure 9)
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Figure 9 Install the IPS-EDIT PWB
Figure 10 Secure the Edit Pad Harness
30. Close the IPS PWB drawer and secure with (6) screws.
34. Install the IOT Control PWB Assy into its upright position and secure with (3) screws.
31. Reconnect the (5) connectors. (2) red and (3) white
35. Reconnect the Flat Cable (FPC-IOT).
32. Reconnect the Video Cable, Black Cable and the CCD Cable. Install the CCD Cable
Cover.
36. Secure the Ground Strips to the Extension Plate.
33. Secure the Edit Pad Harness in the harness clamps. Use additional cable ties as
required. (Figure 10)
38. Install the IIT Rear Cover, IOT Rear Cover and the Right Upper Cover.
37. Install the IOT Control PWB Assy Cover and secure with (7) screws.
39. Reconnect the Power Cord and power up the machine.
40. Enter dc131 and set location 752-012 to 1, to enable Edit Pad (can also be enabled via
dc371).
41. Adjust the Touch Panel Starting Point (ADJ 9.1.18).
42. Verify that the machine and the Edit Pad work correctly.
43. Mark off TAG P24 on the IOT Change Tag Matrix if not already marked off.
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Edit Pad-to-IOT Mounting Kit Installation
Remove Foot Pads (4)
These instructions provide the installation procedure for the optional Edit Pad-to-IOT Mounting
Kit, 98S4450.
Kit Contents
Table 1 Kit Contents
Quantity
Description
Part Number
Actuator
120K91660
Hinges
3E48130
Stopper
3K85090
Magnet
121E90620
Epoxy Adhesive
43P73
Blind Covers
48E66220
Platen Cushion
4E8250
M3 X 12 Screws
158W28255
Screws (for actuator)
26E14060
Screws (for hinges)
153W16055
Kit Instructions
602E74330
Procedure
1.
Place the Edit Pad on a work surface with the bottom side facing up to allow for part
removal and installation.
2.
Gently pry the Foot Pads loose from the Edit Pad (Figure 1).
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Figure 1 Remove Foot Pads

NOTE: The Cover has a post and the Actuator has a hole for proper orientation for installation.
3.
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Install the Actuator (Figure 2).
M3 x 10 mm
screws (2)
M4 x10 mm
screws
(4 each side)
Figure 2 Install the Actuator

4.
Figure 3 Install the Hinges
Install the Hinges (Figure 3).
5.
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Install the Stopper (Figure 4).
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Stopper
Magnet
Remove the peel-off

adhesive backing.
Orientation
Mark
Figure 4 Install the Stopper

6.
Figure 5 Install the Magnet
Install the Magnet (Figure 5).
7.
Disconnect the DADF Wire Harness (PL 12.3) from the IOT.
a.
Slide the Magnet, with proper orientation - white marking, into the slot in the Cover.
8.
Remove the two Knob Screws. (PL 12.3).
b.
Place a small amount of Epoxy Adhesive along the post of the Cover. Allow the
adhesive to set.
9.
Lift the DADF off the IOT and set aside.
10. Install two Blind Covers (PL 11.1).

11. Install the Edit Pad onto the IOT. Leave the assembly in the up (open) position.
12. Insure that the Edit Pad Harness is connected to the IOT.
13. Install the Platen Cushion (refer to REP 11.1.1)
a.
Place the Platen Cushion against the registration edges on the Platen Glass with the
adhesive side of the Cushion facing UP.
b.
Remove the peel-off adhesive backing from the Cushion.
c.
Position the Edit Pad to the down (closed) position and press on the Edit Pad Cover
to insure adhesion of the Cushion to the bottom of the Edit Pad Cover.
14. Reconnect the power cord and switch on the power.

NOTE: MAX Set Up is not required. DO NOT adjust NVM location 715-125.
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Procedure
1.
Cut the bands and remove the outer box (Figure 1).
Figure 2 Remove the Plastic Bag

3.
Break the perforated corners on the corrugated tray (Figure 3).
Figure 1 Remove the Outer Box

2.
Remove the corrugated sleeve.

Remove the plastic bag. (Figure 2).
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Figure 3 Break the Perforated Corners

4.
Figure 4 Roll the HCF
Roll the HCF off of the corrugated tray (Figure 4).
5.
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Remove the paper from the HCF Exit Baffle (Figure 5).
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Figure 5 Remove the Paper

6.
Figure 6 Open the HCF Drawer
1. Open the HCF drawer (Figure 6).
7.
Put the packaged paper size guide to one side (Figure 7).
2. Remove the packaged paper size guide.

3. Remove the HCF mounting bracket and thumbscrews from the drawer.
4. Close the HCF drawer.
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Figure 7 Move the Guide

8.
Figure 8 Unpack the HCF Mounting Bracket
1. Unpack the HCF mounting bracket (Figure 8).
9.
Open the processor left side door (Figure 9).
2. Remove the bag containing the thumbscrews
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Figure 9 Open the Left Side Door
Figure 10 Insert the Bracket
10. 1. Insert the bracket up and over the processor (Figure 10).
11. 1. Secure the bracket to the underside of the processor with the thumbscrew attached to
the left side of the bracket (Figure 11).
2. Slide the bracket toward the front of the machine until the front tab engages the slot in
the processor.
2. Close the processor left side door.
3. Lift the left side of the bracket until it engages the other slot in the processor.
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Figure 11 Secure the Bracket
Figure 12 Unpack the Paper Size Guide
NOTE: The paper size guide is found inside the HCF drawer. It is held in place by a magnet
under the top edge, as well as top and bottom tabs.
NOTE: The paper size guide can be set for either 8.5 x 11 or A4.
13. 1. Align the bottom guide tabs with the appropriate slots on the HCF (Figure 13).
12. Unpack the paper size guide (Figure 12).
2. Align the top guide tabs with the appropriate indicator slots on the HCF.
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Figure 13 Align the Bottom Guide Tabs
Figure 14 Unlock the Rails
NOTE: The HCF is shipped with the rails in the locked position.
CAUTION
Do not pull the rails all the way out. If fully extended, the HCF will tip.
14. Unlock the rails on the HCF (Figure 14):
15. 1. Close the HCF drawer (Figure 15).
1. Locate the locking pin.
2. Pull out the rails enough to allow the rail to mate with the mounting bracket.
2. Lift the pin and rotate it 1/2 turn CCW to unlock the rail.
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Figure 15 Close the HCF Drawer
Figure 16 Lock the Casters
16. 1. Ensure that the processor casters are locked (Figure 16).
17. Attach the rails to the bracket with the two thumbscrews (Figure 17).
2. Align the notches on the rails with the slots in the bracket.
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Figure 17 Attach the Rails
Figure 18 Inspect the Gap
NOTE: If the gap between the processor and HCF is uniform, go to step 22. If the gap is not
uniform, complete steps 19 through 21.
19. 1. Push the HCF away from the processor (Figure 19).
2. Remove the caster wrench from the HCF rails.
18. 1. Push the HCF against the processor (Figure 18).

2. Visually inspect the gap between the HCF and processor.
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Figure 19 Remove the Caster Wrench
Figure 20 Adjust the Casters
WARNING
21. 1. Place the HCF wrench back onto the rails (Figure 21).
2. Push the HCF against the processor.
The underside of the HCF has very sharp edges! Use caution when adjusting.
NOTE: To adjust the casters, raise the HCF by turning the caster nut CCW. Turn the caster nut
CW to lower the HCF. For best results, alternate between casters. The two INSIDE casters
(near the processor) are off the floor when installed, and do not require adjustment.
20. If the gap is not wide enough or is not uniform, adjust the two outside casters (Figure 20).
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Figure 21 Store the Wrench
Figure 22 Remove the Knockout
22. Remove the lower knockout on the processor (to the rear of the bypass tray) (Figure 22).
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23. Connect the HCF harness to the processor (Figure 23).
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Figure 23 Connect the HCF Harness
Figure 24 Close the HCF Drawer
24. Close the HCF drawer (Figure 24).
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Convenience Stapler Installation

Procedure
NOTE: The wing with convenience stapler may come pre assembled.
1.
Unpack the wing with convenience stapler and hardware (Figure 1).

3.
1. Remove the two 5.5 mm screws (Figure 3).

2. Remove the mounting bracket from the Convenience Stapler.
Figure 1 Unpack
2.
1. Remove the two 5.5 mm screws (Figure 2).

2. Remove the upper left side panel.
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4.
Figure 4 Remove the Corner Support Bracket
Remove the corner support bracket attached to the wing with convenience stapler (Figure
4).
5.
1. Slip the corner support bracket into the opening at the left rear (Figure 5).
2. Insert the tab on the bracket through the hole in the frame.
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Figure 5 Position the Bracket
Figure 6 Install the Bracket
CAUTION
7.
There is very little room to install the M4 screw. Be careful not to drop the screw into the
machine.
6.
1. Orient the bracket so that the threaded hole is parallel to the frame of the copier (Figure
7).
2. Use a 5.5 mm wrench to tighten the screw.
Insert an M4 screw into the bottom of the bracket (Figure 6).
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Figure 7 Align the Bracket

8.
Figure 8 Install the Bracket
1. Slip the mounting bracket up and behind the platen surround (Figure 8).
9.
Secure the bracket using seven 5.5 mm M3 screws (Figure 9).
2. Ensure that the holes on the bracket align with the holes on the left side of the processor.
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Figure 9 Secure the Bracket
Figure 10 Prepare the Wing
10. 1. Turn the wing with convenience stapler upside down (Figure 10).
11. Hang the wing with convenience stapler onto the mounting bracket (Figure 11).
2. Remove the screws.

3. Remove the stabilizer bracket from the bottom of the tray. Set the bracket aside.
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Figure 11 Install the Wing
Figure 12 Secure the Wing
NOTE: Be sure to attach the wing with convenience stapler through the mounting bracket and
into the corner support bracket.
13. Install the stabilizer bracket and secure using two 5.5 mm screws (Figure 13).
12. Install two 5.5 mm M4 screws to secure the wing with convenience stapler to the mounting bracket (Figure 12).
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Figure 13 Attach the Stabilizer Bracket
Figure 14 Install the Stabilizer Bracket
14. Attach the stabilizer bracket to the wing with convenience stapler using two 5.5 mm
screws (Figure 14).
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15. Attach the convenience stapler ground strap to the processor (Figure 15).
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Figure 15 Attach the Ground Strap
Figure 16 Prepare the Cutout
16. 1. Remove the screw (Figure 16).
17. Connect the stapler power cord to the processor (Figure 17).
2. Remove the cutout.
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Figure 17 Connect the Power Cord
Figure 18 Install the Cable Anchors
18. Install the two cable anchors on the rear of the processor (Figure 18).
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19. Secure the stapler power cord in the cable anchors (Figure 19).
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Figure 19 Secure the Power Cord
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NOTE: Ensure that the third party device is available before starting this procedure.
Table 1 Accessory Types

Interface Type
NVM Value
Power-OFF the machine and disconnect the Power Plug.
Adder Type (Auditron)
Procedure
Subtraction Type (Prepaid) Coin Vend
WARNING
1.
DCCS50: Remove the Digital Front End (IDFE), by performing steps 1 - 9 of REP 19.1
Removing the IDFE.
2.
Remove the IOT Rear Cover. (PL 11.3)
Removal Procedures
3.
Remove the Tray Module Rear Cover. (PL 11.3)
1.
Reverse the Installation procedures sequence.
4.
Remove the ESS Left Cover. (PL 11.3)
2.
Enter Diagnostics.
5.
Install the Foreign Interface Chassis Assembly. (Figure 1) Place the F/I Chassis Assembly
pivot pin into the hole on the machine frame use the shoulder screw to secure the upper
end of the chassis to the machine.
3.
Enter dC131 [752-002] and change the NVM value to 0.
6.
Remove the Blind Cover. (PL 11.3)
7.
Break away the cable access tab on the Blind Cover.
8.
If the Foreign Device being used is a Coin Op. device, complete steps 9-11. If not, go to
step 12.
9.
Remove the screw that secures the Foreign Interface Module to the mounting bracket and
remove the module.
NOTE: If Fault Code 3-333 displays, repeat steps 2 and 3.
10. Remove the four screws that secure the module cover and remove the cover.
11. Exchange the ROM in position U2 with the ROM supplied in the kit. Install the module
cover and reinstall the module to the mounting bracket.
12. Connect J905 of the F/I Chassis Assembly to P905.
13. Replace the Blind Cover.
14. Connect the Foreign Device Cable (external auditron) to J940 on the F/I Chassis Assembly. Route the Cable through the two cable clamps on the F/I Chassis Assembly to the
outside of the machine.
15. Secure the F/I Chassis Assembly with the 3 screws from the kit.
16. Replace the IOT Rear Cover and the Tray Module Rear Cover.
17. DCCS50: Replace the Digital Front End (IDFE).
18. Connect the machine Power Plug.
19. Power-ON the machine and allow the machine to warm up.
20. Make the following NVM changes, using either UI Diagnostics (steps 21-23) or the PWS
step 24.
21. Enter Diagnostics from the Machine UI. Refer to NVM Read / Write (dC131 NVM UI Diagnostics).
22. Enter dC131 [759-015], set the NVM value for the Foreign Interface type being used
(Table 1).
23. Enter [752-002], set to 1 - Accessory Connection.
24. Use the PWS to enter dC371 Configuration Page and set the Accessory Connection to
match the accessory being used (Table 1).
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Shoulder
Screw
J940
Pivot Pin
Figure 1 Foreign Interface Chassis Assembly
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DocuColor 12/DCCS50
Electronic Pre-Collation (EPC) Enablement Kit Installation
4.
If the Convenience Stapler is not installed: Go to, step 11 and continue with the Scan
Cable installation.
5.
Locate and disconnect the stapler power cord.
6.
Remove the stapler power cord from the cable anchors (2) on the rear of the machine.
7.
Locate and remove the 5.5mm screw securing the green ground wire to the left side of the
machine.
8.
Remove the two 5.5mm screws that secure the stabilizer bracket to the bottom of the Stapler Mounting Cover.
NOTE: The affected machines that require Tag P8 fall within the serial number ranges:
9.
Remove the 2 stabilizer bracket screws M4x5.5mm.
FU2: 040051 to 040198
10. Remove the Stapler Mounting Cover (PL 16.1) from the mounting bracket.
FU3: 310512016x to 310512122x
11. Open the IIT (REP 3.1.2)
Purpose
If the Convenience Stapler is installed: Continue with these instructions at step 5.
The purpose of this kit is to enable installation of EPC (Electronic Pre-Collation) on machines
without TAG P38. If TAG P38 is already installed Place the Shipping Label on this Kit and
Return it.
Prerequisites
The machine must have the following Tags installed:
CAUTION
TAG P8
The VSEL PWB is susceptible to damage from electrostatic discharge Observe all ESD procedures to avoid component damage.
TAG P39 (Check that NVM location 752-017 is set to 1).
Kit Contents
12. Access the VSEL PWB (Figure 1):
The EPC Enablement Kit consists of the following items:
EPC Scan Cable - qty. 1
EPC Mounting Plate - qty. 1
Thumb Nuts- qty. 4
Connector Bracket - qty. 1
Harness Assembly - qty. 1
Connector Cover - qty. 1 (not used)
Locking Clamp - qty. 1
1
Procedure
Installing the Scan Cable
1.
For DCCS50:
Switch off the power. Wait 30 seconds, then unplug the power cord. Remove the
IDFE (REP 19.1).
For DC12 with attached Splash DFE:
Obtain permission from the network administrator and perform the proper shut down
procedure. Switch off the Server power. Disconnect the DocuColor 12 interface
cables (print and scan) from the IOT.
Switch off the machine power. Unplug the power cord.
2
Remove the Cover
For DC12 with attached Fiery DFE:
2.
3.
procedure. Switch off the Server power. Disconnect the Copier Interface Cables
(print and scan) from the interface ports on the copier.
Figure 1 Accessing the VSEL PWB

IOT Rear Cover (PL 11.3)
Wing Tray (PL 11.1), If Present
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CAUTION
it is possible that there is a shorting condition between the EPC Scan Cable and the FPC-ROS
Flat Cable connector (P/J 398). Foam on top of the connector is intended to insulate the pins
from contact. However, the foam can be compressed by the EPC Scan Cable and the pins may
stick through and short against the Scan Cable connector housing.
Using a sheet of transparency or shim stock, cut a strip 45mm X 12mm and adhere to the top
of the foam on the FPC-ROS Cable connector (P/J 398). This strip will function as an insulator.
NOTE: The 80 to 68 pin EPC Scan Cable is longer in length than the 80 to 80 pin Print Cable.
Connect the Scan Cable (Figure 2):
2
Connect the Scan Cable to
TSJ1
Figure 3 Routing the Scan Cable

14. NOTE: Do not reinstall the Right Upper Cover after closing the IIT. The Right Upper Cover
will be reinstalled, later in these instructions.
Close the IIT (REP 3.1.2)
1
Disconnect the flat
cable (P/J389)
Reconnect the flat cable.

Ensure that the cable is routed
under the frame
15. If the EPC Kit is being installed at the same time as the enablement kit: Perform Print
Cable Installation step 2 in the EPC Kit installation instructions, then resume this procedure at Step 17.
16. Route the Scan Cable (and Print Cable if present) as shown in Figure 4:
Figure 2 Connecting the Scan Cable

13. Reinstall the Half Tone PWB Cover. Route the Scan Cable as shown in Figure 3.
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Slide bracket left

then down, to
remove
Remove the
screw (1)
2
Route the Scan cable,
with the ferrite in front of
the Print cable, towards
the rear of the machine
Route the Print cable

towards the rear of the
machine
Detach P/J 899
Figure 4 Routing the Scan Cable and Print Cable
Figure 5 Removing the Connector Bracket
17. If the EPC Kit is being installed at the same time as the enablement kit: Perform Print
Cable Installation (steps 4 and 5) of the EPC Kit installation instructions, then resume this
procedure at Step 19.
3.
18. Reinstall the following:
Wing Tray (PL 11.1), If Present
Convenience Stapler, If present.
4.
Install the EPC Harness Assembly:

a.
Disconnect P/J22 from the IOT LVPS.
b.
Connect J22A (new harness) to P22 on the IOT LVPS.
c.
Connect J22 (existing harness) to P22A (new harness).
d.
Disconnect P/J21 from the IOT LVPS.
e.
Connect J21A (new harness) to P21 on the IOT LVPS.
f.
Connect J21 (existing harness) to P21A (new harness).
Install the new Connector Bracket (Figure 6):
Installing the Harness Assembly

1.
Remove the Tray Module Rear Cover (PL 11.3).
2.
Remove the existing Connector Bracket (Figure 5):
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1
Insert P899 and
P657 (new)from rear
1
Install the
Clamp
2
Install Connector
Bracket at same
location as the old
bracket, using
existing screw
2
Gather the harness
and lock the clamp
Figure 6 Installing the new Connector Bracket
Figure 7 Installing the Locking Clamp

6.
5.
Install the Locking Clamp (Figure 7).
Reinstall the Tray Module Rear Cover (PL 11.3).

CAUTION
Use caution when aligning the Mounting Plate with the IOT Rear Cover. It may be extremely
difficult to separate the Mounting Plate from the IOT Rear Cover, after they have been pressed
together.
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7.
Place the IOT Rear Cover face up on a flat surface. Remove the protective backing from
the five adhesive strips of tape located on the back of the Mounting Plate. Align the
Mounting Plate over the IOT Rear Cover, align the 4 holes, and Press down to fasten
(adhere) the Mounting Plate to the IOT Rear Cover. (see Figure 8)
8.
Install the EPC Mounting Plate and the IOT Rear Cover (Figure 8):
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DocuColor 12/DCCS50
1
Line up the 4
holes
2
Install the IOT Rear Cover and the
EPC Mounting Plate at the same
time. Use the same screws (4)
Figure 8 Installing the Mounting Plate
9.
For DCCS50:
Reinstall the IDFE (REP 19.1).
For DC 12:
Continue with this installation at step 10.
10. Mark off Tag 38 on the IOT Tag Matrix.

11. If the EPC Kit is being installed at the same time as the enablement kit: Go to the
EPC Assembly Installation instructions in the EPC Kit installation instructions and complete the installation.
If the EPC Kit is not being installed at this time: Continue with these instructions.
12. Dock the Finisher.
13. For DC 12 with attached Splash DFE:
Reconnect the DocuColor 12 interface Cables (left side print and right side scan) to
the IOT.
Switch On the Server power.
For DC 12 with attached Fiery DFE:
Reconnect the Copier Interface Cables (left side print and right side scan) to the
interface ports on the copier.
Switch On the Server power.
14. Reconnect the machine power cord; switch On the power.
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Electronic Pre-Collation (EPC) Kit Installation

Purpose
The purpose of this kit is to install the EPC (Electronic Pre-Collation) option on machines manufactured with TAG P38.
Disconnect the
Scan cable
Prerequisites
The machine must have the following Tags installed:
TAG P38
TAG P39 (Ensure that NVM location 752-017 is set to 1).
Kit Contents
The EPC Kit consists of the following items:
EPC Print Cable - qty. 1
EPC Assembly - qty. 1
P-Clamp (6N) - qty. 1
P-Clamp (7N) - qty. 1
Screw M3 - qty. 2
Screw M4x6mm - qty. 4
Procedure
1.
For DCCS50:
Switch off the power. Wait 30 seconds, then unplug the power cord. Remove the
IDFE DDI Cables.
Figure 1 Disconnecting the Scan Cable From the Terminator
For DC12 with attached Splash DFE:
procedure. Switch off the Server power. Disconnect the DocuColor 12 interface
cables (print and scan) from the IOT.
2.
If the EPC Enablement Kit is not being installed at the same time: Connect the Print
cable as shown in Figure 2, then continue with these instructions.
For DC12 with attached Fiery DFE:
procedure. Switch off the Server power. Disconnect the Copier Interface Cables
(print and scan) from the interface ports on the copier.
If the EPC Enablement Kit is being installed at the same time as the EPC kit: Connect the Print cable as shown in Figure 2, then return to Installing the Scan Cable Step 17
of the EPC Enablement Kit installation instructions.
2.
3.
Remove the Right Upper Cover (PL 11.2).
Print Cable Installation

1.
Disconnect the Scan Cable (Figure 1):
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2
Route the Scan
cable, in front of
the Print cable,
towards the rear
of the machine
1
Route the Print
Cable towards
the rear of the
machine
1
Connect the Print
cable (TPJ1)
Figure 3 Routing the Scan and Print Cables
Figure 2 Installing the Print Cable

3.
4.
Route the Scan and Print cables (Figure 3):
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Provide a cable exit on the Right Upper Cover (Figure 4):
EPC Assembly Installation

1.
1
Right Upper
Cover with
break-away
tab
NOTE: If you are installing the EPC Enablement Kit at the same time as the EPC Kit
locate the 4 thumb nuts provided with the enablement kit, they will be used in place of the
4 (M4x6mm) screws for Steps (1 and 2)
Install and temporarily tighten the 2 upper screws on the IOT Rear Cover (Figure 5):
2
Right Upper Cover
with break-away Tab
removed
1
M4x6mm
screws (2)
Figure 5 Preparing to install EPC Assembly

2.
Install the EPC Assembly (Figure 6):
Figure 4 Right Upper Cover Cable Exit

5.
If the EPC Enablement Kit is being installed at the same time as the EPC Kit: Return
to step 19 of Installing the Scan Cable in the EPC Enablement Kit installation instructions.
If the EPC Enablement Kit is not being installed at the same time: Continue with
these instructions.
6.
Reinstall the Right Upper Cover.
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2
Secure the upper
screws (2)
1
Install the EPC
Assembly
1
Connect the EPC DC Power
Connector
3
Install the
remaining lower
screws (2)
Figure 6 Installing the EPC Assembly
3.
Figure 7 Connecting EPC DC Power
Remove the Connector Cover, if present (PL 11.3 Item 12).
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4.
Connect the EPC DC Power connector (Figure 7):
5.
Connect the Scan Cable (Figure 8):
Secure the P-Clamp

(1) M3 screw
Secure the P-Clamp

(1) M3 screw
1
Connect the Scan
Cable
1
Connect the Print
Cable
Install the P-Clamp (6N)
Install the P-Clamp

(7N)
Figure 8 Connecting the Scan cable

6.
Figure 9 Connecting the Print Cable
Connect the Print Cable (Figure 9):
DC 12 / DCCS 50 Machine Checkout

1.
For DC 12 with attached Splash DFE:

Reconnect the DocuColor 12 interface Cables (left side print and right side scan) to the
IOT. Switch On the Server power.
2.
For DC 12 with attached Fiery DFE:

Reconnect the Copier Interface Cables (left side print and right side scan) to the interface ports on the copier. Switch On the Server power.
3.
For DCCS 50:
4.
Dock the Finisher.
5.
Reconnect the machine power cord; switch On the power.
Reconnect the DDI Cables to the IOT.
6.
For DC 12 / DCCS 50 machines with a finisher installed:

From the User Interface, Touch the Job Assembly tab. Ensure Additional Originals and
Output Delivery buttons are displayed. Place 5 colored pages on the DADF, from the
Basic Copying tab select Stapling & More...., select Collated (Staple Options), select
the desired stapling option. Touch Save to return to the Copy Output screen. Touch Save
again to return to the Basic Copying tab, Place 5 colored pages on the DADF, select 3
copies and press Start.
7.
For DC 12 / DCCS 50 machines without a finisher installed:

From the User Interface, Touch the Job Assembly tab. Ensure Additional Originals and
Output Delivery buttons are displayed. Place 5 colored pages on the DADF, from the
Basic Copying tab select the Auto Output collated feature, select 3 copies and press
Start.
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10 Principles of Operation
0. Machine Overview
Introduction .....................................................................................................................
Product Configurations....................................................................................................
Principles of Operation Overview....................................................................................
6. Imaging
10-3
10-3
10-5
Overview .........................................................................................................................
Image Sensing (Digital Copier & Copier/Printer Configuration) ......................................
IIT/IPS Cooling ................................................................................................................
Image Processing (Digital Copier & Copier/Printer Configurations)................................
Image Source Selection ..................................................................................................
Image Processing (All Configurations) ............................................................................
Photoreceptor Exposure..................................................................................................
1. Standby Power
Overview .........................................................................................................................
Voltage Dependent Assemblies ......................................................................................
Unswitched AC Power ....................................................................................................
Power Switching Control Circuitry ...................................................................................
Unswitched DC Power ....................................................................................................
Switched AC Power ........................................................................................................
Switched DC Power ........................................................................................................
Electrical Interlocks .........................................................................................................
10-11
10-11
10-12
10-14
10-16
10-16
10-17
10-23
7. Paper Supply
Overview .........................................................................................................................
Paper Tray Specifications ...............................................................................................
Paper Size Sensing.........................................................................................................
Tray Level Lift and Sensing.............................................................................................
No Paper Sensing ...........................................................................................................
Tray 5 ..............................................................................................................................
2. User Interface
Overview .........................................................................................................................
User Interface Base PWBA.............................................................................................
LCD Display PWBA and Contrast Control PWBA ...........................................................
LCD Backlight Lamp and Power Supply PWBA..............................................................
Key/LED PWBA ..............................................................................................................
Analog Touch Panel........................................................................................................
10-27
10-28
10-30
10-32
10-32
10-35
10-37
10-37
10-38
10-39
10-40
10-41
10-43
10-44
10-45
10-49
10-49
10-51
10-51
10-52
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10-109
10-110
10-112
10-114
10-122
10-123
10-126
10-126
10-129
10-131
10. Fusing
Overview .........................................................................................................................
The Fusing Process ........................................................................................................
Functional Description of Fuser Subassemblies .............................................................
Copy Exit .........................................................................................................................
5. Document Transportation
Overview .........................................................................................................................
Electrical Power ..............................................................................................................
DADF System Control.....................................................................................................
DADF Document Transport.............................................................................................
DADF Operation..............................................................................................................
10-99
10-102
10-104
10-104
10-106
10-107
10-107
9. Xerographics
Overview .........................................................................................................................
Photoreceptor Drum ........................................................................................................
Charging..........................................................................................................................
Development ...................................................................................................................
Intermediate Belt Transfer (IBT)......................................................................................
IBT Assembly ..................................................................................................................
Motors .............................................................................................................................
Cleaning Systems ...........................................................................................................
Air Flow ...........................................................................................................................
Process Controls .............................................................................................................
4. Start Power
Overview .........................................................................................................................
Main Motor ......................................................................................................................
Drum Motor .....................................................................................................................
10-91
10-92
10-95
10-96
10-97
10-97
8. Paper Transportation
Overview .........................................................................................................................
Paper Feeders.................................................................................................................
Vertical Transport ............................................................................................................
Tray 5 ..............................................................................................................................
Paper Registration and Pre-Fuser Transport ..................................................................
Inverter and Duplex Paper Path ......................................................................................
Print Exit ..........................................................................................................................
3. Machine Run Control

Overview .........................................................................................................................
Control Architecture ........................................................................................................
Non-Volatile Memory.......................................................................................................
Machine Usage Modes ...................................................................................................
Self-test ...........................................................................................................................
PWBA LEDs....................................................................................................................
PWBA Test Points...........................................................................................................
Copier Timing..................................................................................................................
Job Control......................................................................................................................
Digital Front End .............................................................................................................
Foreign Interface .............................................................................................................
10-67
10-70
10-80
10-80
10-85
10-86
10-88
10-55
10-56
10-57
10-59
10-63
10-135
10-135
10-136
10-143
11. Sorter / Mailbox

Overview .........................................................................................................................
Mailbox/Sorter Electrical Connections.............................................................................
Offset Catch Tray Electrical Connections........................................................................
Mailbox/Sorter Interlocks.................................................................................................
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10-145
10-146
10-148
10-149
Principles of Operation
Mailbox/Sorter PWBAs....................................................................................................
Print Transport through the Mailbox/Sorter .....................................................................
Offset Catch Tray (OCT) .................................................................................................
Mailbox/Sorter Operation. ...............................................................................................
10-150
10-150
10-153
10-153
12. Finisher
Finisher Power ................................................................................................................
Finisher Interlocks ...........................................................................................................
Finisher Power Components ..........................................................................................
Finisher Control...............................................................................................................
The Finisher Paper Path .................................................................................................
The Decurler ...................................................................................................................
The Finisher Gate ...........................................................................................................
The Mailbox Gate............................................................................................................
Finisher Path for Stacking without Stapling.....................................................................
Finisher Paper Path for Stapling and Stacking ...............................................................
Compiler/Tamper Functional Description........................................................................
Stapler Functional Description ........................................................................................
Eject/Offset Functional Description .................................................................................
Stacker Functional Description .......................................................................................
Mechanical Drive.............................................................................................................
Finisher Transport Motor.................................................................................................
Eject Motor ......................................................................................................................
End Wall Motor................................................................................................................
Tamper Motor..................................................................................................................
Eject Paddle Motor ..........................................................................................................
Eject Clamp/Offset Motor ................................................................................................
Stacker Tray Motor and Sensors ....................................................................................
10-155
10-155
10-156
10-157
10-159
10-160
10-160
10-161
10-161
10-162
10-164
10-168
10-171
10-174
10-174
10-175
10-175
10-178
10-179
10-180
10-182
10-183
19. Digital Front End

Overview .........................................................................................................................
Electrical and Mechanical Operation of the IDFE ...........................................................
Power Distribution - Solid State Relay ............................................................................
Power Distribution - Printer Low Voltage Power Supply (LVPS).....................................
Power Distribution - IDFE................................................................................................
Digital Signal Distribution from the IDFE to the IOT ........................................................
IDFE Enclosure ...............................................................................................................
Network Interface ............................................................................................................
Image Processing ...........................................................................................................
Print Interface..................................................................................................................
Scan Interface ................................................................................................................
10-187
10-187
10-188
10-188
10-188
10-189
10-190
10-190
10-191
10-191
10-192
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Introduction
Product Configurations
This machine is a multipurpose device:
The machine is available in the following configurations:
It is available as a Printer (Figure 1) Copier or Copier/Printer/Scanner (Figure 2 and Figure 3)
As a stand-alone color and monochrome Copier
It can operate in black and white monochrome and 4-color modes
It can produce 50 copies per minute monochrome or 12.5 copies per minute color
As a combined color and monochrome Printer, document Scanner and Copier, also connected to a local area network
As a color and monochrome Printer connected to a local area network
This chapter introduces the following areas:
This machine is available with the following optional accessories:
High Capacity Paper Feeder (HCF) for input paper
Principles of Operation Overview
Edit Pad
Standby Power
Billing accessories for the Foreign Interface
Local User Interface
Mailbox/Sorter for output material
Remote User Interface
500 Sheet Offset Catch Tray (OCT)
Machine Run Control
Envelope Tray
Start Power
Intergrated or external Digital Front End (DFE)
Document Transportation
Stapler
Imaging
Paper Supply
Duplex Automatic Document Feeder
Paper Transportation
Xerographics
Fuser Assembly
Mailbox/Sorter and Offset Copy Tray
Digital Front End (Integrated/External)
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Figure 2 Basic Copier and Printer/Copier Configuration (With DADF)
Figure 1 Basic Printer Configuration
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The Principles of Operation manual is written on a Block Schematic Diagram (BSD) chain-bychain basis. This is done because the BSDs form a good outline for describing copier operation.
The numbers of the chapters in this manual are the BSD chain numbers found in Section 7 of
the Service Manual. Figure 1 shows the interaction between the chains.
Figure 3 Printer/Copier with Mailbox/Sorter/OCT Options
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Product Configurations, Principles of Operation
Figure 1 Interaction between BSD Chains
Standby Power
interlock system. Standby Power filters the AC power input, generates various DC voltages,
and distributes the AC and DC voltages to the subsystems.
Standby Power includes the AC power distribution, DC power distribution, and the electrical
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Local User Interface
The local User Interface, shown in Figure 2, includes the Control Panel, the optional Edit Pad
Assembly and the electronics associated with these assemblies. The User Interface sends
operator commands to Machine Run Control, and displays messages and graphics in
response to commands from Machine Run Control. The displayed messages and their language can be changed by downloading software from a Portable Workstation (PWS) connected at the rear of the machine.
Start Power
It provides cycle-up and cycle-down commands to all other subsystems.
Start Power refers to the motors and drives which are activated when the START button is
pressed on the User Interface, or downloads a print file from a remote user workstation. Start
Power is comprised of the Main Motor and the Photoreceptor Motor and their associated drivetrains. However, these two motors do not provide all of the mechanical drive in the machine.
Motors powering other machine subsystems are described in the chapters associated with
these subsystems.
Document Transportation
In a machine configured as a Copier or Copier/Printer/Scanner, the document is placed on the
Platen Glass. This can either be done manually by the user or automatically by the Duplex
Automatic Document Feeder (DADF) (Figure 4). In both cases, the machine can automatically
determine the size of the original document.
A machine configured as a Copier/Printer/Scanner can also scan documents, and the resulting
images are routed to a user client workstation by the DFE.
Imaging
Imaging is the acquisition and processing the document image, up to being written to the Photoreceptor Drum. As shown in Table 1, the source and destination of the image depends on the
machine configuration.
LCD TOUCHSCREEN
Table 1 Image Sources and Destinations
TOUCH PAD and

LEDS
Configuration
Image Sources
Image Destinations
Printer
User workstation via LAN and

DFE
Photoreceptor Drum
Copier
IIT
Photoreceptor Drum
Copier/Printer/
Scanner
IIT
or
User workstation via LAN and
DFE
Photoreceptor Drum
or
User workstation via DFE and
LAN
Figure 2 User Interface
Remote User Interface

Scan and copy images are created at the IIT when the Xenon lamp illuminates the original document on the Platen Glass, and the Charge Coupled Device (CCD) samples the document at
400 dots per inch (DPI). The image is then manipulated by the Image Input Terminal (IIT) and
the Image Processing System (IPS):
When the machine is configured as a printer or Copier/Printer/Scanner, its Digital Front End
(DFE) appears as an Internet or Intranet server. Users can send their print jobs to the machine,
and retrieve images, which have been scanned from the Platen Glass.
Machine Run Control
1.
Machine Run Control is the hardware and software that controls machine printing and copying
operations. It accepts status information from all machine subsystems and controls their operation. Specifically, Machine Run Control performs the following functions:
It analyzes and implements operator inputs from the User Interface and sends display
messages for the operator to the User Interface.
It receives status inputs from machine sensors and provides timing and sequencing
instructions to machine motors and clutches.
It identifies machine faults, initiates appropriate recovery operations and notifies the operator.
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They determine if the original document is color or monochrome
2.
They digitize the analog data from the CCD
3.
They separate the image into its component colors
4.
They perform any other processing, such as image enlargement or reduction, that the
user has specified
When copying, the image is routed to additional processing circuitry in the Image Output Terminal (IOT). The IOT circuitry drives the laser diode in the Raster Output Scanner (ROS). This
diode writes the latent image onto the Photoreceptor Drum.
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When scanning, the image is sent to the remote user workstation via the Digital Front End
(DFE).
Print images come from the user workstation via the LAN and DFE. These images are also
routed through the IOT processing circuitry to the ROS, which writes them onto the Photoreceptor Drum.
Paper Supply
The Paper Supply provides the paper and other blank copy material for the machine. There are
six possible sources: four paper trays (Trays 1-4), a manual side feeding tray (Tray 5) and the
optional High Capacity Feeder (HCF, Tray 6) (Figure 3). The media which these sources can
hold are different:
Paper Tray 1 and the HCF can hold only for A4 or 8-1/2 x 11 lightweight papers.
Paper Tray 2, 3 and 4 can hold light and medium weight papers up to 11 X 17, and can
be set to accept and detect 12x18 paper.
The Tray 5 can pass any type of paper, cover stock or transparency material which the
machine can process.
High Capacity
Feeder
The Tray 5 is covered in the Paper Transportation section, and the HCF (Tray 6) is covered in
the Paper Supply and Paper Transportations sections.
Figure 3 High Capacity Feeder

The Duplex Automatic Document Feeder (DADF) (Figure 4) permits stacks of original documents to be automatically fed to the Platen Glass where they can be scanned or copied. The
originals can be one-sided or two-sided. Duplex documents are automatically turned over
within the DADF so that both sides can be scanned. The user selects between these choices at
the machines local User Interface.
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4.
All of the components of the developed image are transferred from the IBT Belt to blank
copy media. After the image is transferred to the blank media, the image charge and
residual toner are removed from the IBT Belt, preparing the IBT Belt for the next charging
cycle.
5.
The unfused copy is moved from the IBT to the Vacuum Transport, so that it can be
moved to the Fuser Assembly.
DADF INPUT
TRAY
Fuser Assembly
The Fuser Assembly (Figure 5) receives the unfused copy, fuses the image to the copy material and moves the copy to the output device or inverter. The Fuser Assembly uses heat and
pressure between two rollers to bond toner on to the copy media. The Heat Roll is both internally and externally heated, while the Pressure Roll is internally heated.
DADF OUTPUT
TRAY
Figure 4 Duplex Automatic Document Feeder (DADF)
Paper Transportation
Paper transportation retrieves sheets of blank copy media from the selected source, registers
them, and moves them to the IBT. In addition, Paper Transportation automatically detects the
size of media from the Tray 5 and automatically detects transparencies.
Xerographics
The Xerographics Module develops the latent image written onto the Photoreceptor Drum by
the ROS, transfers the developed image onto the Intermediate Belt Transfer (IBT) and transfers
the image(s) to the paper. This process comprises the following steps:
1.
The ROS writes the image onto the charged Photoreceptor Drum, creating a latent electrostatic image. This is done once for monochrome images and once per color or four
times total for color images.
2.
The latent image is developed by depositing toner of the proper color onto the Photoreceptor Drum. This is also done once for monochrome images and four times for color
images.
3.
Figure 5 Fuser Assembly
Mailbox/Sorter and Offset Copy Tray

The combination of the Mailbox/Sorter and/or OCT can stack completed copies in a variety of
ways, depending on the mode selected by the operator.
The toner comprising the developed image is transferred from the Photoreceptor Drum
onto the Intermediate Belt Transfer (IBT) Belt. The residual toner and image charge are
then removed from the Drum. This is the last step which is done a different number of
times for monochrome and color images.
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Collated sets
Uncollated sets
Sorted by user
The Offset Copy Tray (OCT) is a standard accessory for Printer configurations. and an optional
accessory for Copier and Copier/Printer configurations. The Mailbox/Sorter (Figure 6) is an
optional accessory. The OCT can be mounted on either the basic machine or the Mailbox/
Sorter. However, the OCT can offset only for print jobs received over the network via the DFE.
10 or 100 Mbps Ethernet
4 or 16 Mbps Token Ring
TCP/IP, SMB, NetWare or AppleTalk protocol
Banyan VINES or NetBEUI/NetBIOS protocol via an external adaptor
The DFE is included for machine Printer configuration and is an option for Copier/Printer configurations. With the DFE attached, users on the LAN can download Postscript, Adobe PDL,
Hewlett-Packard PCL or ASCII files from their workstations through the LAN, and the machine
will print them. In addition, when the machine is configured as a Copier/Printer/Scanner,
images scanned at the IIT can be sent via the DFE to the remote user workstation.
Figure 6 Mailbox/Sorter
Digital Front End (Integrated/External)

The DFE is designed to appear as an internet or intranet server when connected to a local
area network (LAN). Several different LAN interfaces are possible:
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Overview
Voltage Dependent Assemblies
This chapter describes the control, distribution and processing of electrical power, the safety
interlock function, and the power saving function. The machine generates a several DC voltages from its AC power input. Certain machine circuits are powered regardless of whether the
main power switch is off or on. There are four types of Standby Power:
Since this machine is used worldwide, the voltage of the Prime AC Power Input can vary. Several machine assemblies have different part numbers depending on the voltage of the Prime
AC Power input. The Prime AC Power is:
115 VAC at 16 amperes in the digital copier configuration and 12 amperes in the printer
configuration for Xerox Corporation (XC) markets
220/230/240 VAC at 10 amperes for the Xerox Europe (XE) markets
AC power which is present when the machines main power switch is off (Unswitched AC
Power)
DC power which is also present when the Main Power Switch is off (Unswitched DC
Power)
The modules which are changed depending on the Prime AC Power Input are:
AC power which is only present when the Main Power Switch is on (Switched AC Powerr)
The IDFE Low Voltage Power Supply (IDFE LVPS)
DC power which also is present only when the Main Power Switch is on (Switched DC
Power)
The Image Output Terminal Low Voltage Power Supply (IOT LVPS)
The Image Input Terminal/Image Processing System Low Voltage Power Supply (IIT/IPS
LVPS)
This chapter also describes Electrical Interlocks.
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The 18 VAC Transformer
The Fuser Solid State Relay (SSR)
The IDFE LVPS SSR
The Oil Pump
The External Heat Roll Lamp
The Pressure Roll Lamp
The Heat Roll Lamp
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Overview, Voltage Dependent Assemblies
Unswitched AC Power
As shown in Figure 1, unswitched Prime AC Power enters the machine and is immediately
routed through the GFI Circuit Breaker and the Noise Filter. The Noise Filter prevents
unwanted signals from entering the machine on the power line. The Noise Filter Output is provided to the 18 VAC Transformer and to the Choke Coil. The Choke Coil is another type of
noise filter and supplies the IDFE LVPS. The output of the 18 VAC Transformer goes back to
the AC Driver PWBA. Figure 2 shows the locations of the assemblies used for Unswitched AC
Power.
Figure 1 Unswitched AC Power Routing
Unswitched AC Power
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NOISE
FILTER
18 VAC
TRANSFORMER
(BEHIND IOT
LVPS)
GFI
CIRCUIT
BREAKER
AC DRIVER PWBA
Figure 2 Locations of Assemblies Using Unswitched AC Power
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Unswitched AC Power
Power Switching Control Circuitry

As shown in Figure 1, power switching control uses circuitry on the AC Driver PWBA with
inputs from other assemblies. Machine power can only be switched on by toggling the Main
Power Switch. When pressed, this switch energizes the Set Coil of Power Relay 1, which energizes Power Relay 2 and causes Switched AC Power to be supplied by the AC Driver PWBA.
AC power can be switched off by any of three events:
The operator toggles the Main Power Switch.
The IOT CPU PWBA asserts the Main Power Off line. This only occurs due to abnormal
execution of CPU firmware. When the operator again toggles the Main Power Switch, the
entire machine, including the IOT CPU, is rebooted.
The IOT CPU PWBA asserts the Power Off line. This places the machine in to Sleep
Mode and is done as a power saving technique.
Each of these inputs activates the Reset Coil of Power Relay 1, deenergizing the relay and
releasing Power Relay 2. This removes Switched AC Power from the machine.
The machine saves power in two stages. The first transition is from Ready Mode to Low Power
Mode. This occurs 15 minutes (default time) after the machine operation initiated by the user.
This delay period is stored in IOT NVM and can be adjusted over a range of 1 to 240 minutes.
When in Low Power Mode, the fuser heaters are off.
The second transition is to Sleep Mode. The default delay is 60 minutes after the transition to
Low Power Mode. The delay value is also stored in IOT NVM and can be adjusted over a range
of 15 to 240 minutes.
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Figure 1 Power Switching Control Circuitry Block Diagram

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Unswitched DC Power
Switched AC Power
All unswitched DC power originates from the AC Driver PWBA.
Switched AC Power from Power Relay 2 on AC Driver PWBA goes to the following assemblies:
AC Driver PWBA
IOT LVPS
The AC Driver PWBA generates +5 VDC and +12 VDC. Both DC voltages are derived from the
output of the 18 VAC Transformer. The +12 VDC output goes to the Fuser Fan, while the
+5VDC is supplied as EVER +5V to several assemblies:
Oil Pump
IIT/IPS LVPS
Fuser Solid State Relay (SSR)
AC Power from the Fuser SSR goes to the following assemblies:
The IOT Drive PWBA
Vsel PWBA
Halftone PWBA
Pressure Roll Lamp
EPSV
Heat Roll Lamp
The IOT CPU PWBA, via the IOT Drive PWBA
The Main Power Switch
External Heat Roll Lamp
The AC Driver PWBA contains Prime AC Power switching relays, but control of these relays is
distributed among several assemblies. The topic is covered in detail in the Power Switching
Control Circuitry section.
Unswitched DC Power, Switched AC Power
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Switched DC Power
The IDFE LVPS has two outputs:
Switched DC Power comprises the outputs of the IDFE LVPS, IOT LVPS and the IIT/IPS LVPS.
+5.1 VDC at 11 amps
IDFE Low Voltage Power Supply (IDFE LVPS)
+12 VDC at 2 amp
As shown in Figure 1, the AC input power to the IDFE LVPS is supplied by Unswitched AC
Power through a Choke Coil and an SSR. The SSR is controlled by the IDFE LV SEQ from the
AC Driver PWBA; IDFE LV SEQ is controlled by the Main Power Switch. When switching off
machine power, an RC network on the AC Driver PWBA delays the change of state of IDFE LV
SEQ by approximately 22 seconds. This permits the IDFE to perform an orderly shutdown.
Figure 2 shows the location of the IDFE LVPS.
Figure 1 IDFE LVPS AC Power Switching and DC Power Distribution
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Switched DC Power
IDFE LVPS
(Behind AC
Driver PWBA)
Figure 2 IDFE LVPS Location
IOT Low Voltage Power Supply (IOT LVPS)

The IOT LPVS has four outputs:
+5 VDC at 11 amps
+12 VDC at 1.8 amps
-12 VDC at 1.0 amps
+24.5 VDC at 17 amps
Figure 3 and Figure 4 show the assemblies supplied by the IOT LVPS. Figure 5 shows the
location of the IOT LVPS, Distribution PWBA and IOT Drive PWBA.
Switched DC Power
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Figure 3 IOT LVPS +24 VDC Power Distribution
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Switched DC Power
Figure 4 IOT LVPS +5 VDC and +/- 12 VDC Power Distribution
Switched DC Power
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DISTRIBUTION
PWBA
IOT DRIVE
PWBA (BEHIND
IOT CPU PWBA
AND IOT NVM
PWBA)
IOT LVPS (BEHIND

COVER)
Figure 5 IOT LVPS, Distribution PWBA and IOT Drive PWBA Locations
IIT/IPS Low Voltage Power Supply

The IIT/IPS LVPS has 4 outputs:
+3.5 VDC at 10 amps
+5.1 VDC at 6 amps
+13.3 VDC at 1.1 amps
+24.5 VDC at 4.5 amps
Figure 6 shows the assemblies supplied by the IIT/IPS LVPS, and Figure 7 shows the location
of the IIT/IPS LVPS.
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Switched DC Power
Figure 6 IIT/IPS LVPS DC Power Distribution
Switched DC Power
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Electrical Interlocks
Equipment interlocks are devices which disconnect power to machine circuitry when a particular condition occurs. In this machine, they disconnect power when a machine outer door is
opened and when internal assemblies are moved into their service position. This machine uses
the following interlocks:
Front Door Interlock Switch (shown in Figure 1)
Inverter Cover Interlock Switch (R/H) (shown in Figure 2)
Drawer/IBT Interlock Switch
Paper Takeaway Cover (L/H) Interlock Switch
IIT/IPS LOW VOLTAGE

POWER SUPPLY
Figure 7 IIT/IPS LVPS Location
FRONT PANEL
INTERLOCK
SWITCH
Figure 1 Front Door Interlock Switch Location
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Switched DC Power, Electrical Interlocks
+5 VDC is interlocked by the machine paper path Drawer and front door. Figure 3 shows
the associated signal routing.
+5 VDC is interlocked by the machine Inverter Cover
+24 VDC is interlocked by the machine front door Figure 4 shows the associated signal
routing.
+24 VDC is also interlocked by the machine left hand door. Figure 5 shows the associated
signal routing.
Figure 2 Inverter Cover (L/H Door) Interlock Switch Location

Whenever an interlocked assembly is opened, the associated interlock switch disconnects
power from the supplied circuitry.
Figure 3 Front Door +5 VDC Power Interlock Signal Flow
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Figure 4 Front Door & Drawer +24 VDC Power Interlock Signal Flow
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Figure 5 Paper Takeaway Cover (L/H) +24 VDC Power Signal Flow
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Overview
As shown in Figure 1, the User Interface (UI) consists of:
3.
Key/LED PWBA
4.
Analog Touch Panel
5.
LCD Backlight Lamp and Power Supply PWBA

Edit Pad
1.
User Interface Base PWBA
6.
2.
LCD Display PWBA and Contrast Control PWBA
The locations of these assemblies are shown in Figure 2.
Figure 1 User Interface Simplified Block Diagram
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Overview

The UI Base PWBA contains the logic to control the remaining assemblies in the UI. As shown
in Figure 1, this PWBA includes three microcontrollers:
CONTRAST
CONTROL
PWBA
LCD BACKLIGHT POWER

SUPPLY PWBA ANALOG TOUCH PANEL (TOP);
LCD PWBA/DISPLAY;
LCD BACKLIGHT LAMP;
UI BASE PWBA (BOTTOM)
a PWBA Microcontroller
an LCD Display Microcontroller
a Control Panel/Touch Panel Microcontroller
KEYPAD /LED
PWBA
Figure 2 User Interface Assemblies Locations
Overview, User Interface Base PWBA
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Figure 1 User Interface Base PWBA Block Diagram

The PWBA Microcontroller and Display Microcontroller share DRAM and ROM. (Both microcontrollers also include on board RAM and ROM.) The PWBA Microcontroller disables the LCD
Display Microcontroller whenever it must access that memory. The PWBA Microcontroller also
multiplexes the communications links with the IOT CPU PWBA and Edit Pad LED Control
between itself and the LCD Display PWBA. It also provides separate communications interfaces with the Edit Pad and the Portable Workstation (PWS). The PWS is used to download
software into the UI Base PWBA.
The Control Panel/Touch Panel Microcontroller detects changes in the status of the push-button using seven row lines and four column lines. It also drives the LEDs on the Key/LED
PWBA, and connects with the Left, Right, Up and Down analog input/outputs from the Analog
Touch Panel.
The LCD Display Microcontroller uses the data in the Frame Buffer RAM to drive the display on
the LCD Display PWBA. The LCD Display Microcontroller also outputs drive signals to the
buzzer located on the Push-button/LED PWBA. These outputs are routed through individual
attenuators, each of which has a different value of attenuation. This permits the buzzer to have
three different volume levels and an almost infinite number of tones.
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The LCD PWBA, shown in Figure 1, contains the 640 by 240 pixel LCD display as well as its
drive circuitry. All data and timing signals to the LCD are generated by the LCD Display Microcontroller on the UI Base PWBA and routed through the Contrast Control PWBA. Two DC voltages, V-EE (+28 VDC) and V-LCD (0 to +5 VDC adjustable), control the brightness and
contrast of the LCD display. V-LCD can be adjusted by a variable resistor located on the Contrast Control PWBA and accessible to user.
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Figure 1 LCD Display PWBA and Contrast Control PWBA
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LCD Backlight Lamp and Power Supply PWBA
Key/LED PWBA
The LCD Backlight Power Supply PWBA (Figure 1) accepts +24 VDC from the UI Base PWBA
and a Backlight Enable control signal from the UI Base PWBA. When enabled, the LCD Backlight Power Supply PWBA outputs 585 VAC to the LCD Backlight Lamp. The level of LCD illumination isnt adjustable.
The Key/LED PWBA contains 25 push-button switches, a buzzer and 10 LEDs. The push-button are shown in Figure 1, and the LEDs and buzzer are shown in Figure 2. Twenty four of the
switches are electrically arranged in a row-column matrix. The LED/Push-button Processor on
the UI Base PWBA individually and sequentially asserts the matrix rows while accepting inputs
from all of the matrix columns simultaneously. A column line will be asserted only when a pushbutton is pressed and that push-buttons row line is asserted. The Power Saver push-button
also connects between row and column when pressed, but the connection is made through an
IC analog switch. A separate section of the same switch routes the V-DD input to the Power
Saver LEDs on this PWBA.
Eight of the ten LEDs are controlled by discrete lines from the LED/Push-button Interface Processor on the UI Base PWBA. The remaining two LEDs are controlled by a signal from IOT
CPU PWBA.
The Buzzer is driven by outputs from the LCD Display Microcontroller on the UI Base PWBA.
LCD Backlight Lamp and Power Supply PWBA, Key/
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Figure 1 Push-button/LED PWBA Input Device Control and Connections
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Key/LED PWBA
Figure 2 Push-button/LED PWBA Output Device Control and Connection
Key/LED PWBA
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Analog Touch Panel

The Analog Touch Panel is mounted over the LCD Display PWBA. As shown in Figure 1, the
touch panel is connected to the UI Base PWBA via the Key/LED PWBA by four analog input/
output lines. The LCD Display Microcontroller on the UI Base PWBA alternately samples the
touchscreens X dimension and its Y dimension. These samples alternate rapidly enough that
when the user presses the touchscreen, at least one X dimension measurement and at least
one Y dimension measurement are taken.
The LCD Display Microcontroller takes a Y dimension measurement by driving the Y dimension lines (Up and Down) as outputs and accepting the Right X dimension line as an input.
When used as an output, the Up output is grounded and a Down output is at about +5 VDC.
When the panel is touched, two internal conductive layers make contact. The voltage at the
Right input is proportional to the Y position where the touch occurred.
The X dimension input is taken in a similar fashion. The LCD Display Microcontroller drives the
X dimension lines and samples the Up line as an input. When driven, Right is at ground and
Left is at about +5 VDC.
Figure 1 Analog Touchscreen Interconnect Block Diagram
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Analog Touch Panel
Analog Touch Panel
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Overview
Control Architecture
This machine uses distributed computer technology and data communications to control its
operation. Overall machine control is provided by the Image Output Terminal (IOT) CPU
Printed Wiring Board Assembly (PWBA). However, additional intelligent PWBAs control subsystem functions. These PWBAs talk with each other using serial communications paths.
There is no local network bus. Run-time monitoring and self-tests allow the control system to
detect faults.
As shown in Figure 1, the center of the control architecture is the IOT CPU PWBA. This
assembly uses 2-wire and 4-wire serial communications links to pass command and status
messages with several other standard and optional assemblies.
This chapter will discuss the following subjects:

1.
Control Architecture
2.
Non-Volatile Memory
3.
Machine Usage Modes
4.
Self-test
5.
Copier Timing
6.
Job Control
7.
Digital Front End
8.
Foreign Interface
The Post-IPS (Image Processing System) PWBA
The Pre-IPS PWBA via the Post-IPS PWBA
The Duplex Automatic Document Feeder (DADF) via the Post-IPS PWBA and Pre-IPS
PWBA
The User Interface (UI) Base PWBA
The Portable Workstation (PWS)
The Tray 6 (High Capacity Feeder - HCF)
The Sorter/Mailbox/Offset Copy Tray (OCT)
The Foreign Interface
The Integrated Digital Front End (IDFE)
In addition, the address and data buses from the IOT CPU are connected to the following:
The IOT Non-Volatile Memory (NVM) PWBA
The IOT Drive PWBA
The Halftone PWBA.
Three of these PWBAs deserve special mention. First, the IOT Drive PWBA contains the
decoders and drive circuitry which connect the IOT CPU with discrete line outputs and discrete
line inputs. These discrete lines are connected with motors, clutches, solenoids and sensors
throughout the machine.
Second, the IOT CPU PWBA provides all of the connections between the User Interface and
the rest of the machine. All status data from other PWBAs must be processed by the IOT CPU
PWBA, which then provides the appropriate messages to the UI Base PWBA. When something is entered at the UI, the UI Base PWBA typically sends messages to the IOT CPU PWBA.
As a result of these messages and its own processing, the IOT CPU PWBA sends commands
to the rest of the machine.
Third, the control and status communications path between the IOT CPU PWBA and the DADF
is routed via both the Post-IPS PWBA and Pre-IPS PWBA. The nature of the routing differs
between the two PWBAs. The signal path through the Post-IPS PWBA is direct, and no active
circuitry on that PWBA is involved. However, all messages between the IOT CPU PWBA and
DADF are handled by the control processor on the Pre-IPS PWBA. Therefore, the Pre-IPS
PWBA control processor shares control of the DADF with the IOT CPU.
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Overview, Control Architecture
Figure 1 Communications Architecture Block Diagram
Non-Volatile Memory
Control Architecture, Non-Volatile Memory
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Three PWBAs include Non-Volatile Memory (NVM). These are shown in Table 1. This memory
holds setup parameters which are specific to the particular machine. The NVM for the IOT CPU
PWBA is located on the IOT NVM PWBA. This PWBA includes a 3 volt lithium battery. This
battery supplies RAM power when the PWBA is disconnected from the IOT CPU PWBA or
when prime AC power is removed from the machine. When the IOT CPU PWBA is replaced,
the IOT NVM PWBA must be disconnected from the old PWBA and reinstalled onto the new
PWBA.
Table 1 NVM Locations and Contents
The machine has both local and remote usage modes. The remote usage mode is accessible
from a client workstation connected to the network. This is described in the Chapter 12, Integrated Digital Front End. The local mode is accessible only from the machine local User Interface and is described below.
The local usage mode has five submodes:
User Mode
System Administrator Tools Mode
IIT and DADF
Auditron Administrator Tools Mode
IPS
User Interface Diagnostic Mode
IOT and UI
Copier User Mode
Location
Memory Type
Values For
Pre-IPS PWBA
Flash ROM
Post-IPS PWBA
Flash ROM
IOT NVM PWBA (for IOT CPU PWBA) Battery-Backed RAM
Machine Usage Modes
The User Mode provides all copier functions not reserved for System Administrator Tools
Mode, Auditron Administrator Tools Mode and User Interface Diagnostic Mode.
Copier System Administrator Tools Mode

The System Administrator can select the following parameters:
Paper tray defaults
Copy density and color defaults
Copy position and shift
Document orientation defaults
Simplex/Duplex default
N-up default
System Administrator password
Reduction/enlargement default
User registered colors
Photo/text separation levels
Audio tone
Copy quantity limit
Timer values
Tone reproduction parameter values
Copier Auditron Administrator Tools Mode

The following parameters can be selected in this mode:
Auditron Administrator password
Auditron mode on/off
Password, copy limit and copy counter by user number
Copier User Interface Diagnostic Mode

The following parameters can be selected in this mode:
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Remote Maintenance Mode
NVM Reset
NVM Read/Write
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Non-Volatile Memory, Machine Usage Modes
NVM Initialize
Password
Self-test
All machine subsystems which contain microcontrollers and microprocessors perform PowerOn Self-Test (POST) when DC power is first applied to them. If all POST procedures are
passed, the machine goes to normal operation. If a circuit fails a POST procedure, the machine
will attempt to notify the user. However, some failures may be due to a catastrophic hardware
failure which causes the machine to completely suspend operations.
The following are the PWBAs that are connected together or that communicate the machine
status and operation.
The IOT CPU PWBA (Image Output Terminal) checks communications for the following:
UI PWBA
Post IPS PWBA
Mail Box Control PWBA
Serial Port for the PWS
Pre IPS PWBA (Image Process System):
Checks communications through the Post IPS PWBA and MEM. SYS PWBA
Controls the IOT through a direct connection with the IOT Drive PWBA
Checks DADF Control PWBA communications
UI PWBA (User Interface) Controls:
Control Panel Switches, LCD and the Touch Panel
Self-test for RAM and Control Panel
Post IPS PWBA implements image processing.
Post IPW PWBA and the MEM SYS PWBA are connected together and assist communications between the Pre IPS PWBA and the IOT CPU PWBA.
MEM SYS PWBA stores the Image Data sent from the Pre IPS PWBA
IOT Drive PWBA controls the IOT by signals sent from the IOT CPU PWBA
DADF Control PWBA controls the DADF and runs self-test of the RAM
Mailbox/Sorter Control PWBA controls the Mailbox/Sorter
Integrated Digital Front End (IDFE) Self-Test

Table 1 lists the POST routines performed by the IDFE.
Table 1 IDFE Power-On Self-Test
Test Performed
Whats Tested
DC Power Test Power Switch ON
DC Power to IDFE Power LED stays on

Motherboard
Power LED is off
BIOS Level Test
IDFE Motherboard Failure LED goes off at

components
end of test
Failure LED remains on

at end of test
Software Bootup
Sequence Test
Application software integrity
Software load attempts

fail; Heartbeat LED
remains on constantly
Printer Interface
UART (internal
DDI Comms Test 1 loopback)
Machine Usage Modes, Self-test
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Pass Indication
Heartbeat LED blinks

continuously
Fail Indication
Client level command to Failure LED blinks patIOT

tern 2, but software boot
continues
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PWBA LEDs
Table 1 IDFE Power-On Self-Test

Test Performed
Whats Tested
Pass Indication
Printer Interface
End-to-End
Failure LED doesnt
DDI Comms Test 2 Comms test to IOT blink pattern
CPU PWBA
Scan Out Interface UART (internal
DDI Comms Test 1 loopback)
Fail Indication
Failure LED blinks pattern 2, but software boot
continues
Failure LED blinks pattern 4, but printer operates normally
Network/connectivity Hardware,
part 1
Network link hard- Link LED stays lit

ware
Link LED isnt lit
part 2
Network visibility to Activity LED flashes pat- Activity LED does not
IDFE
tern mimicking network flash
traffic flow
part 3
Ethernet speed
detection circuitry
part 4
Token Ring speed

detection circuitry
Configuration report,
web client and XCMI
setting contain correct
speed connection
Configuration report,
web client and XCMI
setting contain incorrect speed connection
LED or other media dis- LED or other media indiplays sensed or set
cates wrong speed conspeed connection
nection. Desired speed
can be set manually
Network/connecTCP/IP connectivtivity Software, part ity and SMB test

1
using Ping functionality
At least 1 ICMP echo

response is received
and message is printed
on configuration report
No response is
received; message
printed on configuration
report
Network/connecNetware connectivity Software, part tivity using Get2

NearestServer
functionality
A GetNearestServer
response is received
and message is printed
on configuration report
No response is
received; message
report
Network/connecAppletalk connectivity Software, part tivity using Get3

MyZone
functionality
A Zone response is
received and message
is printed on configuration report
No response is
received; message
report
DocuColor 12/DCCS50
Table 1 IOT CPU PWBA LEDs
Client level command to Failure LED blinks patIOT

tern 3, but printer operates normally
Scan Out Interface End-to-End

Failure LED doesnt
DDI Comms Test 2 Comms test to IOT blink pattern
CPU PWBA
Reissue
Table 1, Table 2, Table 3, Table 4, Table 5, Table 6, Table 7, and Table 8 list the diagnostic
LEDs on various machine PWBAs. These can be used to determine the status of both onboard and off-board circuitry.
LED
Color
Signal
Comment
CR5
Red
CPU Reset
Lit indicates that reset line to CPU is being

asserted
CR6
Green
PWS Rx Data
Flickering indicates data transitions
CR7
Green
Tray 6 (HCF)
CR8
Green
ESPV Rx Data
CR9
Green
Decurler Rx Data
CR10
Green
+5 VDC
Lit indicates presence of PWBA power
CR14
Green
UI PWBA Tx Data
CR16
Green
UI PWBA Rx Data Flickering indicates data transitions
CR17
Green
IIT PWBA Rx Data Flickering indicates data transitions
CR18
Green
IPS PWBA Rx
Data
Table 2 Pre-IPS PWBA LEDs

LED
Color
Signal
Comment
CR5
Green
T1
Firmware check
CR6
Green
IIT_CMD, SYS
Flickering indicates command being

received from IOT
CR7
Green
ADF_SYS, ADF
Flickering indicates status information being

received from DADF
CR8
Green
LED_MEM_RDY,
MRDY
Lit indicates that MEM_RDY signal is active
CR9
Red
RST_LED, RST
Lit indicates that reset line from IOT is active
CR10
Red
CPU_HG, MRST
Not lit when CPU firmware operating correctly
LED
Color
Signal
Comment
CR1
Yellow
POWER
Indicates +3.3 VDC is present on the PWBA
CR2
Yellow
IPSPSI/IPS-PS
Page Sync signal from POST to MEMORY, lit

when signal is active
CR3
Yellow
CPE_PS/CMMPS(B)
Output Page Sync signal from CMM1 (blue),

Lit when signal is active.
CR3
Yellow
CMMPSG/CMMPS(G)
Output Page Sync signal from CMM2

(green), Lit when signal is active.
Table 3 Memory System PWBA LEDs
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Self-test, PWBA LEDs
Table 3 Memory System PWBA LEDs

LED
Color
Signal
Comment
CR4
Yellow
CMMPSR/CMMPS(R)
Output Page Sync signal from CMM3 (red),

Lit when signal is active
CR5
Yellow
IIT-PS/IITPSI
Page Sync signal from Pre-IPS to memory.

CR6
Yellow
nMEMRDYd/
nMEMRDY
Lit indicates that memory can be written to.
CR7
Yellow
DRRE
Lit indicates that memory can be red from
Table 6 IDFE Print Server LEDs

LED
Color
Signal
Comment
Link
Indicates integrity of Ethernet connection
Activity
Indicates activity on the Ethernet connection
Table 7 IDFE BNC Transceiver LEDs

LED
Color
Signal
Comment
Link
Activity
Table 4 Post-IPS PWBA LEDs

LED
Color
Signal
Comment
CR1
Yellow
/IPSRST
IPS Reset from IOT CPU PWBA
CR2
Yellow
/LIPS-STAT
From Post-IPS PWBA CPU; Status output to

IOT CPU PWBA
Table 8 Edit PWBA LEDs

LED
Color
Signal
Comment
CR1
Yellow
+3.3 VDC
Indicates presence of +3.3 VDC to PWBA
CR2
Yellow
+5 VDC
Indicates presence of +5 VDC to PWBA
Yellow
CPE_PS
Page Sync signal from Post-IPS PWBA to

Edit PWBA
Yellow
PS0
Page Sync signal from Edit PWBA to PostIPS PWBA
CR3
Yellow
/IPS-CON
Control input from IOT CPU PWBA; after

buffer
CR3
CR4
Yellow
/LIOTEPS1
Page Sync from IOT CPU PWB to Post-IPS

PWBA. Lit when signal is active.
CR4
CR5
Yellow
/LIOT\PS0
Page Sync from Post-IPS PWBA to IOT CPU

PWBA
CR6
Yellow
LSFMSP0
Output Page Sync signal from SFM1 ASIC.

CR7
Yellow
LED0, TIOCA3
From Post-IPS PWBA CPU
CR8
Yellow
LED1, TIOCB3
CR9
Yellow
LED2, TIOCC3
CR10
Yellow
LED3, TIOCD3,
CR11
Yellow
LED4, TIOCA4
CR12
Yellow
LED5, TIOCB4
CR13
Yellow
LED6, TIOCA5
CR14
Yellow
LED7, TIOCB5
Table 5 IDFE Motherboard LEDs

LED
Color
Signal
Comment
<To Be
Green
Supplied>
Power
Indicates DC power available to Motherboard
<To Be
Green
Supplied>
Link
Yellow
Activity
Red
Failure
Software controlled with various patterns;

indicates fault detection Drente software
boot-up sequence test
Yellow
Heartbeat
Software controlled with stable pattern; indicates proper operation of software
PWBA LEDs
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PWBA Test Points
Table 2 IOT Drive PWBA Test Points
As shown in Table 1 and Table 2, some of the PWBAs contain test points which can be monitored.
Table 1 IOT CPU PWBA Test Points
Test Point
Level
Comment
TP11
+5VDC
IC Supply Voltage
TP12
Ground
IC Supply Ground
TP13
Ground
IC Supply Ground
TP14
+5VDC
IC Supply Voltage
Test Point
Level
Comment
TP2
TTL
Send data to PWS
TP15
0 to +5VDC
HR_Cont_Sys From Fuser
TP3
TTL
Receive data from PWS
TP16
0 to +5VDC
E_HR_Cont_Sys
TP4
TTL
Send data to IIT
TP17
+12VDC
Supply Input
TP5
TTL
Send to EPSV (FX only)
TP18
+24VDC
Interlocked Supply Input
TP6
TTL
Send to Tray 6 (HCF)
TP19
0 to +5VDC
PR_Cont_Sys
TP7
TTL
Send to Decurler
TP20
0 to +5VDC
ADC_SNR_VP
TP8
TTL
Receive from IIT
TP21
0 to +5VDC
ADC_SNR_V_DIF
TP9
TTL
Receive from IPS
TP22
TTL
ADC_LED_ON
TP11
TTL
Receive from UI
TP23
0 to +5 VDC
DTS_DC_V_MONI
TP12
TTL
Receive from EMB Scan
TP24
0 to +15 VDC
2BTR_V_MONI
TP13
+5V DC
Power Input
TP26
0 to +5VDC
Pre Reg1 Snr
TP14
TTL
Receive from EMB Print
TP27
0 to +5VDC
Reg1 Snr
TP15
TTL
Receive from Dual Device Interface

(DDI) Scan
TP28
+24VDC
Supply Input
TP16
TTL
Receive from DDI Print
TP17
TTL
Send to DDI Print
TP18
TTL
Send to DDI Scan
TP19
TTL
Send to EMB Print
TP20
TTL
Send to EMB Scan
TP21
0V
Ground
TP22
+5V DC
Power Input
TP23
----
Not Used
TP24
TTL
Send to UI
TP25
TTL
Send to IPS
TP26
0V
Ground
Test Point
Level
Comment
TP1
+5VDC
VAREF
TP2
TTL
/Fuser On
TP3
TTL
PCC_AC_PWH
TP5
0 to +5VDC
PR_DH_Sys, From Fuser
TP6
0 to +5VDC
Sys_Ext_H/R_Cont From Fuser
TP7
0 to +5VDC
Temp_Air_Therm1
TP8
0 to +5VDC
HR_On_Sys From Fuser
TP9
Ground
12V Return
TP10
-12VDC
Supply Input
Table 2 IOT Drive PWBA Test Points
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PWBA Test Points
Copier Timing
The main machine timing signal is the Transfer Roll Zero (TR0) Signal. This signal is used to
synchronize the various steps of the process to correctly position the image on the output
media. TR0 is produced when the leading edge of a timing strip across the Intermediate Belt
Transfer (IBT) Belt passes over the TR0 sensor.
The IBT has two timing patches which are separated by one-half of the IBT circumference.
Since the IBT has a circumference of the IBT is 527.81 mm, this means that the two timing
patches are 263.905 mm apart. Therefore, an 8-1/2 x 11 or A4 sheet (or smaller) will fit LEF
on the IBT between the timing patches and two sheets will fit on the entire IBT. An 11 x 17,
12x18 or A3 sheet will fit SEF on the entire IBT, across one of the patches.
In addition, the Drum Motor includes an encoder which outputs one pulse per revolution to the
IOT Drive and Control PWBAs. This is used for motor speed control rather than as a paper
transport timing reference. The Interval between TR0 pulses and the frequency of the Drum
Motor output pulses depends on the process speed. The process speed depends, in turn, on
the type of media being used for the copies. The following Table shows the correlation between
these three factors.
Table 1 Copy Input Media, Process Speed and TR0 Interval
Input Media
Process Speed
Motor Clock
Pulse Frequency
TR0 Interval
Extra Heavy Weight

164-250 gsm paper
90-140 lb index
90 lb cover
Transparencies
59.82 mm/sec
544.0 Hz
4.412 sec
Heavy Weight
106-163 gsm paper
28-90 lb index
129.68 mm/sec
1179.4 Hz
2.035 sec
Normal
less than 105 gsm paper
less than 28 lb index
219.47 mm/sec
1996.0 Hz
1.202 sec
Transparency material must be inserted in Tray 5 and can be detected automatically. For other
media, the user must manually enter its weight at the start of a job. Therefore, the machine
knows the paper copy weight of the start of a job and adjusts the process speed accordingly.
The default value is paper less than 105 gsm or 28 lb. Therefore, the default process speed is
220 mm/sec.
Copier Timing
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Job Control
The User Interface (UI) PWBA provides overall job control through communications with the
IOT CPU PWBA. The TR0 signal controls the timing of the job control sequence.
Job Control Sequence

This machine is capable of a large variety of job control sequences, depending on how it is
being used:
Is the task a print job from the DFE or a copy job from the Platen?
Is the output sheet size larger than 8.5 X 11 and A4?
Is the output simplex or duplex?
Does the output include color?
Does the unit include a DADF? Is its automatic feed function being used?
Does the unit include an output Mailbox/Sorter option?
Does the unit include an OCT option?
These factors can be mixed in any combination.

Figure 1 shows the job control sequence when using the machine as a Printer accessed from
the DFE. This figure shows decisions for:
Small prints (8.5 x 11/A4 and smaller) vs. larger sheets
Color vs. black and white images. Note that this decision is made on a sheet by sheet
basis, not for the entire print job
Simplex vs. duplex operation
This figure ignores Mailbox/Sorter and OCT operation.

Figure 2 shows the job control sequence shows decisions for print size and color/B&W operation. This figure ignores the simplex/duplex output decision, Mailbox/Sorter operation and OCT
operation.
Figure 3 shows the job control sequence with originals placed in the DADF. Like Figure 2, this
figure shows the job control sequence making decisions for print size and color/B&W operation. However, it ignores the simplex/duplex output decision, Mailbox/Sorter operation and
OCT operation.
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Job Control
Figure 1 Machine as a Printer: Print Simplified Job Control Sequence
Job Control
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Figure 2 Machine as a Copier: Copy Simplified Job Control Sequence - Original on Platen
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Job Control
Figure 3 Machine as a Copier with DADF: Copy Simplified Job Control Sequence - Originals in DADF
Job Control
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Digital Front End
Foreign Interface
The DFE includes the hardware and software which permits the machine to function as an
Internet server. In this capacity, the machine can be used as a 400 dpi color scanner or 600 dpi
color printer using a variety of software. Refer to Chapter 12, which describes the IDFE in
detail.
The following Figure 1 shows the Foreign Interface permits connection of external accessories.
These accessories include a Copylyzer, Coin Operation Unit, Xerox Card unit, Foot Switch
and/or a Key Switch.
Figure 1 Foreign Interface Simplified Block Diagram
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Digital Front End, Foreign Interface
Digital Front End, Foreign Interface
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Overview
Main Motor
The Start Power Chain comprises the Main Motor and Drum Motor, their control circuitry and
their mechanical drive systems. The Start Power Chain is activated when the user presses the
Start button on the User Interface with the machine powered.
The Main Motor is a multispeed motor whose speed is controlled by a clock signal from the IOT
CPU PWBA. As shown in Figure 1, the Main Motor drives the following machine elements:
The Mag Roller, the Auger, and the Pickoff Roll (BPO) in the Developer Subsystem
The Intermediate Belt Transfer (IBT) Cleaner Cam and the IBT Cleaner Auger
The IBT Second Bias Transfer Roller (BTR)
The Waste Toner Auger, the Waste Toner Bottle Entrance Auger and the Toner Bottle
The Photoreceptor (PR) Drum Brush, the PR Drum Cleaner Auger Rear and the PR Drum
Cleaner Auger Front
MAIN MOTOR
MAIN MOTOR DRIVE

BELT (1 OF 2)
Figure 1 Main Motor Location and Mechanical Drive System

The Main Motor operates at three speeds, depending on the type of blank media being processed. Motor speed is controlled by the IOT CPUIOT CPU PWBA which uses its address and
data buses to write control data to decoder circuitry on the IOT Drive PWBA.
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Motor speed is controlled by the IOT CPU PWBA which uses its address and data buses to
write control data to decoder circuitry on the IOT Drive PWBA. As shown in Figure 2, the individual outputs from the decoders are sent through drivers to the motor. Table 2 shows the Main
Motor operating states resulting from various combinations of control lines.
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Overview, Main Motor
Figure 2 Main Motor Control Circuit

Table 1 Main Motor Control Lines and Condition
On
Sel 1
Sel 2
CLK
Main Motor Operating Condition
N/A
Motor Off
545.37 Hz
59.82 mm/sec process speed
N/A
Not used
1182.31 Hz
130 mm/sec process speed
2000.8 Hz
Drum Motor
The Drum Motor is a clock-controlled multispeed device which can operate at three different
speeds, as shown in Table 2. Also like the Main Motor, the Photoreceptor Motor is controlled by
the IOT CPU PWBA and IOT Drive PWBA. The Photoreceptor Motor includes two additional
connections: BRAKE ON and ENC A. Figure 1 shows the control and power lines going to the
Drum Motor, and Figure 2 shows the motors location.
Main Motor, Drum Motor
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Figure 1 Photoreceptor Motor Control Circuit

Table 1 Photoreceptor Motor Control Lines and Condition
On Gain 1 Gain 2 CLK
Brake
ENC A
Main Motor Operating Condition
N/A
0 Hz
Motor Off
544.0 Hz
544.0
N/A
1179.4 Hz
1179.4
1996.0 Hz
1996.0
0 Hz
Locked
Not used
The Photoreceptor Motor drives the Photoreceptor Drum and the IBT Drive Roll.
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Drum Motor
PHOTORECEPTOR
DRUM DRIVESHAFT END
PHOTORECEPTOR
DRUM MOTOR
Figure 2 Photoreceptor Motor Location and Mechanical Drive System
Drum Motor
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Overview
This chapter describes the electrical and mechanical components of the Duplex Automatic
Document Feeder (DADF). The DADF performs these primary functions:
Automatically feeds a document or a stack of documents, one at a time, from an Input

Tray onto the Platen Glass of the machine for copying.
Deskews the document before copying.
Aligns the document onto the Platen Glass for proper copier registration.
Automatically inverts (turns over) a two-sided document, deskews, and registers it onto
the Platen Glass for copying the second side of the document.
Automatically stacks the documents that have been copied onto an Output Tray. A user
selected option allows two-sided documents to be re-inverted (turned over again) for
proper stacking onto the DADF Output Tray.
This chapter will cover the following:
Overview
Electrical Power
DADF System Control
DADF Document Transport
DADF Operation
The original documents are placed face up onto the Input Tray. The documents are fed from the
top of the stack into the DADF. A Nudger Roll supplies the top sheet to the nip of the Feed and
Retard Roll. The Feed Roll transports the document sheet to the Registration Roll. The DADF
temporarily stalls the Registration Roll to deskew the document before sending it to the Platen
Belt. The Platen Belt, driven by a Belt Motor, positions the document on the Platen Glass. For
one-sided documents, the Platen Belt moves each document to the Output Tray when scanning is complete. For two-sided documents, each document is routed through an invert path,
then scanned again. Depending on a user selection, the document can be again routed
through the invert path to preserve original order stacking after scanning. Regardless of what
has proceeded, the document is ultimately routed to the Output Tray by the Platen Belt and Exit
rolls. Refer to DADF Document Transport and Inverting Documentation for additional information.
The DADF can automatically sense the document size. This is done by:
Two Size Sensors in the DADF read front to back dimensions (feed width)
A pulse count of the Belt Motor while the Registration sensor is blocked and reads the
(run) length dimension
The DADF has two operator selectable modes:
Same Size Mode is used when all documents are of the same size. This mode provides
the highest productivity, since the copier does not slow down to detect the size of each
document.
Mixed Size Mode is used when documents of different sizes are placed in the DADF. The
copier automatically detects the size of each document as it is fed onto the Platen Glass.
Figure 1 shows the DADF.
DADF INPUT TRAY
When either of these modes are selected, they will be applied to all the documents in the stack.
Refer to DADF Document Size Sensing for more information on this function.
DADF OUTPUT
TRAY
Figure 1 Duplex Automatic Document Feeder
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Overview
Electrical Power
All electrical components in the DADF operate on +5 VDC or +24 VDC power supplied by the
IIT/IPS LVPS. Figure 1 shows the location of the power supply. The +24 VDC power for the
Exit and Belt Motors is routed through individual fuses on the DADF Control PWBA.
IIT/IPS LVPS
Figure 1 IIT/IPS LVPS
Electrical Power
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DADF System Control

The DADF Control PWB monitors the status and controls the operation of the DADF. The
DADF Control PWBA also accepts commands from the Pre-IPS PWBA and provides it with
status information, such as DADF Belt Motor status and a Document Ready signal. However,
the Pre-IPS is itself partially controlled by the IOT CPU PWBA (via the Post-IPS PWBA).
Therefore, DADF control is ultimately a shared function of these three PWBAs. Command and
status communication with the DADF uses a bidirectional serial communications port. Refer to
Figure 1 for a DADF simplified block diagram and Figure 2 for the communication links
between the DADF and the machine.
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DADF System Control
Figure 1 DADF Control Simplified Block Diagram
DADF System Control
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The DADF feeds the documents in the Input Tray Assembly from the top of the stack. For single-sided document copying, the following process is used:
1.
The document is transported from the Input Tray onto the Platen Glass.
2.
The downward facing side of the document is scanned.
3.
The document is transported to the Output Tray
For two-sided copying, additional steps are required.
Figure 2 DADF Simplified Control Communications Path

The DADF Control PWBA includes several LEDs to rapidly determine the status of selected
signals. Table 1 lists these LEDs.
Color
Signal
Comment
CR2
Green
RXD
Flickering indicated serial data from Pre-IPS

PWBA
CR3
/Reset
Lit when DADF Control PWBA CPU is being

reset
CR4
+5 VDC
Lit when +5 VDC present
CR5
+24 VDC
Lit when +24 VDC present
The document is transported from the Input Tray onto the Platen Glass.
2.
Side one is scanned
3.
The document is transported through an inverter paper path within the DADF and back to
the Platen Glass for copying the second side.
4.
Side two is scanned
5.
When selected by the user, the document may again be sent through the inverter and
again placed on the Platen Glass. This preserves the original order of the documents.
6.
The document is transported to the Output Tray.
To load the Input Tray, the user positions the document by placing its left side against the raised
Entrance Gate. The back edge of the document is placed against the Back Guide of the Input
Tray.
Table 1 DADF Control PWBA LEDs

LED
1.
The DADF can automatically feed up to 40 copies/minute (A4 or 8.5x11 LEF) onto the Platen
Glass for copying.
The Input Tray capacity is:
DADF and IIT Interaction

The DADF detects the size of each original document while the document is fed from the input
tray onto the platen glass. The Fast Scan or Y dimension is determined by two size sensors
just before the Registration Roll in the paper feed path. The Slow Scan or X dimension is determined by measuring the length of time that Registration Sensor is blocked for a known transport speed.
50 sheets of 38-100 gsm (10-24 lb.)
40 sheet of 101-128 gsm (24-30 lb.)
The document weight range for duplex copying from the DADF is 50 - 110 gsm (13-28 lb.). This
is because the DADF has a sharp turn in the inverter paper path.
Document Feeding Components

Figure 1 shows the document transport components of the DADF. Figure 2 shows the locations
of the sensors.
These dimensions are passed from the DADF Control PWBA to the Pre-IPS PWBA using their
serial communications link. The Pre-IPS PWBA compares these values with the contents of a
lookup table in its NVM. This measurement technique reduces the delay between the documents arrival on the platen glass and the start of document scanning.
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DADF System Control, DADF Document Transport
Drive Motors
Upper Duplex Roll
Feed Roll
Retard Roll
Table 1 DADF Motor Driven Rolls
Exit Roll
Nudger Roll
Motor
Rolls
Transport Speed
(Forward - ccw)
Feed Motor
+ 24 VDC
Nudger Roll (cw)
223.9 mm/sec
Feed Roll (cw)
268.7 mm/sec
Belt Motor
+24 VDC Stepper
Bi-directional
Registration Rolls
810.6 mm/sec
Belt Drive Rolls
806.0 mm/sec
671.7 mm/sec
873.7 mm/sec
when re-inverting
for exit stacking
only
Upper Duplex Rolls
671.7 mm/sec
873.7 mm/sec
when re-inverting
for exit stacking
only
Pinch Rolls
Registration Roll
Lower Duplex Roll
Exit Motor
+24 VDC Stepper
873.7 mm/sec
Lower Duplex Roll
Belt Idler Roll

Belt Drive Roll
Transport Speed
(Reverse - cw)
Exit Rolls
840.2 mm/sec
Figure 1 DADF Drive Component Locations

Feed Motor
SIZE SENSORS
(F and R)
TOP COVER INTERLOCK

SWITCHES (F and R)
The Feed Motor is controlled by the DADF Control PWBA and turns the Nudger and Feed
Rolls. The Nudger Rolls feeds the top sheet into the nip of the Feed and Retard Roll. The Feed
Roll turns against the Retard Roll, which drags against sheets below the top and prevents prevent multiple sheet feeds.
The Feed Motor is energized 200 msec. after the user presses the Start Button. The Feed Roll
takes the top document in the stack and transports it into the nip of the stationary Registration
Rolls. The Feed Motor deenergizes 50 msec.after the trailing edge of the document passes the
Registration Sensor.
DUPLEX
SENSOR
DOCUMENT
SENSOR
REGISTRATION
SENSOR
DADF OPENSWITCH (R)
EXIT
SENSOR
The DADF Control PWBA does not energize the DADF Feed Motor unless the following safety
interlock switches are closed:
The Platen Interlock is closed by lowering the DADF onto the Platen Glass.
Two Top Cover Interlocks are closed by closing the top cover on the left side of the DADF.
Belt Motor Drive

Figure 2 DADF Sensor Locations
The DADF Belt Motor is a +24 VDC, bidirectional stepper motor. This motor drives these rollers:
Registration Roll
Belt Roll
Lower Duplex Roll
Upper Duplex Roll
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Table 1 shows the speed and direction of the rollers driven by the DADF Belt Motor drive.
A description of these sensors follows:
The DADF Belt Motor operates in the forward direction when moving documents from the Input
Tray Assembly to the Platen Glass, and when moving documents from the Platen Glass to the
Output Tray.
Document Set Sensor - When a document is loaded into the Input Tray, it pushes a lever
causing a flag to block this sensor. This signal is sent to the DADF Control PWB.
Size Sensors (2) - These are reflective Optical Sensors that sense the document length of
the leading edge. See DADF Document Size Sensing for more information on this function.
Registration Sensor - This is a reflective Optical Sensor that is before the Registration
Roll. It is used to sense misfeeds from the Input Tray and to start the time sequence for
deenergizing the Feed Motor and energizing the Belt Motor.
The Belt Motor moves in the reverse direction to turn over the document for copying the second side, and for re-inverting the document for correct order stacking in the Output Tray. Refer
to Inverting Documentation for more information on this function.
This sensor also is used to determine the documents transport run length. This is calculated by multiplying the length of time that the sensor is blocked by the transport speed of
the DADF.
Duplex Sensor - This is a reflective Optical Sensor in the inverter paper path the senses
paper jams.
Exit Sensor - This is a reflective Optical Sensor that is used to verify documents exit to the
Output Tray, indicate paper jams, signal the DADF PWB to deenergize the Exit Motor and
to energize the Set Gate Solenoid to raise the Set Gate.
Refer to Figure 2 for more information on the use of sensors for DADF control.
Document Feeding Control

The document is fed from the top of the stack. The feed edge of the document is placed
against the Entrance Gate in the Input Tray Assembly. The Entrance Gate is in the raised position when no documents are covering the Document Set Sensor, and the front and rear Top
Cover Interlocks are both closed.
When the Document Sensor senses a document in the DADF Input Tray Assembly and after
the user presses the machines Start button, the Entrance Gate Solenoid drops the Entrance
Gate so that the document can be fed into the DADF.
DADF Document Size Sensing

The document length (transport dimension) is measured by the DADF Control PWBA counting
the number of Belt Motor pulses while the document passes the Registration Sensor. The
width of the document is determined by the Front and Rear DADF Size Sensors. The Rear (#1)
DADF Size Sensor is positioned 226 mm from the rear guide of the Input Tray Assembly. The
Front (#2) DADF Size Sensor is positioned 287 mm from the rear guide of the Input Tray
Assembly. Table 2 lists the states of these two sensors for the different sizes of documents.
Figure 3 Belt Motor Drive Rotation

Exit Motor
The Exit Motor is a +24 VDC stepper motor that drives the Exit Roll. The Exit Motor is energized when each document has been scanned and the document is not being routed through
the invert path. Its run duration depends on the document run length dimension. The DADF
Control PWBA provides drive to the Exit Motor in intermittent pulses. This technique is used to
help conserve energy consumption in the machine. An Exit Senor senses the document trailing
edge and this signal is sent to the DADF Control PWB. This signal deenergizes the Exit Motor.
Table 2 DADF Document Size Sensing

Document Size
(in)
Length of
DADF Rear (#1) DADF Front (#2) detected Original
Length of
(mm)
Sensor
Sensor
Original (mm)
A4 SEF
OFF
OFF
240.14
297
Refer to Figure 1 for more information on the timing of the DADF motors.
B5 SEF
OFF
OFF
200.14
257
A5 SEF
OFF
OFF
153.14
210
DADF Sensors
A5 LEF
OFF
OFF
91.14
148
8.5x14 SEF
(Regal)
OFF
OFF
298.74
355.6
The DADF uses six sensors for detecting document transport and document size. Refer to Figure 2 for more information on the DADF sensor timing.
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Table 2 DADF Document Size Sensing

Document Size
(in)
Length of
DADF Rear (#1) DADF Front (#2) detected Original
Length of
Sensor
Sensor
(mm)
Original (mm)
8.5x11 SEF (letter)

8 x10.5 SEF
8x10 SEF
OFF
OFF
197.14~222.54
254~279.4
8.5x13 SEF
8.5x12.4 SEF
OFF
OFF
258.1~273.34
314.96~330.2
5.5X8.5
OFF
OFF
82.84
139.7
11X17 SEF
11X14.9 SEF
ON
OFF
321.6~374.94
378.46~431.8
B4 SEF
ON
OFF
307.14
364
8.5X11 LEF (letter)
ON
OFF
159.04
215.9
8.5X11 LEF
8X10.5 LEF
8X10 LEF
ON
OFF
146.34~159.04
203.2~215.9
B5 LEF
ON
OFF
125.14
182
A3 SEF
ON
0N
363.14
420
A4 LEF
ON
ON
153.14
210
There are two possible document path faults that can be determined by the size sensing system. The following message is displayed by the IOT. The Document Feeder has a failure. This
message is displayed when:
The Front and Rear Size Sensors detect a document and the DADF is not in use.
The Front and Rear Size Sensor detects a document, but the Registration Sensor does
not detect a document.
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DADF Operation
Document Loading
The operator loads the original documents face up into the Input Tray Assembly. The operator
aligns one edge against the Rear Paper Guide and moves the documents to the left until the
documents stop against the Entrance Gate.
Entrance Gate and Entrance Gate Solenoid
The Entrance Gate is raised and lowered by a Entrance Gate Solenoid. The Entrance Gate is
in the raised position for any of the following conditions:
There are no documents covering the Document Set Sensor and the trailing edge of the
last document passes the DADF Exit Sensor from this or a previous job.
The copier machine runs through the Start Power procedure.
The DADF Document Set Sensor senses when documents are loaded into the Input Tray
Assembly. A green arrow appears in the LED window at the top back cover of the DADF to indicate proper document loading of the DADF. When the Entrance Gate is in the raised (up) position, it also holds up the Nudger Roll so that documents can be loaded into the Tray.
When the Start Button is pressed on the machine, the Entrance Gate Solenoid energizes
downward for 300 ms, and the solenoid magnetically latches in that position. In this position,
the solenoid holds the Entrance Gate down, allowing documents to be fed past the Gate. This
Gate remains down for the entire copy job.
After the last document has passed the DADF Exit Sensor, the DADF Control PWBA energizes
the Entrance Gate Solenoid in the up direction, causing it to release the Entrance Gate. The
solenoid latches in the up position.
Refer to Figure 1 for more information on DADF operation timing.
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DADF Operation
Figure 1 DADF Timing Sequence

DADF Operation
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Prefeed and Feed operation
The document Prefeed and Feed operation is activated when the Start Button is pressed. This
energizes the Feed Motor, which drives both the Nudger Roll and Feed Roll. The Nudger Roll
feeds the top document into the nip of the Feed Roll and the Retard Roll. The Feed Roll transports the document, one sheet at a time, into the DADF. The Feed Rolls work against friction
Retard Rolls to assure single feed operation.
The Belt Motor operates in one direction during document feed, registration, transport to the
Platen Glass and document exit. The Belt Motor reverses direction when inverting the document.
Two-sided documents are routed through the DADF differently than single sided documents:
The document is first de-skewed at the Registration Rollers.
The document is registered on the Platen Glass by the Platen Belt.
For single sided documents, the new document sheet is not fed from the Input Tray
Assembly until the current document sheet passes and clears the DADF Registration
Sensor.
For two-sided documents, the new document sheet is not fed from the Input Tray Assembly until the current document sheet has been inverted through the DADF inverter path
and clears the DADF Registration Sensor a second time.
For two-sided documents to be re-inverted, the new document sheet is not fed from the
Input Tray Assembly until the current document sheet has been sent through the DADF
inverter path a second time, and it passes and clears the Registration Sensor for a third
time.
#2 Duplex Roll (one-way clutch)
There are two steps used in the DADF to register the document:
Registration Roll and Registration Pinch Roll

The Belt Motor drives the Registration Roll through a belt. The Registration Roll uses a oneway clutch and rotates forward only when the Belt Motor is rotating in the forward direction. The
Registration Roll creates a nip with the Registration Pinch Roll.
The Belt Motor is deenergized and the Registration Roll is stationary when the lead edge of the
document enters the registration nip. The Feed Motor continues to drive the document for 50
msec to de-skew the lead edge of the documentation against the Registration Roller nip. Then,
the Belt Motor turns the Registration Roll and transports the document to the Platen Belt.
Nudger Roll
Platen Belt and Belt Roll
When the Entrance Gate is in the up position, it holds the Nudger Roll up so that documents
can be loaded into the Input Tray. When the Start Button is pushed on the copier machine, the
Entrance Gate drops. This allows the Nudger Roll to drop onto the top copy of the documentation and feed a sheet into the nip of the Feed Roll and the Retard Roll. The Feed Motor drives
the Nudger Roll through a belt drive, and operate in one direction using internal one-way
clutches.
The Belt Motor drives the Belt Roll through a belt. The Belt Roll moves the Platen Belt, transporting the document onto and across the Platen Glass. The Belt Motor pulses for 51 counts
after the trailing edge of the document passes the Registration Sensor. This positions the document onto the Platen Glass for copying.
Feed Roll
The Feed Motor drives the Feed Rolls through a belt. The Feed Rolls rotate in only one direction, using a one-way internal clutch. The Feed Roll transports the document from the Input
Tray Assembly, past the Registration Sensor and into the nip of stationary Registration Rolls.
The Feed Motor deenergizes 50 msec after the Registration Senor senses the lead edge of the
document. The document being fed by the Feed Roll into the stationary Registration Rolls deskews the document.
For single sided documents: Immediately after the document has been scanned by the copier,
the Belt Motor energizes in the forward direction. This moves the copied document off the
Platen Glass and feeds the next document to be copied from the Registration Roll onto the
Platen Glass. Again, the Belt Motor pulses for 51 counts to register the second document to be
copied onto the Platen Glass.
For two sided documents: See Inverting Documentation
Inverting Documentation
The DADF can automatically turn over two sided documents to copy both sides.
Retard Roll
The Retard Roll is not motor driven. This roll uses internal one-way clutches to provide the
needed friction resistance for single sheet feed operation. A spring lever rests against surface
of the Retard Roll inside the mounting assembly. The lever rotates the Retard Roll a small
amount each time the Retard Roll is pushed down and released by a passing document. This
movement prevents uneven wear around the Retard Rolls. (verify!)
Registration System
The DADF Belt Motor drives the registration system. This bi-directional stepper motor uses a
belt drive to power the following rollers:
Registration Roll (one-way clutch)
Belt Roll (bi-directional)
#1 Duplex Roll (one-way clutch)
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Belt Motor Reversing

The DADF uses a bi-directional stepper Belt Motor to invert the documents. For two-sided document handling, the Belt Motor first energizes in the forward direction (ccw when viewed from
the machine front) to feed the top, or side one, of the document onto the Platen Glass for copying. After side one has been copied, the Belt Motor reverses direction. This causes the Platen
Belt to run in reverse direction, transporting this original document from the Platen Glass into
the inverter path. See Figure 3 concerning the assemblies driven by the Belt Motor in forward
and reverse directions.
The Lower and Upper Duplex Rollers are driven through one-way clutches. They activate only
when the Belt Motor is energized in the reverse (cw) direction. The Lower and Upper Duplex
Rolls turn over the document so that side two will face the Platen Glass for copying.
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DADF Operation
As the document comes out of the inverter path, the lead edge passes the Registration Sensor
and enters the nip of the stationary Registration Roller for deskewing. 50 msec after the lead
edge passes the Registration Sensor, the Belt Motor deenergizes for 200 msec. The Belt Motor
then energizes in the forward (ccw) direction. This activates the Registration Roll in the forward
direction which transports the inverted document to the forward running Platen Belt. Side two
of the document is then registered onto the Platen Glass for copying.
The user has the option to re-invert the duplex document, so that side one is stacked face
down on the Output Tray. This is initiated after the second side has been copied. The Belt
Motor reverses direction again to transport the document back through the inverter path. Coming out of the inverter path, the document delays at the Registration Roll, primarily so the Belt
Motor can change back to the forward direction. The document is then transported through the
Registration Roll, across the Platen Glass and to the Exit Rolls. The speed through the inverter
path and across the Platen Glass is increased for this inversion process.
Registration Gate Solenoid
The Registration Gate on the copier by the Platen Glass must be lowered at the start of the
inversion cycle, so the document can enter the inverter path as the Platen Belt reverses for
duplex copying. This is accomplished by activating a Registration Solenoid in the DADF. This
solenoid presses down on the gate any time the Platen Belt is in reverse. When the Belt Motor
changes to a forward direction, the Solenoid deenergizes. This permits springs to raise the
Registration Edge.
Inverter Drive Rollers
The DADF Lower and Upper Duplex Roll transport the document as it travels through the
DADF Inverter Paper Path. Because of their one-way clutches, the rolls are driven only when
the Belt Motor energized in the reverse (cw) direction. A belt connects the motor to the rolls.
Exit System
Documents are moved to the Output Tray by a the Exit Roll. This is a +24 VDC stepper motor,
which is pulsed conserve energy. The Exit Motor is controlled by the DADF Control PWBA,
when it is informed by the Pre-IPS PWBA that the page has been scanned.
When the Exit Sensor detects the lead edge of the document, the DADF Control PWBA begins
counting Exit Motor pulses. The Exit Motor continues running until an adequate number of
pulses has been counted. The exact number depends on the run dimension of the document,
as determined while the document was being fed onto the Platen.
After the document has been removed from the Platen, the Exit Motor is deenergized.
DADF Operation
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Overview
This machine performs three possible functions: scanning, printing and copying. As shown in
Figure 1, the sources of the image and its processing paths are different, although several
assemblies are used by more than one function. Figure 2, Figure 3 and Figure 1 show the locations of some of the assemblies related to image processing.
As shown in Figure 1, imaging includes the following subsystems:
1.
The Image Input Terminal (IIT) senses the image, converts it to a digital format and compensates for differences in original document attributes.
2.
The Image Processing System (IPS) converts between color spaces, provides for image
editing and converts the signal from 400 dpi to 600 dpi.
3.
The Image Source Selector (ISS) permits a Digital Front End (DFE) to provide a print
image to the following subsystems or the preceding subsystems to provide a scanned
image to the DFE.
4.
The IOT Image Processing subsystem selects between inputs from the DFE and the preliminary IPS, converts the image from digital form to analog form and provides the analog
signal to the Laser Diode Driver (LDD).
5.
The Image Output subsystem accepts the analog drive signal and uses it to modulate the
Raster Output Scanner (ROS).
The machine can have two possible configurations: Digital Copier (DC) or Copier Printer (CP).
These correlate to functions and assemblies as shown in Table 1. The DC configuration cannot
perform either scanning or printing because it lacks a DFE.
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Overview
Figure 1 Imaging Simplified Signal Flow Diagram
Overview
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A separate IIT/IPS Low Voltage Power Supply (LVPS) supplies all of the preliminary IPS
assemblies, the Pre-IPS PWBA in the IIT and most of the image scanning assemblies and circuitry. However, the Xenon Lamp which illuminates original document is powered by a dedicated power supply.
POST-IPS PWBA
LASER DIODE
DRIVE PWBA
IIT/IPS LVPS
VSEL EXTENSION
PWBA
RASTER OUTPUT
SCANNER (ROS)
VIDEO SELECT (VSEL)
PWBA (TOP LAYER)
PRE-IPS PWBA
(TOP LAYER)
HALFTONE PWBA
(BOTTOM LAYER)
MEMORY PWBAS
(MIDDLE LAYER)
MEMORY SYSTEM PWBA (BOTTOM LAYER)
BR PWBA
(TOP LAYER)
Figure 3 IPS Major Assemblies Locations (Below IIT/IPS Tray)
Table 1 Machine Configuration vs. Included Imaging Functions and Assemblies
Figure 2 IIT and IPS Major Assemblies Locations (IIT/IPS Tray)
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Configuration
Included Imaging
Functions
Digital Copier
Copying
Copier/Printer
Scanning, Printing and Copy- Same as Copier Only

ing
Included Imaging Assemblies

Scanning Assemblies and Circuits, PreIPS PWBA, Memory PWBA, Post-IPS
PWBA, VSEL PWBA, Halftone PWBA,
LDD PWBA, ROS
Overview
Image Sensing (Digital Copier & Copier/Printer

Configuration)
The image sensing components are shown in Figure 2 and Figure 3.
XENON LAMP
HALR-RATE
CARRIAGE
FULL-RATE
CARRIAGE
CARRIAGE
MOTOR
MOTOR/
LAMP/FAN
DRIVE PWBA
CCD LENS
CCD ARRAY
Figure 1 Scanning Optical System Mechanical Components Locations
Figure 2 Motor/Lamp/Fan Drive PWBA Location
Xenon Lamp and Drive Circuitry

A Xenon Lamp (Figure 1) is used in this machine as a means of reducing heat. Unlike incandescent Lamps, including quartz Lamps, the illumination of Xenon Lamp is not continuous It
varies directly with the instantaneous voltage of the driving signal. This is similar to fluorescent
bulbs and means that if the driving signal is AC (Alternating Current), the bulb emits no light
when the instantaneous voltage is zero.
If the bulb drive frequency is 60 Hz or higher, the human eye sees this as a constant level of
illumination. However, the CCDs on the CCD PWBA are fast enough to see the change in illumination caused by the AC drive signal used for the Xenon Lamp. Therefore, the CCD must
capture its image when the Xenon Lamp outputs are known to be non-zero.
Two techniques are used to compensate for this:
Image Sensing (Digital Copier & Copier/Printer Con-
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The Pre-IPS PWBA adjusts the effective sensitivity of the CCD so that it is the inverse of
the Xenon Lamp AC drive signal.
The drive signal to the Xenon Lamp is intermittently interrupted as shown in Figure 4.
Figure 3 IIT Lamp, Motor and Fan Simplified Block Diagram
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Figure 4 Xenon Lamp Interrupted Drive Waveform
Carriage Motor and Drive
The Carriage Motor is a high-torque five-phase stepping motor driven by five magnetic control
lines: A through E. These lines are +24 VDC outputs of the Motor/Fan/Lamp Driver PWBA
which is under the control of the CPU on the Pre-IPS PWBA. +24 VDC is applied to all lines
when the motor is locked in one position.
C is the distance between the mirrors on the Half-Rate Carriage, and is constant
D is the maximum distance between the bottom Half-Rate Carriage mirror and the stationary mirror in front of the CCD PWBA. This occurs when the two carriages are at the start
of their travels. During carriage travel, this distance decreases to a minimum of D - T.
The motor uses rubber dampers to isolate vibrations from the rest of the IIT. It also uses magnetic damping to maintain a constant speed.
The motor emits a pulse ever 0.72 degrees of rotation. This is equivalent to 500 pulses per one
complete motor revolution. These pulses are routed back to the Motor/Fan/Lamp Driver PWBA.
This assembly uses the interval between the pulses to determine if the carriage speed is correct and the cumulative number of pulses to determine the current location of the carriage.
B is the minimum distance between the Full-Rate Carriage mirror and the top mirror on
the Half-Rate Carriage. This occurs when the two carriages are at the start of their travel.
During carriage travel, this distance increases to a maximum of B + 2T - T=B + T.
At the start of carriage travel, the conjugate is A + B + C + D. At the end of carriage travel, the
distance is A + (B + 2T - T) + C + (D - T) = A + B + C + D.
Full and Half-Rate Carriages

The Xenon Lamp is mounted in the Full-Rate Carriage (Figure 1). Reflected light from the original document is passed via mirrors through a stationary lens to a CCD PWBA. To maintain a
constant image size, the distance between the original document and CCD (known as the conjugate) must remain constant. Therefore, an additional Half-Rate Carriage, traveling at half the
speed of the Full-Rate Carriage, is used. Figure 5 shows the carriages and their relative
motion.
T is the distance which the Half-Rate Carriage Moves
2T is the distance which the Full-Rate Carriage moves
A is the distance from the original document to the mirror on the Full-Rate Carriage. This
distance is constant
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Figure 5 Constant Optical Path Length
CCD Color Image Sensor

The CCD Array is 3 sets of 2 rows of 500 pixels (Figure 6). Each set of pixel rows is filtered to
detect a different color: red, green and blue. The two rows within each set are offset by.0025
inches (0.0635 mm), permitting the array to gather two lines of data at once. The sensor can
scan a document 12.5 inches wide.
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Refer to Figure 7. Each row of the array acquires its image from the original document in a parallel fashion. However, the image is retrieved serially at a 9.97 MHz rate. and passed to the
Pre-IPS PWB. While an image is being shifted out, the CCD array cannot acquire another
image. In addition, image acquisition takes time, reducing slightly the image line acquisition
rate. However, having two CCD rows per color doubles the image line acquisition rate. Furthermore, the image acquisition line rate must be the same as the rate at which the Full-Rate Carriage sweeps the document original (225 mm/sec. [8.858 inches/second] at 100%
magnification) X the desired pixel rate (400 pixels/inch or 15.748 pixels/mm). The end result is
that the CCD acquires image lines, in all three colors, at a rate of 3543.3 per second.
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Figure 6 CCD Color Image Sensor
Figure 7 CCD Image Data Clocking
Initialization
3.
Shading Control
Initialization includes several measurements and calculations to calibrate the image scanning
and processing circuits to images of known color and color purity. These include:
4.
White Variation Correction
5.
Automatic Density Control
1.
Automatic Gain Control
2.
Automatic Output Control
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Automatic Gain Control (AGC) compensates for variations in the sensitivity of pixels in the CCD
array, while the array looking at an brightly-illuminated pure-white image. During this calibration, the Full Rate Carriage is placed under the White Reference Strip, the Xenon Lamp is lit
and readings are taken from all pixels in the CCD array. The most extreme (highest) value from
any pixel is taken to be the correct value. A multiplier is then calculated for each remaining
pixel to make its measured white value equal to this reference. During document scanning, all
readings from each pixel which are above a threshold value are adjusted by this multiplier to
create a corrected value.
Automatic Output Control
Automatic Output Control (AOC) compensates for variations in the readings between pixels in
the CCD array, when looking at a black image. Immediately after the AGC readings, with the
Full Rate Carriage still under the White Reference Strip, the Xenon Lamp is shut off and readings are taken from all pixels in the CCD array. The most extreme (lowest) value from any pixel
is taken to be the correct value. A multiplier is calculated for each remaining pixel to make its
measured black value equal to this reference. During document scanning, all readings from
each pixel which are below a threshold value are adjusted by this multiplier to create a corrected value
Shading Control
Shading Correction compensates for the fact that the Xenon Lamp does not provide consistent
illumination across its length. The ends of the Lamp are dimmer than the center. Because of
this, a multiplier is calculated which is then applied to the pixels on the end. One distinct difference between Shading Correction and AGC is that readings for Shading Correction are taken
in two places on the White Reference Strip.
White Variation Correction
White Variation Correction compensates for the fact that the White Reference Strip isnt white
everywhere. In this test, a lighted reading is taken from two separate locations on the White
Reference Strip. The more extreme (higher) value is taken to be correct and is used in future
calculations.
Automatic Density Control
Automatic Density Control (ADC) is a joint function of the Imaging circuitry and the Xerographics module. It ensures that the density of the image on the copy doesnt change over time with
a constant image input density
NOTE: APS means Automatic Paper Sensing. SEF means Short Edge Feed. LEF means
Long Edge Feed
This machine determines document size by one of two methods:
Through the DADF (See DADF Document size sensing)
From the Platen Glass
When reading the document size from the Platen Glass, the machine does this by detecting
the number of Pixels of Image Data read by the CCD Color Image Sensor (for Feed Side, FS)
and the reading by the document edge (Sub-Scanning) with the Automatic Paper Sensor
(APS) Sensor.
Two switches are used to sense the position of the Platen Cover. A Platen Open Switch and a
Platen Angle Sensor (a switch).
The Platen Open Switch is in a LOW state when the Platen Cover is up off the Platen Glass
and goes to a HIGH state when the Platen Cover is closed against the Platen Glass (or on the
document).
The Platen Angle Sensor, located by the Cover Hinge, detects the angle of the Platen Cover.
As the Platen Cover is closed, (approximately <40degree angle off the Platen) the Angle Sensor energizes the Xenon Lamp.
The detection of the Sub-Scanning dimension of the document is done by taking two readings
with the APS Sensor. The first reading is done with the Lamp energized and the Platen Cover
in an angled position (See Figure 8, Case B, not closed against the Platen Glass). The APS
Sensor detects the document edge by sensing the dark background around the document.
This value is stored as X1 by the Pre IPS PWBA.
The second reading by the APS Sensor is done when the Platen Cover is down and the Platen
Open Switch is in the HIGH state (Case C in Figure 8). The APS Sensor performs this second
edge detection reading of the document and against the reflective Platen Cover. This value is
stored as X2 in the Pre IPS PWBA. A comparison of the values for X1 and X2 will determine the edge for the Sub-Scanning dimension of the document. (See Figure 9.)
The Feed Side dimension of the document is done by the CCD Color Imaging Sensor. This is
accomplished by detecting the number of Pixels for that dimension.
Determining the Attributes of the Document Original

Certain attributes of the document originals must be determined so that machine circuits can
be configured. These include:
1.
2.
Color Document Detection
Unlike most machines, this unit typically doesnt require a prescan to determine these
attributes. They are calculated during normal machine operation
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Scanning the Document

Carriage Positions
Refer to Figure 10 and Figure 11. The True Registration Position is where the Full-Rate Carriage begins to scan the document original. It occurs where the REG1 Sensor detects a particular left edge on the Full-Rate Carriage. All other carriage positions are calculated relative to
True Registration Position.
The White Reference Position is where the CCD Array is directly under the middle 100 pixels of
the White Reference Strip. For machines without a DADF, this is 20 mm to the left of the True
Reference Position. For machines with a DADF, it is 62 mm to the left of the True Reference
Position.
The Home Position is where the Full-Rate Carriage rests after initialization and between jobs.
In all machines (with and without a DADF installed), this is 30 mm to the right of True Registration Position. This location places the CCD array under the document original. Therefore, the
CCD array is used to detect the Fast-Scan dimension of the original document.
The Start Position is where the Full-Rate Carriage begins moving when scanning. In the interval between the Start Position and the True Registration Position, the carriage accelerates to
the appropriate speed for the selected image reproduction ratio. All possible start positions are
given in Table 1, and an example is shown in Figure 10 and Figure 11. Since the Full-Rate Carriage moves faster at lower magnifications, a longer acceleration distance is required and the
Start Position is further from the True Registration Position.
Figure 8 Document Size Detection with Platen Cover
NOTE: The Scanning speed of the Full Rate Carriage/Half Rate Carriage is determined by the
following formula:
Scanning Speed = 225 X 100 / magnification (mm/s) for 50 - 400% magnification
Scanning Speed = 225 X 100 / (Magnification X 2) (mm/s) for 2 to 49% magnification

Table 1 Full-Rate Carriage Start Positions
Configuration:
Reproduction Ratio
Start Position (Relative to

True Registration Position)
Without DADF
25% to 97.1%
40 mm Left
Without DADF
97.2% to 400%
20 mm Left
With DADF
25% to 97.1%
35 mm Left
With DADF
97.2% to 400%
15 mm Left
The End Position is the furthest that the Full-Rate Carriage travels when finishing a scan. The
maximum possible distance between the End Position and the True Reference Position is
approximately 432 mm or 17 inches. However, the Slow-Scan dimension of the document original may be less than this. (The size of the original can be detected automatically or entered
manually, see Document Size Detection.) The carriages will travel no further than necessary
for the originals Slow-Scan dimension.
Figure 9 Cluster Dot Screen Patterns

Color Document Detection
Color is detected during original scanning by examining the a* parameter for a non-zero value.
is examined.
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Figure 10 Home and Start Positions of Full Range Carriage - Without DADF
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Figure 11 Home and Start Positions of Full Range Carriage - With DADF
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Carriage Speed Control

The Carriage Motor is driven at different speeds depending on the task being performed. In
addition, while scanning, the Carriage Motor speed depends on the selected magnification setting. Both the Full-Rate Carriage and the Half-Rate Carriage must be driven at faster speeds
as the magnification ratios are reduced. Selected values are shown in Table 2. The forward
scanning speed equals 225 mm/sec. divided by the magnification expressed in decimal form.
Table 2 Full-Rate Carriage Speeds
Mode of Operation
Full-Rate Carriage Speed
Initialization
112.5 mm/sec or 225 mm/sec
Post-Initialization AGC/AOC/Shading Operations and Carriage Motions

(No DADF)
If the machine includes a Platen Cover and no DADF, the following events occur during initial
calibrations:
1.
The FRC moves from the Home Position to the White Reference Position, which is 20 mm
to the left of Registration Position.
2.
The Xenon Lamp is lit for 2 seconds.
3.
AGC readings are taken.
4.
The Xenon Lamp is shut off.
Scanning Forward, 400% magnification 56.25 mm/sec
5.
AOC readings are taken.
Scanning Forward, 100% magnification 225 mm/sec
6.
The Lamp is lit for 2 seconds
Scanning Forward, 25% magnification
900 mm/sec
7.
The first of two readings for Shading Correction is taken.
Scanning Return, all magnifications
675 mm/sec or 927 mm/sec
8.
The FRC moves rightward 2 mm and takes the second Shading Correcting reading.
9.
The FRC moves leftward 2 mm and takes a White Variation Correction reading. This
value is stored in the NVM.
Scan Length Control

The Carriage Motor emits a pulse every 0.72 degrees of rotation (500 pulses per one complete
revolution). This corresponds to 0.0761565 mm of linear travel by the Full-Rate Carriage.
These pulses are routed to the Pre-IPS PWBA. Carriage position is determined by keeping
track of the total number of pulses which have occurred in each direction since the last transition of the REG1 Sensor.
10. The Xenon Lamp is shut off and the FRC goes back to the Home Position.
Carriage Overrun
If the machine includes a DADF, the following events occur during initial calibrations:
Unlike some machine designs, this machine includes no over-limit sensors in either the forward
or reverse directions. Instead, the current position of the carriages is calculated based on the
REG1 Sensor transitions and Carriage Motor pulses.
1.
Initialization Carriage Motions

Upon equipment power up or when returning from low power state, the Full-Rate Carriage
(FRC) moves to its Home Position. This is 30 mm to the right of the Registration Position. The
sequence of motions to get there depends entirely on where the FRC was initially. The initial
position can be accurately determined by the state of the REG1 Sensor. An On state indicates
the FRC is left of the Registration Position, and an Off state indicates that the FRC is right of
the Registration Position. If the FRC started left of the Registration Position, it does the following:
Post-Initialization AGC/AOC/Shading Operations and Carriage Motions

(With DADF)
The FRC moves from the Home Position to the White Reference Position., which is 62
mm to the left of the Registration Position.
2.
The Xenon Lamp is lit for 2 seconds.
3.
AGC readings are taken.
4.
5.
AOC readings are taken.
6.
The Lamp is lit for 2 seconds
7.
The first of two readings for Shading Correction is taken.
8.
The FRC moves rightward 2 mm and takes the second Shading Correction reading.
9.
The FRC moves rightward 5 mm and a second White Variation Correction reading is
taken.
It moves rightward to a position 20 mm right of the Registration Position
10. The FRC moves rightward 40 mm to a location 20 mm to the left of the True Registration
Position. The first White Variation Correction reading is taken.
2.
It waits 30 msec
11. The Xenon Lamp is shut off and the FRC goes back to the Home Position.
3.
It moves leftward to a position 20 mm left of the Registration Position
4.
It waits 30 msec
5.
It moves rightward to the Home Position.
1.
If the FRC started to the right of the Registration Position, it does the following:
1.
It moves leftward to a position 20 mm left of the Registration Position.
2.
It waits 30 msec.
3.
It moves rightward to the Home Position.
Document Scanning Carriage Motions (Manual Document Positioning)

These events are performed whenever the user places a document on the platen manually.
They occur regardless of whether a DADF is installed. However, the physical locations of the
White Reference Positions and Start Scan Positions differ between units with or without a
DADF. These are shown in Figure 8 and Figure 9. In both cases, however, the events are as
follows:
1.
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The user opens the platen cover and places a document original on the platen.
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2.
While the user lowers the platen cover, the Xenon Lamp is lit and the CCD array detects
the Fast-Scan (Y or Front-Back) dimension of the original. Simultaneously, the Slow-Scan
size sensors determine the left-right (or Y) dimension of the document original.
3.
The Xenon Lamp is shut off and the document original size is calculated. If the size is
unrecognizable, the user is prompted to enter its size manually.
4.
The user presses the Start key on the User Interface.
5.
The FRC moves to the White Reference Position and performs additional readings calculations necessary for White Reference Correction.
6.
For magnifications between 97.2% and 400%, the FRC doesnt move; it is already at the
appropriate Start Position. However, if the magnification is between 25% and 97.1%, the
FRC moves leftward to a different Start Position. This permits the carriages more distance
in which to accelerate.
7.
The Lamp is lit and the FRC scans at a rate determined by the magnification for a distance determined by the document originals Slow-Scan dimension. While scanning, the
document original is examined for color content.
8.
The Lamp is shut off and the FRC returns to the White Reference Position.
9.
If another scan is required, then either step 6 through 9 are repeated. Additional scans
may be delayed by image processing PWBAs until they are ready to receive scan data.
8.
The Full-Rate Carriage returns to the high magnification Start Position, 15 mm to the left
of the True Reference Position.
9.
The DADF removes the current document from the platen.
If there are no more documents in the DADF and the time interval since the most
recent AGC/AOC/Shading readings are less than a threshold value stored in the
NVM, the FRC moves to the Home Position.
If there are no more documents in the DADF, but the time interval since the most
recent AGC/AOC/Shading readings is greater than the threshold value, then the
Xenon Lamp is lit for 2 seconds, and the Post-initialization AGC/AOC/Shading Operations and Carriage Motions are repeated. At the end of these operations, the FRC
goes to its Home Position
If there are more documents in the DADF, then the DADF places the new document
on the platen. When a image processing PWBAs indicate that they are ready to
receive scan data, the Xenon Lamp is lit and White Variation Correction is performed. Depending on the magnification rate, the FRC may remain stationary or
move to the low magnification Start Position. In either case, it then scans at the rate
dictated by the magnification rate.
Steps 7. through 9 are repeated until the DADF Input Tray is empty.
10. The next steps depends on how long the job has taken to run.
If the time interval since the last AGC/AOC/Shading readings is less than a threshold
value stored in the NVM, then the FRC moves rightward to the Home Position.
If the time interval since the last AGC/AOC/Shading reading exceeds the threshold,
then the Xenon Lamp is lit for 2 seconds, and the Post-initialization Operations and
Carriage Motions are repeated. At the end of these operations, the FRC goes to its
Home Position.
Document Scanning Carriage Motion (DADF Document Positioning)

The events described in this subsection apply only if the document original is placed on the
platen by the DADF. These events are as follows:
1.
The user places the originals in the DADF, and presses the Start key on the User Interface.
2.
The DADF places the first document original on the platen. While moving the document,
the DADF determines the documents Slow-Scan (X or Left-Right) and Fast-Scan (Y or
Front-Back) dimensions.
3.
The Xenon Lamp is lit and the FRC moves to the Start Position associated with higher
magnification values. This is 15 mm to the left of True Reference Position.
4.
White Variation Correction is performed.
5.
For magnifications between 97.2% and 400%, the Full-Rate Carriage doesnt move; it is
already at the appropriate Start Position. However, if the magnification is between 25%
and 97.1%, the Full-Rate Carriage moves leftward 20 mm to a different Start Position.
This permits the carriages more distance in which to accelerate.
6.
The Full-Rate Carriage scans at a rate determined by the magnification for a distance
determined by the document originals Slow-Scan dimension. While scanning, the document original is examined for color content.
7.
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IIT/IPS Cooling
The IIT drawer (including the carriages, lamp, lens and CCD array) includes no fan, since the
Xenon Lamp is much cooler than a quartz halogen Lamp. As shown in Figure 1, the IPS
drawer includes a small fan to remove heat from the PWBAs located there.
The circuitry for fan power and control is shown in Figure 3.
MOTOR/LAMP/FAN
DRIVE PWBA
IPS FAN
Image Processing (Digital Copier & Copier/Printer

Configurations)
Image Processing for copiers and copier/printers is divided into two groups of PWBAs. The
Pre-IPS PWBA, Memory System PWBA, Memory PWBAs and Post-IPS PWBA are only
included in these configurations and perform all image processing associated with image sensing and scanning.
The remaining PWBAs in the image processing path are common to all machine configuration.
Of these, only the Halftone PWBA performs significant image processing.
All image processing PWBAs in all configurations are shown in Figure 1, Figure 2 and Figure 3.
Pre-IPS PWBA
The Pre-IPS PWBA accepts six line of analog color data from the CCD PWBA. These are in
the form of two sets of three color lines: Red, Green and Blue. The Pre-IPS PWBA contains the
Application Specific Integrated Circuits (ASICs) listed in Table 1, which also contains their functions. Figure 1 shows the signal flow through the PWBA.
Table 1 Pre-IPS PWBA ASICs and Their Functions
ASIC Name
Functions
Analog Interface
1.
Amplifies the analog signal
2.
Offsets DC offset for varying analog AC signal
3.
Multiplexes between two analog inputs for each color
Analog-to-Digital
Converter
Converts analog input to digital value between 0 and 1023 (10 bit resolution)
IIC
1.
Converts W-Reference
2.
Corrects W-Level
3.
Corrects shading using 7.5 kilobytes of RAM for each color
4.
Corrects gap using a 7.5 kilobyte FIFO (First In First Out) chain
for each color
SID
TRE
Figure 1 IPS Fan Location
5.
1 X 5 Filter
6.
Generates the CCD PWBA 9.97 MHz sample and shift clock.
1.
Senses original document size
2.
Senses background color (ENL [Equivalent Neutral Lightness])
3.
Senses original color (ACS [Automatic Color Sensing])
4.
Corrects color (ACC [Automatic Color Correction])
1.
Enlarges/reduces image in one direction, when enlargement/

reduction is requested by user
2.
Rotates/repeats image, when requested by user
3.
Creates mirror image, when requested by user
In addition, the Central Processing Unit (CPU) on the Pre-IPS PWBA accepts inputs from the
following sensors:
IIT/IPS Cooling, Image Processing (Digital Copier &
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Platen Sensor, indicating the presence of paper on the platen
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Angle Sensor, indicating that the cover is angled approximately less than <40 degrees
from horizontal
Reg1 Sensor, indicating when the Full Rate Sensor passes through the True Registration
Position
One Automatic Paper Sensor (APS), indicating how far the document original extends
from the True Reference Position
Figure 1 Pre-IPS PWBA Simplified Block Diagram
BR PWBA
The BR PWBA contains the currency detection functionality. Because disabling this functionality would enable counterfeiting, no information is being given of this PWBA.
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Memory System PWBA and Memory PWBAs

Each scanned image is stored in a memory subsystem comprising a Memory System PWBA
and three Memory PWBAs. As partially shown in Figure 2, the image is accepted by the Memory System PWBA from the Pre-IPS PWBA and is provided to the Post-IPS PWBA. Each
image pixel is defined by eight bits for each of three colors: red, green and blue. The images
are actually stored in three Memory PWBAs, one per color. Each Memory PWBA has a standard capacity of 32 MBytes or an optional capacity of 64 MBytes of Random Access Memory
(RAM). The standard 96 MB total RAM capacity is large enough to store a single 11 by 17
image or two 8-1/2 by 11 images. The optional RAM capacity of all three Memory PWBAs
provides storage for 11 by 17 images.
Each Memory PWBA is controlled by a unique CMM, located on the Memory System PWBA.
The three CMMs are themselves controlled by common address and data buses from the PostIPS PWBA.
Figure 2 Red Memory Simplified Block Diagram
Post-IPS
Table 2 Post-IPS PWBA ASICs and Their Functions
The Post-IPS PWBA (Figure 3) processes 8-bit RGB image pixels retrieved from the Memory
PWBA and provides them in YMCK (yellow, magenta, cyan, black) format to the Video Select
PWBA. The Post-IPS PWBA first converts the RGB data to a L*a*b* format. This intermediate
data can be passed to and from the optional Edit PWBA. All of the boards functionality is contained in the ASICs listed in Table 2, which also describes the functions included in the
devices.
ASIC Name
Functions
TRE
Enlarges/Reduces in one dimension; Creates mirror image; Shifts

Image
TBC
Converts 400 DPI to 600 DPI; generates timing signals
CPI
Generates chip selects; Contains priority interrupt controller; Generates delay signals
Table 2 Post-IPS PWBA ASICs and Their Functions

ASIC Name
Functions
CST
Converts image from RGB format to L*a*b* format
MAX (3 total)
Differentiates between text and image areas of document original
The Post IPS PWBA retrieves the RGB information from the Memory PWBA four times on a
pixel by pixel basis. This is because all three input values are required to construct all four output values. The images pixel color information is provided to the VSEL PWBA circuitry four
times, once per output color, in the following order:
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1.
All yellow (Y) information
2.
2.
All magenta (M) information
However, the images are extracted from the Memory PWBA in a different order:,
3.
All cyan (C) information
4.
All black (K) information
This ensures that toner will be placed onto the paper in the order: black (bottom), cyan,
magenta, yellow (top).
Likewise, all of a pixels RGB data must be extracted from memory before it can be translated
to L*a*b* format and provided to the Edit PWBA.
This process is modified if the document originals are 8-1/2 X 11/A4 or smaller. In this case,
the two images are loaded sequentially into the Memory PWBA in the following order:
1.
R2, G2, B2 simultaneously
1.
R1, G1, B1 simultaneously to construct Y1 and L1*a1*b1*
2.
R2, G2, B1 simultaneously to construct Y2 or L2*a2*b2*
3.
R1, G1, B1 simultaneously to construct M1
4.
R2, G2, B2 simultaneously to construct M2
5.
R1, G1, B1 simultaneously to construct C1
6.
R2, G2, B2 simultaneously to construct Y2
7.
R1, G1, B1 simultaneously to construct K1
8.
R2, G2, B2 simultaneously to construct Y2
This enables the Post-IPS PWB to present the color information in the following order: Y1, Y2,
M1, M2, C1, C2, K1, K2, enabling the Xerographic subsystem to simultaneously process two 81/2 X 11/A4 sheets.
R1, G1, B1 simultaneously
Figure 3 Post IPS PWBA Simplified Block Diagram
Edit PWBA
The optional Edit PWBA permits portions of the scanned image to be removed. As shown in
Figure 2 and Figure 3, the Edit PWBA is a daughterboard of the Post-IPS PWBA. The image is
accepted from the Post-IPS PWBA format in L*a*b* format and processed in two ASICs.
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Figure 4 Edit PWBA Simplified Block Diagram
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Image Source Selection

As shown in Figure 1, the VSEL PWBA controls the routing of the image. The possible sources
are the scanned image from the Post-IPS PWBA and the print image from the Digital Front End
(DFE). The selected image is always routed to the Halftone PWBA. In addition, the selected
image can be routed to the DFE. Therefore, the machine can be used as a scanner, with the
resulting images being sent to client workstations.
The Halftone PWBA controls the selection of input and output. In addition, it can load a test
image into the VSEL PWBA, permitting an end-to-end test of the all succeeding assemblies.
Figure 1 VSEL PWBA Simplified Block Diagram
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Image Source Selection
Image Processing (All Configurations)
All machine configurations include a Halftone PWBA. This board accepts the image from the
VSEL PWBA four times, once per color: yellow, magenta, cyan and black. For each color, each
pixel has a value from 0 to 255 (8 bits/pixel). This value controls the amount of time that the
ROS drive pulse is active. A value of 0 shuts off the pulse completely, while a value of 255 provides the maximum pulse width. Most the functionality in this PWBA is located in six ASICs.
Figure 1 LDD PWBA and ROS Simplified Schematic Diagram

The Halftone PWBA uses its 600 DPI image data input to create pixels of various sizes and at
various pitches when printing text and graphics. As shown in Table 1, these include the following combinations of types and resolutions:
600 vertical and horizontal lines per inch (600L)
300 vertical and horizontal lines per inch (300L)
200 rotated lines per inch (200R)
200 pixel clusters per inch (200C)
150 pixel clusters per inch (150C) (Only available for files received from the DFE).
The positioning of the rotated lines depends on the color of the line. Magenta is placed at 45
clockwise of horizontal, yellow and black are vertical and cyan is placed at 45 clockwise from
vertical. These are shown in Figure 2.
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Figure 2 Line Screen Rotation

Table 1 Print Screen for Modes
Photo Type
Mode
Color
Color
4 Color
3 Color
Single
Color
Original
Type
Text
Halftone Original
Copied
Original
Map
Mode
Text/
Photo
600L/
200R
600L/
200R
600L/
200C
600L/
200R
N/A
Text
600L/
200R
N/A
N/A
N/A
N/A
Photo
N/A
200R
200C
200R
N/A
Map
N/A
N/A
N/A
N/A
300L
Text/
Photo
600L/
200R
600L/
200R
600L/
200C
600L/
200R
N/A
Text
600L/
200R
N/A
N/A
N/A
N/A
Photo
N/A
200R
200C
200R
N/A
Map
N/A
N/A
N/A
N/A
300L
600L/
200R
600L/
200R
600L/
200C
600L/
200R
N/A
600L/
200R
N/A
N/A
N/A
N/A
Photo
N/A
200R
200C
200R
N/A
Map
N/A
N/A
N/A
N/A
300L
Black,
Text/
Yellow,
Photo
Magenta, Text
Cyan
In cluster mode, the ROS laser beam is modulated to create fewer but larger pixels on the photoreceptor drum. The size of these pixels by can be changed by changing the total amount of
energy which the lasers transmit to the photoreceptor drum. The pixels are arranged in groups
or clusters with one pixel per color, with each pixel being effectively rotated. The arrangement
of pixels is shown in Figure 3.
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Photoreceptor Exposure
Photoreceptor exposure is the function of the Laser Diode Driver (LDD) PWBA and the Raster
Output Scanner (ROS).
Figure 3 Cluster Dot Screen Patterns
Image Processing (All Configurations), Photorecep-
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Figure 1 LDD PWBA and ROS Simplified Schematic Diagram
LDD PWBA
The LDD PWBA provides the interface between the Halftone PWBA and the ROS. The LDD
PWBA switches on the ROS laser diodes while the pulse from the Halftone PWBA is active.
See Figure 1.
ROS
The ROS, shown in Figure 2, includes two solid-state diode lasers whose output is directed as
follows:
1.
Slit
2.
Expander Lens
3.
Two Mirrors
4.
Rotating 12-sided Polygonal Mirror
5.
Scan Ray Mirror
6.
Mirror Cylinder
7.
Photoreceptor Drum
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The output wavelength is 780 nm which is in the infrared range of the electromagnetic spectrum. Therefore, the laser diode outputs are invisible to the human eye. By precisely timing
when the LED is lit, the LED output can be reflected from a mirror face anywhere along a line
extending across the width of the photoreceptor drum. The light striking the photoreceptor
drum causes a latent image on the drum.
Since the rotational velocity of the mirror must be both very accurate and stable, the mirror is
mounted on air bearing. Control signals for the ROS are provided by the IOT Drive PWBA,
under the control of the IOT CPU. The IOT LVPS provides +24 VDC via the IOT Drive PWBA.
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MIRROR
CYLINDER
LENS
LDD PWBA
SOS PICKUP
LENS
SLIT
DUAL SPOT LD
MIRROR
LENSES
START-OF- SCAN
PWBA
MOTOR
POLYGON
ASSY
MIRROR
CYLINDER
HOUSING
Figure 2 ROS Components Locations
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Overview
The paper supplies for the DocuColor 12 and the DocuCentre Color Series 50 machines are
the same. They consist of four (4) Paper Trays and a bypass tray (Tray 5) for single feeding or
special weights of copy material. Refer to Figure 1
This Paper Supply chapter will describe up to the point where the paper or copy material is
ready to feed into the paper path. Chapter 7 includes:
Paper Tray Specifications
Paper Size Sensing
Tray Level Lift and Sensing
No Paper Sensing
Tray 5
Refer to Chapter 8 for paper transportation issues.
Paper Size Guides

Tray 5
Paper Trays 1-4
Tray 2
Figure 1 Paper Supply Trays
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Overview

The Paper Trays are numbered 1-4, with Tray 1 at the top. Tray 1 is different in size and paper
holding capacity from the other trays. Trays 2, 3 and 4 are identical and can be interchanged
within the machine. The trays slide in and out on a side rail assembly from of the front of the
machine. When the trays are inserted all the way into the machine, a switch is activated to indicate on the User Interface that a tray is present.
Each tray has Paper Guides that can be adjusted by the user to accommodate different paper
sizes. The Paper Guides in each tray automatically indicate to the machine the paper size in
that tray. This information is provided on the User Interface for the operator.
Tray 5 is located on the side of the machine. This is used for feeding 1 to 100 sheets of paper
(28lb-30lb), heavier weight papers and transparency material. It also holds the optional envelope feeder.
Refer to Table 1 for the tray specifications. Figure 1 shows the electrical interface for Tray 1,
and Figure 2 shows the electrical interface for Tray 2. The electrical interfaces for Trays 3 and
4 are the same as Tray 2.
Table 1 Paper Tray Specifications
Trays
Capacity
Paper Sizes
Tray 1
500 sheets
8.5x11.0
8x10
A4
B5
No envelopes,
transparencies, or
heavy weight
paper
Trays 2, 3, 4
550 sheets
11x17
8.5x14
8.5x13
8.5x11
8x10
B4
A3
B5
A4
No envelopes,
transparencies, or
heavy weight
paper
Tray 5
100 sheets
Any
(20 lb, or less
sheets for
heavier weights)
Paper Weights Notes
less than 250

gsm,
less than 140 lb
index;
less than90 lb
cover
Optional envelope
feeder; usable for
transparencies,
heavy weight and
hole punched/
drilled papers
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Figure 1 Tray 1 Interface Block Diagram
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Figure 2 Trays 2 - 4 Interface Block Diagram (Tray 2 Shown)
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Paper Size Sensing

The user must manually enter the paper size in Tray 1, and the value is stored in the IOT CPU
NVM. Trays 2 through 4 have a paper Size Sensor Assembly which automatically reads the
paper size loaded in that Tray. These switches are located in the back of the machine where
the trays are slid.
The tray Size Sensor Assembly reads the paper size in the tray. This assembly uses four
switches that read high and low conditions, The Size Sensor Actuator pushes different combinations of high/low switch settings which correspond to specific paper sizes and configurations.
Refer to Table 1.
Paper Guides in the trays slide for selecting various papers sizes. As the Paper Guides slide,
camming levelers on the bottom of the tray move a Size Sensor Actuator on the back of the
tray. This Size Sensor Actuator pushes the switches on the Size Sensor Assembly to indicate
what paper is loaded in that tray. The paper tray needs to be inserted all the way into the
machine for the Actuator to engage the Size Sensor switches, activating this paper size sensing feature. Refer to Figure 1 for Sensor locations.
Paper Size Sensors

Paper Tray Sensor
Nudger Solenoid
Size Sensor Actuator

Paper Size Guides
Table 1 Paper Size Switch Settings, Trays 2-4

Paper Size & Orientation
Tray Size Switch

1
No Tray Present
low
low
low
low
11.0x17.0 SEF
low
low
low
hi
8.5x14.0 SEF
low
low
hi
low
B4 SEF
low
low
hi
hi
A3 SEF
low
hi
low
low
(TFX Special) SEF
low
hi
low
hi
8.5x13.0 SEF
low
hi
hi
low
B5 SEF
low
hi
hi
hi
A4 SEF
hi
low
low
low
(TFX Special) LEF
hi
low
low
hi
8.5x11.0 SEF (Letter)
hi
low
hi
low
B5 LEF
hi
low
hi
hi
A4 LEF
hi
hi
low
low
8.5x11.0 LEF (Letter)
hi
hi
low
hi
A5 SEF
hi
hi
hi
low
8.0x10.0 LEF
hi
hi
hi
hi
Paper Feed Motor

Paper Out Sensor
Prefeed Sensor
Figure 1 Paper Size Sensors (Shown Inside the Machine)
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Paper Size Sensing

The paper level within the trays must be maintained within a certain height range for proper
paper feeding into the machine. This is achieved by the Tray Level Left mechanism and the
Stack Height Sensor within each Paper Tray. Figure 1 shows the relationship between motor
rotation and the resulting action.
As paper is fed from the tray, the following process keeps the paper at the correct height to feed
into the machine:
1.
Paper level in the tray drops as paper is fed into the machine.
2.
As the paper level drops, the Nudger Roll also drops further into the tray to reach the top
sheet of paper. The Nudger Roll Solenoid activates, allowing a spring to push the Nudger
Roller onto the paper stack
3.
When the Nudger Roll drops into the tray to a certain level, a flag on the Nudger Roll
mechanism blocks the Stack Height Sensor.
4.
When the Stack Height Sensor is blocked, its output line to the IOT Drive and Control
PWBAs changes its level.
5.
The IOT CPU and Drive PWBAs activate the Feed Motor for that tray, causing it run in the
clockwise direction.
6.
The Feed Motor running in a clockwise direction results in:
The Nudger Roll stops rotating, because of its one-way clutch.
The Feed Roll stops rotating, again due to a one-way clutch.
The Lift Shaft starts turning, raising the paper level in the tray.
7.
As the paper level rises, it raises the Nudger until the Stack Height Sensor is no longer
blocked.
8.
When the Stack Height Sensor is no longer blocked, its output line to the IOT Drive and
Control PWBAs changes back to its original level.
9.
The IOT CPU and Drive PWBAs activate the trays Feed Motor in the counter-clockwise
direction.
Figure 1 Tray Motor Rotation
10. The Feed Motor running in the counter-clockwise direction results in:
The Paper Tray Level Lift stops rising.
The Nudger Roll starts rotating.
The Feed Roll starts rotating.
11. The paper is at the proper height and is fed into the machine.
When opening or removing the Paper Trays from the machine, the trays Paper Level Lift Mechanism automatically drops the paper level. Inserting or closing the Paper Trays automatically
raises the paper level by the Paper Feed Motor.
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No Paper Sensing
Tray 5
A No-Paper Sensor detects when the Paper Tray is empty. When the last sheet is fed from the
tray, the No-Paper Sensor actuator drops into a hole within the Tray Level Lift. The actuator
blocks the sensor and the sensors output switches to high.
Tray 5 is used mainly to feed transparencies, thick paper, and envelopes. It can also be used to
feed small quantities of paper not in Paper Trays 1 through 4. Tray 5 has a maximum capacity
of 1-100 copies.
This level is sent to the IOT Drive and Control PWBAs, which deactivates the trays Feed Motor.
In addition, these PWBAs cause a message to appear on the User Interface display. send a
status message to the User Interface Base PWBA. Figure 1 shows the circuitry relating to the
No Paper Sensor. This circuitry is the same for Trays 1 through 4.
When material is placed in Tray 5, it pushes against an actuator finger of the Tray 5 Paper Sensor, causing it to change level. The switch output is routed to the IOT Drive and Control
PWBAs.
Refer to Figure 1 for the Tray 5 components.
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No Paper Sensing, Tray 5
Figure 1 Tray 5 Electrical Block Diagram.

Paper feeding and paper size sensing is described in Section 8, Paper Transport.
Tray 5
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Overview
Paper Path Description
Paper Transportation includes:
The paper feeding process is the same for all four paper trays. The following is a brief description of the copy paper path through the entire machine. For a more detailed explanation, refer
to each subassembly listed above.
Paper Path Description
Paper Feeders
Tray 5
Paper Registration and Pre-Fuser Transport
Inverter and Duplex Paper Path
Print Exit
The Tray Lift raises the paper in the Paper Trays to the Feeder Assembly. A solenoid activated
Nudger Roll feeds paper into the nip of the Feed Roll and the Retard Roll. These two rolls
advance the paper into the vertical transport area which have a series of magnetically clutched
Take Away Rollers (TAR).
The Take Away Rollers advance the paper to the Preregistration Rollers. As the paper
advances through the Preregistration Roller, the lead edge of the paper passes a reflective
sensor. The signal from this sensor is compared to the TR0 signal from the IBT by the machine
run control. The machine run control will have the Preregistration Roller run slower or faster so
that the paper will synchronize for proper image transfer at the IBT.
The Registration Rollers are not energized and their movement is momentarily delayed as the
lead edge of the paper enters the nip. The Registration Sensor sees the lead edge of the paper
and starts a timing delay for energizing the Registration Rollers. While these rollers are not
moving, the paper is still being advanced by the Preregistration Rollers. This forces the lead
edge of the paper onto the non-moving Registration Rolls, and aligns or de-skews the paper
square to the Registration Rollers. After de-skewing, the Registration Rolls are energized and
advance the paper to the xerographic marking area of the machine.
The IBT allows all 4 color layers of toner to be transferred to the paper in one pass. The paper
goes between the IBT Belt and the second Bias Transfer Roll. There, a combination of pressure and electrostatic charge transfers the toner from the belt to the paper. Exiting the IBT
area, the paper is transported to the Fuser by a Vacuum Belt. A metal guide directs the lead
edge into the nip of the Fuser.
The Fuser has a Heat Roll and Pressure Roll which cam together to create a Contact Arc or
pressure point in the roller nip. The Heat Roll and Pressure Roll apply heat and pressure which
fuses the toner into the paper. The paper leaves the Fuser, passing into the nip of the Fuser
Exit Rollers. If the paper is exiting the machine, it is guided by Exit Inverter Rolls to the Paper
Shelf or the Mailbox/Sorter.
For duplex copying, or for paper that is to be stacked in reverse order, the paper is diverted by
a solenoid activated Invert Gate before reaching the Exit Inverter Rolls. The Invert Gate directs
the paper into the duplex paper path.
Two pairs of Inverter Rolls drive the paper down into the duplex path. Copy that is to be
reversed stacked is stopped before the trailing edge reaches the second set of Inverter Rolls.
At this position, the paper has passed a strip of Mylar which acts as a gate. The paper reverses
its direction of travel and moves up into the Mylar gate, which guides the paper to the Exit
Invert Roll to leave the machine for reverse stacking.
Figure 1 Motor Drives of the Paper Path
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Overview
For Duplex printing, the paper travels further into the duplex path to a dup point. At this position, the paper has passed a second Mylar gate. The copy reverses direction, driven by the
Duplex Inverter Roll, and the Mylar gate guides the paper to the Dup Path. Two sets of prealignment rolls (Duplex In Roll and Duplex Path Roll) drive the copy, while three sets of crossed
rolls (Alignment Rolls 1, 2 and 3) push the copy into the Side Guide Rail for alignment prior to
copying on the second side.
Duplex Out Rolls transport the copy to the Preregistration Rolls. From there, the copy is again
de-skewed and sent for copying on the second side by passing through the IBT, Fuser and then
exiting the machine as a finished duplex copy.
Table 1 Paper Transport Motors

Function
(drives the following:)
Motor
Duplex Out Motor
24 VDC
Exit Motor
+/- 24 VDC
Align Roll 1
Align Roll 2
Align Roll 3
Dup Out Roll
Machine Exit Inverter Roll
Pressure Roller Cam
Refer to Table 1 for information on the different drive motors used to transport the paper
through the machine.
Table 1 Paper Transport Motors
Function
(drives the following:)
Motor
Trays 1-4 Feed/Lift Motors
24 VDC
Nudger Roller (ccw)
Bidirectional Stepper Motor
Paper Level Lift (cw)
300 mm/sec (feed operation)
Take Away Clutch
Take Away Motor
24 VDC
Feed Roller (ccw)
Take Away Rollers 2-4
450 mm/sec.
Tray 5 Motor
24 VDC
Tray 5 Feed Clutch
Nudger Roll
Feed Roll
220 mm/sec.
130 mm/sec.
Tray 5 Take Away Roll
60 mm/sec.
Take Away Feed Clutch
Pre-Registration Roll
Tray 5 Lifter-Up
Tray 5 Lifter-Down
Registration Roll
Invert Motor
24 VDC
Invert Roll 1
Invert Roll 2
Reversing Stepper Motor
Dup Invert Roll
350 mm/sec.
Dup In Roll
450 mm/sec.
Dup Path Roll
Tray 5 Lifter Motor
24 VDC
#1 Take Away Roll
Stepper Motor
Regi Motor
24 VDC
Stepper Motor
220 mm/sec.
130 mm/sec.
60 mm/sec.
Overview
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Figure 2 Paper Path
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Overview
Paper Feeders
Paper Path Component Description and Locator (See Figure 2)
Item
Description
Item
Description
The purpose of the Paper Feeders is to:
Extract the copy material, a single sheet at a time, from the Paper Trays and feed this
copy material into the vertical transport area of the machine
Tray 1 Sensor
28
Tray 4 Feed Out Sensor
Tray 1 Level Sensor
29
Take Away Motor
Maintain the correct height levels in the Paper Trays for proper feeding
Tray 1 No Paper Sensor
30
Tray 1 Take Away Feed Clutch
Indicate when there is a jam or double feed from the Paper Feeder mechanism
Tray 1 Prefeed Sensor
31
Sense when the Paper Tray is empty
Tray 1 Feed/Lift Motor
32
33
Each of the four Paper Trays have their own motor driven Paper Feeder Assembly. The four
Feeder Assemblies are located above each Paper Tray, in the lower left side of the machine.
34
Take Away Sensor
Tray 2 Paper Size Sensor
35
Pre Registration Sensor
Tray 2 Level Sensor
36
Tray 5 Motor
10
37
Regi Sensor
11
38
Transparency Sensor (OHP)
12
39
Regi Motor
13
40
Pre IBT Sensor
14
41
Pre Fuser Sensor
15
42
Fuser Exit Sensor
16
Tray 3 Level Sensor
43
Invert Gate
17
44
Invert Gate Solenoid
18
45
Exit Path Sensor
19
46
M/C Exit Sensor
20
47
Invert Motor
21
48
Release Solenoid
22
49
Inverter Path Sensor
23
Tray 4 Level Sensor
50
Duplex In Sensor
24
51
Duplex Path Sensor
25
52
Duplex Out Sensor
26
53
Duplex Out Motor
27
Retard Roll
Friction Clutch
Feed Roll
Feed/Lifter Motor
Paper Out Sensor
Nudger Roll
Nudger Roll Sensor
Nudger Roll Solenoid
NOTE: Bottom View
Figure 1 Paper Feeder Assembly
Feed Motors
Each Tray Assembly has a +/- 24 VDC, bidirectional stepper Feed Motor:
Overview, Paper Feeders
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When rotating clockwise, it raises the Tray Lifter in the Paper Tray.
When rotating counterclockwise, it rotates the Nudger and Feed Rolls for the tray.
The Feed Motors are controlled by the IOT Control and Drive PWBAs. The circuit is the same
for all four Paper Trays and their Feeder Assemblies. See Figure 2 for the electrical schematic.
The paper feed process starts either when:
The machine functioning as a printer, receives a print job from the network connection.
The machine functioning as a copier, the user enters a print job on the User Interface correctly, provides the document in the Document Feeder or on the Platen Glass and
presses the Start Button, and there is the correct copy material in one of the paper supply
sources.
Paper Feed
The IOT Control PWBA manages paper feed timing using the TR0 signal from the IBT Belt as a
reference. In the selected tray, the Feed Motor is energized, rotating the Nudger Roll, and the
Feed Roll. The Retard Roll rotates by being cammed against the Feed Roll. For each sheet of
paper to be fed, the Nudger Roll solenoid momentarily activates, allowing a spring to push the
Nudger Roll down to the top sheet of paper in the tray. The Nudger Roll feeds the paper into the
nip of the Feed/Retard Roll. The paper is fed at a rate of 300 mm/sec. to the Take Away Rollers.
If the lead edge of the paper is not sensed by the Pre-Feed Sensor within the correct time duration, then a Feed Sensor jam is declared. (See Tray Level Lift and Sensing for maintaining the
paper level in the Paper Trays)
Retard Roller Operation

The Retard Roll prevents more than one sheet of paper from being fed into the paper path at
the same time.
Figure 2 Partial electrical schematic for paper feed control in Trays 1-4
The Retard Roll in each Paper Tray is classified as a semi-active type. The Retard Roll is
mechanically cammed against the motor-driven Feed Roll when the Paper Tray is inserted into
the machine. The rotation of the Retard Roll comes from this contact with the Feed Roll.
A friction clutch on the shaft of the Retard Roll provides rotation resistance. When there is no
copy, or a single sheet of copy in the nip of the Retard/Feed Roll, the resistance from the friction clutch is not enough to prevent the Retard Roll from rotating with the motor-driven Feed
Roll. This allows the rotating Retard and Feed Rolls to feed a single sheet of copy. If more than
one sheet of copy is fed into the Retard/Feed Roll nip, then the resistance from the Friction
Clutch is greater than the resistance between the multiple sheets of copy. This resistance prevents the Retard Roll from rotating, which holds the extra sheets of copy back in the tray while
only the top copy is advanced by the motor-driven Feed Roll.
Paper Feed Control

Figure 2 is a partial electrical schematic of the paper feed control.
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Paper Feeders
Vertical Transport
Tray 5
The purpose of the Vertical Transport module is to provide copy transportation from the Paper
Trays to the registration system. The vertical Transport also provides access to the paper jams
in the Paper Feeders and Take Away Rolls (TAR).
Tray 5 is used to feed copy material that cannot be reliably fed from one of the four Paper Trays,
or for a copy size that is not available in any of the Paper Trays. Copy material that is to be fed
from Tray 5 includes:
As paper is feed from the Paper Trays, it enters the Vertical Transport module. The Take Away
Rolls 2 through 4 are individually clutched magnetically and are driven by the Take Away Motor.
Paper transport speed is at 450 mm/sec. Each TAR clutch can engage or disengage from the
TAR Motor as the paper enters and leaves the nip. This function reduces the energy used by
the TAR Motor and also releases the paper as required when the paper enters the variable
speed Preregistration Rolls.
Transparency material
Heavy weight paper (105 gsm - 190 gsm)
Extra heavy weight paper (191 gsm - 250 gsm)
Manual duplex copy needs
Multi-hole drill/punched paper
The Take Away Roll 1 is clutch driven by Tray 5 Motor at 450 mm/sec. These rolls are also electromagnetically clutched to disengage from the Tray 5 Motor. These rolls disengage when the
paper enters the nip of the Preregistration Rolls.
An optical Feed Out Sensor at each TAR reads the lead and trail edge of the paper to energize
the clutched rolls and to detect paper jams at each of Paper Trays.
Tray 5 feed operation

Tray 5 has a switch that is activated when the top of the tray is dropped down. This sends a signal to the machine run control, which energizes the Tray 5 sensor circuitry and indicates on the
User Interface screen that the Tray 5 is open.
When copy material is placed in Tray 5 with the lead edge of the material against the Tray 5
Gate, a Paper Set Sensor is actuated. This sensor signals machine run control that copy is
present in this tray. A paper Size Guide is manually adjusted to accommodate the lead edge
dimension of the copy. The Size Guide uses a variable resistor sensor for providing the lead
edge dimension to the machine run control.
Two optical sensors are used to monitor the copy stack height that is placed in Tray 5 for proper
feeding into the machine:
Tray 5 Level Up Sensor - This sensor performs the same way as the Stack Height Sensor in Paper Trays 1-4. When the Nudger Roll has to drop too far down to reach the top
sheet of paper, the Tray 5 Level Up Sensor is unblocked and the Tray 5 Lifter motor is
energized counterclock wise to raise the Paper Lifter, bring the paper level up to the
Nudger Roll for proper feeding.
Tray 5 Level Down Sensor - This sensor indicates when the Paper Lifter is down. The
Tray 5 Lifter Motor is energized clockwise to lower the paper.
A delayed time interval from the TR0 signal starts the Tray 5 Motor. The Nudger Roll Solenoid
momentarily energizes to lower the Nudger Roll to the top copy. This feeds the top copy into
the nip of the Feed Roll and the Retard Roll. The Retard Roll has a friction clutch which provides resistance to prevent multiple copy feedings (See Retard Roller Operation for more
details of this roller function.)
The copy travels from Tray 5 Feed/Nudger Rolls to the Tray 5 Take Away Rolls. The Tray 5 Feed
Sensor detects the lead and trail edge. If the lead edge is not sensed within the designated
time, then a paper jam error is generated.
The Tray 5 feed mechanism is similar to that used in Paper Trays 1-4 (See Paper Feeders for
more information on paper feeding). Tray 5 Nudger Roll feeds the paper to the nip of the Feed
and Retard Roll. The Retard Roll is a semi-active type. From there, the single sheet of paper is
fed to the Tray 5 Take Away Rolls.
Vertical Transport, Tray 5
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As the paper advances through Tray 5 Take Away Rolls, the lead edge of the paper passes a
reflective sensor. The signal from this sensor is compared to the TR0 signal from the IBT by the
machine run control. The machine run control signals Tray 5 Motor to run the Take Away Rolls
faster or slower so that the paper will synchronize with the IBT for proper image transfer.
PAPER LEVEL SENSOR
FEED ROLL
NUDGER ROLL
SOLENOID
PAPER OUT
SENSOR
The same alignment procedure occurs when the paper comes from the Vertical Transport and
Paper Tray direction. In this case, a Preregistration Sensor signals the machine run control
which has the Tray 5 Motor vary the speed of the Preregistration Rolls. Refer to Figure 1 for
Tray 5 Motor speed adjustments of these rollers. From either Tray 5 Take Away Rolls or the
Preregistration Rolls, the copy is advanced to the Registration Rolls for deskewing. (See
Paper Registration and Paper Transport to the IBT Belt.)
SIZE
GUIDE
PAPER TRAY
LIFT
FEED OUT
SENSOR
RETARD ROLL
Figure 2 Tray 5 components
Tray 5 Copy Size Sensing

When paper is placed in Tray 5, a paper Size Guide is manually adjusted to accommodate the
lead edge dimension of the copy. The Size Guide uses a variable resistor sensor (0-5 VDC) for
providing the lead edge dimension to the machine run control. The length of the paper (run
dimension) is determined by the activation time of the Pre Fuser Sensor.
Tray 5 Motor
Nudger Roll
Tray 5 Take Away Roll
Figure 1 Motor Speed Adjustments for Paper and Image Alignment
Tray 5 Mechanical Drives

Tray 5 uses two motors:
Tray 5 Motor drives Tray 5 Nudger roll, Tray 5 Feed Roll, Tray 5 Take Away Rolls, PreRegistration Rolls and Take Away Rolls #1.
Tray 5 Lifter Motor raises or lowers the Paper Lifter to control the paper level for correct
feed height in Tray 5.
Paper Size Sensor
- Clockwise raises the Paper Lifter

- Counter clockwise lowers the Paper Lifter
Figure 3 Tray 5 Drive and Size Sensor
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Tray 5
Differentiating between paper and transparencies
The components and assemblies involved in paper registration accept a sheet of blank copy
material and ensure that its edges are absolutely parallel or perpendicular to the sheets direction of travel. This is done immediately before feeding the sheet to the IBT Belt.
Transparencies can only be fed from Tray 5. When transparency material is detected, the transport speed for IBT, the Vacuum Transport, Fuser and Fuser Exit Rolls drops to its slowest
speed of approximately 60 mm/sec. When copy material is fed from Tray 5, two OHP Sensors
examine the edges of the material to determine if the material is opaque on that edge through
its whole length. The outputs of these sensors are routed to the IOT Drive and Control PWBAs
for processing.
Paper Registration and Paper Transport to the IBT Belt

The paper registration system uses a stalled-roll technique. As the blank copy material is being
transported by the Preregistration Rollers (from trays 1 through 4) or by the Tray 5 Take Away
Rollers, the lead edge of the media reaches the nip of the Registration Rollers. At that instant,
the Registration Rollers are not rotating. This forces the lead edge of copy into the nip, causing
the copy to buckle and making the lead edge parallel with the nip.
After a 100 to 140 ms delay, the Registration Motor begins turning the Registration Rollers,
moving the blank copy material to the nip between the IBT Belt and the 2nd Bias Transfer Roll.
The start of the developed image on the IBT Belt and the leading edge of the copy material
must be synchronized so that they meet. Therefore, the IOT Control and Drive PWBAs can
vary the speed of the Preregistration Rollers and the Dup Out Rollers from 360 mm/sec. to 540
mm/sec. This results from comparing the timing of the Preregistration Sensor signal caused by
the blank copy materials leading edge with the timing signal from the TR0 Sensor on the IBT.
Any timing difference causes the speed of the Tray 5 Motor and Duplex Out Motor to be
adjusted.
The OHP Senors are a LED transmitted-light-detection type. Since paper is opaque, it blocks
light from the sensors LEDs to their photoreceptors. This isnt the case with transparency
material, except for a short interval when either or both sensors encounter the opaque white
strip on some transparency material.
When the Registration Sensor detects the lead edge of the copy material, the signal from both
OHP Senors is also read. If the material is paper, then these sensors are blocked. If the transparency material is fed with the white strip (5 mm in width) first, then the OHP Sensors are also
blocked. Readings from the OHP Sensors are taken at 0.1 second intervals. If the LED of the
sensors are detected, this indicates the material is a transparency that is being transported.
After the copy material has been set to synchronize with the IBT and has been deskewed at the
Registration Rollers, it enters the nip of the Second Bias Transfer Roll (BTR) with the IBT Belt.
Refer to Xerographics for more information on the Xerographics process.
Paper Transport from the IBT Belt

A Vacuum Transport Belt carries the unfused print to the Fuser Subassembly. To maintain consistent print transport speed during the Fusing process, the Fuser Motor transports the print
into, through and out of the Fuser Assembly. (See Table 1 for Drive Motor information).
The vacuum that is used to hold the print to the belt comes from the Exhaust Blower Assembly
through the Xerographic and Vacuum Transport duct system. This means that the belt vacuum
may be diminished if the machines service doors are open.
The Fuser Entrance Sensor detects the lead edge for paper jams on the Vacuum Transport
Belt or from the IBT.
Refer to the Fuser Section for more information on this subassembly.
As the fused print exits the Fuser, the lead edge enters the Fuser Exit Roller nip. A Fuser Exit
Sensor detects the lead edge of the print as it leaves the Fuser Exit Rollers. If the lead edge is
more then 20 ms late, the Fuser will stop and a jam error code will be indicated.
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Inverter and Duplex Paper Path
Print Exit
After fusing, a print would enter the Inverter Path, instead of exiting the machine, for one of two
reasons:
Print exit moves the finished print out of the machine. Depending upon machine options, exiting prints can go to a Sorter, a Mailbox or a Tray Stacker.
To be stacked in the Exit Tray or Stacker/Mailbox/Sorter in the same order that they were
printed or copied.
As the first step in duplex printing or copying
Prints can reach the exit port from either the Inverter Paper Path or the Fuser Path. When the
print is coming from the Inverter Path, the critical condition is the state of the solenoid controlling the Inverter Gate. When the print is to exit the machine, the solenoid is not activated. This
allow the print to be transported directly to the Exit Invert Rolls instead of being routed into the
Inverter Paper Path.
The print is diverted into this paper path by a solenoid activated Inverter Gate. This solenoid
and gate is activated by the IOT Control and Drive PWBA.
Duplex Path
The Duplex Path transports the print back to a location before IBT image transfer so that its
reverse side can be marked.
When duplex printing is required, the Invert Solenoid activates the Inverter Gate. This Inverter
Gate directs the lead edge of print down the Invert/Duplex paper path to Inverter Rolls 1 and 2,
and the Duplex Inverter Roll. These rolls transport the print down past a Duplex Gate to a
Duplex Invert Point. At this Duplex Invert Point, the Invert Motor stops and reverses direction to
move the print up in the paper path. The Mylar Duplex Gate directs the print into the duplex
paper path.
When the print is coming from the Inverter Path, the critical condition is how far down the
Inverter Path the print is driven by Invert Rolls 1 and 2 and Duplex Invert Roll. If the trailing
edge of the print goes down past the Mylar Duplex Gate, it will be directed along the Duplex
Paper Path when it reverses direction and moves upward. If the Mylar Duplex Gate isnt
passed, the upwardly moving print will be routed to the Exit Inverter Rolls when it reaches the
Mylar Inverter Gate.
The Exit Sensor detects paper jams by monitoring the leading and trailing edges of the print.
The Exit Motor drives only the Exit Invert Rolls. This allows the print material to exit the
machine at a transport speed of 350 mm/sec.
The print enters the Duplex Paper Path, and the prints leading edge passes the Duplex In Sensor. This sensor detects paper jams, and initiates a timing sequence which eventually results in
the IOT Control and Drive PWBAs energizing the Duplex Out Motor. The Invert Motor drives
Duplex In Roll and the Duplex Path Roll. These rolls transport the print to the duplex alignment
area.
When the Duplex Path Sensor detects the leading edge of the print, the Invert Motor deenergizes and the Duplex Out Motor energizes. The Duplex Out Motor drives three sets of Align
Rolls which are rotating at an angle to the transportation direction of the print. This angled drive
pushes the print edge into a Side Guide Rail and aligns the running side dimension to the side
dimension of the IBT for the second marking process. After the print is aligned, it is sent to the
Preregistration Rolls to be again deskewed against the Registration Rolls. A Duplex Out Sensor detects the leading and trailing edge of the print, to detect paper jams as the print leaves
the Duplex Paper Path.
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Inverter and Duplex Paper Path, Print Exit
Inverter and Duplex Paper Path, Print Exit
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Overview
This module describes the electrical and mechanical components of the Xerographics process.
Xerographics includes these primary functions:
Providing a charge to the Photoreceptor Drum which can then be exposed with a laser for
the image data. This creates a latent image on the Photoreceptor Drum.
Develop the latent electrostatic image on the Photoreceptor Drum by depositing toner
onto the image areas.
Transfer the developed image from the Photoreceptor Drum to the Intermediate Transfer
Belt (IBT). The IBT receives all required toner colors before the image is transferred to the
paper.
Transfer the complete toner image from the IBT to the paper.
Clean both the IBT and the Photoreceptor Drum of developer residue.
Suppling developer to the Developer Rotary Assembly
Photoreceptor Drum
The major sections in this module are:
Photoreceptor Drum
Charging
Development
Toner Supply
Intermediate Belt Transfer (IBT)
Motors
Cleaning Systems
Air Flow
Process Controls
IBT Belt
Figure 1 Two Step Image Transfer Process
The Xerographics processes in this machine use a number of design improvements which
helps it achieve the full color copy rate of 12.5 copies per minute. Unlike other color copier
technology that has the developed image on the Photoreceptor Drum layering one color at a
time directly onto the paper, this machine makes use of a subassembly called the Intermediate Belt Transfer (IBT). The IBT receives and accumulates all four color toner layers from the
Photoreceptor Drum, and then passes this completed image onto the paper in one pass. Using
this process there are actually two steps for image transfer. These are:
1.
The charged and developed image on the Photoreceptor Drum is transferred to the Intermediate Belt Transfer (IBT). The IBT accepts the image from the Photoreceptor Drum,
one color at a time, until all four colors are layered on top of each other on the IBT.
Layering sequence: YMCK, where Y is the first color put onto the Photoreceptor Drum
and transferred onto the IBT.
2.
The complete colored image on the IBT is transferred to the final copy material in one
pass.
The advantage of the IBT is that it provides a more stable and consistent base than paper for
receiving the toner from the Photoreceptor Drum. When transferring four different toner layers
onto a substrate, factors such as: registration, surface charge, consistent transport speed,
moisture content, and surface texture all are critical variables that impact quality of that toner
transfer process. The wide variety of copy materials (different paper/plastic surfaces and
weights) make it difficult to control these variables, which impacts the color toner layering process.
By using the IBT, the variables of surface charge, speed, registration, moisture content and surface texture are either eliminated or reduced. This allows for more consistency in building the
toner layers. Once all the required image layers have been accumulated onto the IBT, this final
image is then passed onto the paper at the 2nd Bias Transfer Roll (BTR) through a controlled,
electrically charged, roller nip. By using one pass to transfer the complete image onto the
paper, an increase in image quality, image consistency and color copy rate is achieved.
Because of this two step transfer process, the image on the IBT is an upside-down, mirror
imaged and reversed colored layered of the image that ends up on the copy material. Refer to
Figure 1 for more information on this two step image transfer process.
Layered sequence: KCMY, where K is the bottom color layer that is on the copy material
and Y is the top color layer.
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Overview
Photoreceptor Drum
Photoreceptor Drum
This machine uses the black writing or Discharge Area Development (DAD) system for
exposing and charging the Photoreceptor Drum. With black writing, a high negative charge is
placed uniformly on the drum and forms the image background. The Photoreceptor drum is
discharged in those areas written by the ROS. The developer is also highly charged negatively
and is only attracted to the more discharged areas. Therefore, if there is an image writing failure, such as a ROS failure, the result will be blank prints.
This machine uses a STX Organic Photoreceptor Drum. The multiple layered, organic coated
aluminum drum is 84 mm in diameter. The layers on the Photoreceptor Drum are:
The bottom layer is called a Blocking Layer and forms the interface to the grounding aluminum layer.
The middle layer is called the Charge Generation Layer and has the capability of generating charges in the presence of light.
The top layer is called the Charge Transport Layer and it transports charges from the surface.
NOTE: The top STX organic layer is more sensitive to light than some other Photoreceptor
Drums. When removing from the machine, cover the Drum with the black plastic bag, which is
located in the closed compartment of Tray 1. Do not leave the Drum exposed to direct ambient
light for more than one minute at 1000 lux. If this time limit is exceeded, the drum becomes
desensitized and unusable. Unlike other Photoreceptor Drums, this unit cannot be refreshed
by placing it in a dark environment. It must be replaced.
For information on cleaning the Photoreceptor Drum, refer to Cleaning Systems
Photoreceptor grounding
The Photoreceptor Drum must be electrically grounded in order to function properly. The aluminum substrate of the Photoreceptor Drum is electrically common with the Drum Shaft. The
Drum Shaft is grounded through the Photoreceptor CRU, which is itself grounded to the
machine through a connector pin.
Drum Drive
The Photoreceptor Drum is driven by a 24 VDC brushless DC motor. This motor also drives the
IBT. In this manner, synchronization between the Drum and IBT Belt is easier to maintain for
the image transfer process.
A 9.38 pound (3.5 kilogram) flywheel is installed on the IBT Drive Roll Shaft to prevent fluctuations in speed that would impact image quality.
Figure 1 Black Writing Xerographics Process

The black writing steps used on this rotating Photoreceptor Drum are as follows:
1.
Charging the Drum (see: Charge Corotron)
2.
Exposing the image onto the Drum with the Laser (see: Imaging section)
3.
Developing the image on the Drum (see: Development)
4.
Transferring the image to the IBT (see: Toner Transfer Overview)
5.
Cleaning the Drum and IBT Belt (see: Cleaning Systems)
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The IOT CPU PWBA and IOT Drive PWBA control the Drum Motor. This PWBA contains the
electronics that drive the Drum Motor and converts the encoder pulses into the Machine Clock.
Motor Control is described in detail in the Start Power section.
Drum Data
The Photoreceptor Drum has a PWBA that contains Drum data and that provides information
that is used by various machine control functions. The data that is stored on the Drum PWBA
is:
Figure 2 Photoreceptor Drum CRU

The Drum Motor assembly includes an encoder that provides pulses at the rate of once per
revolution. The IOT CPU PWBA uses these pulses to accurately time many of the copier functions.
The Drum Motor rpm speed varies, depending upon what type of copy job is being processed.
Table 1 show the relationship between paper transport speed and Drum Motor speed.
Table 1 Photoreceptor Speeds
Transport Speed
(mm/sec)
Motor Speed
(rpm)
Normal Copy
219.47
1996.0
Heavy weight
129.68
1179.4
Super Heavy Wt. + Transparencies
59.82
544.0
Reissue
Drum Type
Drum serial number
Drum usable cycles number
Drum Initial installation date
Drum final installation date
Drum installation frequency
Dispense Motor usable time
Charge Corotron discharge time
Preclean Charge Corotron discharge time
B/W and Color copy counters
When a new Photoreceptor Drum (a CRU) is inserted into the machine, the new Drum serial
number is read and compared to the serial number stored in the NVM of the machine. When
the machine senses a different serial number, it interprets that a new Photoreceptor Drum has
been installed. The following occurs when a new Drum is installed:
PHOTORECEPTOR
DRUM
DocuColor 12/DCCS50
The Drum Initial installation date is stored when the machine detects the Drum Installation Frequency is read as 0
The Drum Installation Frequency, Serial Number, Final Installation Date and other
Drum data is read and then stored on NVM of the machine.
The previous Drum data in NVM is stored as back-up data.
Detection of the Drum Replacement Time is implemented after the Drum data is stored
and determined usable. When this is done, then any fail status related to the Drum CRU is
cancelled.
The various Drum run times and cycles from the Drum PWBA are stored and counted. Drum
replacement time is detected by the value of Drum Usable Cycles Number and Dispense
Motor Usable Time. The following error codes are related to the Drum CRU:
09-410: Drum CRU Change Soon - when the values of the above cycle numbers and time
reach a fixed value.
09-378: Drum CRU Change - when the values of the above cycle numbers and time are
zero (0).
09-372: Drum Not In Position - when the machine can not detect the Photoreceptor Drum.
09-311: Drum Type Mismatch - when the machine detects the incorrect type of Photoreceptor Drum.
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Photoreceptor Drum
Charging
The surface of the rotating Photoreceptor Drum receives negative charge VH from the Charge
Corotron in preparation to the image exposure from the Laser. The level of this negative charge
on the Drum is measured by the Electrostatic Voltmeter (ESV) and is shown in Table 1. Note
that the charge voltage varies with the temperature and humidity as measured by the
machines Environmental Sensor (ENV). The charge voltage will also decrease after the first
50,000 cycles of the Photoreceptor Drum at a ratio of -1 V per 10,000 cycles.
Table 1 Photoreceptor Drum Voltages
Zone
Temperature Humidity
VH
VL
VBias
28 C
85%
623
300
510
22 C
55%
700
300
(for 0-50K cycles,
then decreases by -1
V/10K cycles)
560
10 C
20%
710
656
300
The laser beam from the ROS writes an image onto the negatively charged Photoreceptor
Drum. When the laser writes the image data to the Photoreceptor Drum, the voltage on the
part of the Drum containing the image is discharged from VH to VL, also shown in Table 2.
(The background or non-image areas remain at VH.) This black writing technique creates the
latent image that the negatively charged developer will be attracted to, developing this image
area.
Figure 1 Charging Circuit
Note that the level of Vh varies with ambient temperature and humidity. Temperature and
humidity are measured by a dedicated sensor which is connected to the IOT Drive and Control
PWBAs. The IOT CPU PWBA uses these parameters as one input in adjusting the output voltage and current of the Charge Corotron Grid/Preclean Corotron High Voltage Power Supply
(CC/PCC-HVPS) (PSHV-L2).
Charge Corotron
The Charge Corotron is replaced every time the customer replaces the Photoreceptor Drum (a
CRU). The Charge Corotron can also be replaced by the service engineer (an Engineer
Replaceable Unit, ERU) This unit consists of a single 30 micron diameter wire and a metal
screen grid positioned between the Corotron Wire and the Drum.
The Charge Corotron provides a constant current for charging the surface of the Photoreceptor
Drum with a uniform negative potential. This bias voltage on the Corotron Grid determines the
potential to which the drum is charged. As shown in Figure 2, this bias voltage and current is
supplied by the CC/PCC-HVPS (PSHV-L2). The power supply output voltage can vary
between -300 VDC and -1000 VDC. The output current is a constant 700 microamperes. The
IOT Drive provides the +24 VDC power source to the power supply. It also controls and monitors the output voltage. Figure 2 shows the location of the CC/PCC-HVPS (PSHV-L2)
The Corotron Grid is coated with a neutralizing agent (catalyst) so that it cannot give off any
substance that would be detrimental to the life of the Photoreceptor.
Charging
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Figure 3 ESV circuit

Charge Corotron HVPS
DEVELOPER BIAS HIGH VOLTAGE
POWER SUPPLY (PSHV-L1)
The CC/PCC-HVPS (HVPS-L2) provides a regulated constant current to the Charge Corotron.
This is typically in the range of 630 to 770 microamperes. To accomplish this, the power supply
charges the Charge Corotron to -300 to -1000 VDC. The output current and voltage are controlled by Pulse Width Modulator (PWM) control signals from the IOT Drive and Control
PWBAs. Interlocked +24 VDC from the IOT Drive PWBA is the power input from which the high
voltage output is generated.
CC/PCC HIGH VOLTAGE

POWER SUPPLY (PSHV-L2)
Figure 2 Charge Corotron Grid/Preclean Corotron High Voltage Power Supply (PSHV-L2)
and Developer Bias High Voltage Power Supply (PSHV-L1) Location (09-095)
Charge Corotron Cleaning
The Charge Corotron is not cleaned. It is part of the Photoreceptor Drum CRU, or can be
changed by a service engineer (ERU).
ESV
The Electrostatic Voltmeter (ESV) consists of an ESV Sensor and an ESV PWBA. The ESV
Sensor produces an output which is proportional to the drum surface potential. The ESV
PWBA processes this output and provides a signal to the IOT Drive and Control PWBAs. This
output is a scaled representation of the drum surface potential and has a range of 0 - 4.9 VDC.
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Charging
Development
Developer Rotary Assembly
NOTE: In common practice, the terms toner and developer are often used interchangeably,
which can result in confusion. For the purpose of this discussion, the following definitions
apply.
The Developer Rotary Assembly contains all four color Developer Housings (YMCK). These
are separated by 90 angles in the Rotary Assembly. A 24 V, 4 Phase Stepper Rotary Motor
drives the assembly. The Rotary Motor is controlled by 3 signals:
Developer consists of a mixture of toner particles and carrier beads and exists before developing the latent image on the Photoreceptor Drum.
Toner particles are used to develop the latent image on the Photoreceptor Drum and then
transfers as the final image onto the copy material.
Rotary Motor ON
Rotary Motor CLOCK
This machine starts with developer (a toner and carrier bead mixture) within the Toner Cartridges and the Developer Housings. For that reason, this documentation will use the term
developer throughout the Toner Supply processes, and the term toner for the developed
image on the Photoreceptor Drum, the IBT and on the copy material.
The Development subsystem consists of four color Developer Housings mounted on a Developer Rotary Assembly. This Rotary Assembly rotates the four individual color Developer Housings, one at a time, into position in order to transfer the developer to the electrostatic latent
image on the Photoreceptor Drum. (See Developer Rotary Assembly)
Rotary Motor HIGH
The Rotary Motor Clock is a pulse output signal coming from the Rotary Stepper Motor. It is
used to determine the Rotary Housing position. The Rotary Assembly rotates once every 2,400
steps.
Braking of the Rotary Assembly is performed by directly controlling the stepping-type Rotary
Motor. In B&W operation, the Rotary Assembly is mechanically locked via a Rotary Latch Solenoid and gear.
The development method in this machine is called Semi-Conductive Magnetic Brush (S-CMB)
development. It is a compromise between Insulative Magnetic Brush (IMB) and Conductive
Magnetic Brush (CMB). The advantages of IMB and CMB are retained with S-CMB. The disadvantages of rough graininess and the CMB disadvantages of brush marks and a non-linear
tone reproduction curve are minimized.
Rotary Assembly
The high negative charge (VH) on the Photoreceptor Drum represents the background, or nonimage area. This will repel the developer, which is charged at -500 to -565 VDC (VBias). This
VBias varies, depending upon humidity and Photoreceptor Drum cycles.
NOTE: Vdev (=VL-VBias) and Vclean (=VH-VBias) are always constant. VBias is changed by
the VH value.
When the Laser beam exposes the image area onto the Drum, it reduces the negative potential
charge in the Image area of the drum to approximately -300 VDC (VL). This image area will
attract the negatively charged toner from the Developer Roll, creating a developed image for
that particular color.
The developed image on the Photoreceptor Drum rotates down to the IBT. The developed
image will then transfer from the Drum to the IBT at the First Bias Transfer Roll (1st BTR). If
there is more than one color in the copy job, these colors will follow the same development and
transfer process as just explained, with the different color layers accumulating on top of each
other onto the IBT. When all colors have been transferred to the IBT, then the final image will be
transferred to the paper in one pass. This is done at the Second Bias Transfer Roll (2nd BTR)
which cams up to the IBT, with the copy material passing through this nip.
The developer is delivered from the four Toner Cartridges to the Developer Housings by a system of augers. These augers deliver the different toner colors to a Toner Dispenser which funnels the toner into the appropriate Developer Housings. (See Toner Supply.)
Development Point
Developer Roll
Developer Housing
Assemblies (4)
Figure 1 Developer Rotor Assembly
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Developer Rotary Position
The Developer Rotary Assembly has a home position that it always returns to at the start of
any print job. The home position for the Rotary Assembly places the development point with
the Photoreceptor Drum between the Black and Cyan Developer Housing Assemblies. (Black
is 45 before the development point and Cyan is 45 past the development point). This allows
the Machine Run Control to have a consistent reference point to move the correct color into a
development point for each image pass on the Photoreceptor Drum. A flag mounted on the outside of the Rotary Assembly end frame is detected by the Rotary Home Position Sensor.
The Rotary Assembly rotates only in a clockwise direction when viewed from the front of the
machine. The Rotary Assembly moves a color Developer Housing Assembly into the development point with the clockwise rotating Photoreceptor Drum. When in the development point,
the Developer Roll begins to rotate counter clockwise and receives the bias charge. This bias
charge causes the toner leave the rotating Developer Roll, developing the latent image on the
Photoreceptor Drum. The carrier beads are mostly held onto by the magnetic polarity of the
Developer Roll.
One color at a time is transferred to the Photoreceptor Drum and then to the IBT before the
next color is used to develop the latent image on the Photoreceptor Drum. The order that the
color moves into the development point with the Photoreceptor Drum is:
4.
53 steps before the Developer Housing reaches the Development Point, the Developer Clutch is deenergized and the Main Motor drives the Developer Roll in the
Developer Housing.
Rotary Stepper Motor electronically locks the Developer Housing at the Development
Point. The latent image on the Photoreceptor Drum is then developed.
If any color is not used in the image, the ROS does not write to the Photoreceptor
Drum and no Development Bias is applied to the Developer Roll in the Developer
Housing for that particular color.
5.
When the Yellow development is completed, the Development Clutch is energized and the
Rotary Motor is electronically released.
6.
The Rotary Motor rotates the Developer Rotary Assembly clockwise 90 to the Magenta
Developer Housing. Steps 3 - 5 is implemented for Magenta, Cyan and Black colors.
7.
When Black Developing is completed, the Developer Rotary Assembly resets to Home
Position.
The steps for the Rotary Developer Assembly for B/W Copying are as follows:
1.
When the Copy process is started, the Developer Rotary Assembly rotates and resets to
Home Position. (Home Position = Development Point between Black and Cyan Developer
Housings.)
1.
Yellow (Y)
2.
Magenta (M)
2.
The Rotary Motor is switched off and the electric lock of the Developer Rotor is released.
3.
Cyan (C)
3.
4.
Black (K)
Developer Rotary Assembly rotates clockwise 45 (300 steps) to bring the Black Developer Housing to the Development Point.
Black will always be the last color to be transferred to the Photoreceptor Drum (and also laid
onto the IBT) for a copy job. This order is required so that Black will be the first layer placed
onto the final copy material when transferred from the IBT to the copy material.
When a certain color is not used for a color copying job, the Developer Housing for that color is
still moved into the development point with the Photoreceptor Drum. No development occurs
because the Laser does not mark a latent image on the Drum and no charge is applied to the
Developer Roll in the Developer Housing. The exception to this Rotary Assembly rotation
sequences is for black only copies. For this type of job, The Rotary Assembly does not stop at
any of the other colors (Y, M, C). See Table 1 for the Developer Rotary sequences and refer to
Developer Bias and Power Supply for more information on the charging the Development Roll.
99 steps before the Developer Housing reaches the Development Point, the Development Bias is energized.
53 steps before the Developer Housing reaches the Development Point, the Developer Clutch is deenergized and the Main Motor drives the MAG Roll in the Developer
Housing.
4.
When the Black Developer Housing reaches the Development Point, the Rotary Latch
(self-holding) Solenoid is energized to lock the Rotary Assembly in place and the latent
image on the Photoreceptor Drum is developed.
5.
When the Black development is completed, the Rotary Latch (self-holding) Solenoid is
energized to unlock the Rotary Assembly.
6.
The Developer Rotary Assembly resets to Home Position.
The steps for the Rotary Developer Assembly for Color Copying are as follows:
1.
When the Copy process is started, the Developer Rotary Assembly rotates and resets to
Home Position. (Home Position = Development Point between Black and Cyan Developer
Housings.)
2.
The Rotary Motor is switched off and the electric lock of the Rotary Developer Assembly
is released.
3.
Developer Rotary Assembly rotates clockwise 135 (900 steps) to bring the Yellow Developer Housing to the Development Point.
99 steps before the Developer Housing reaches the Development Point, the Development Bias is energized.
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NOTE: * Rotary Sequence Key for the previous Table:
represents the Developer Rotary rotating to the next color Developer Housing
Assembly
/ represents the repeated development by one color, with the Developer Housing
Assembly remaining stationary
Developer Housing Assembly

Each Developer Housing Assembly is made up of the following components:
Toner Entrance Port - accepts replenishment developer from the Rotary Dispenser and
Toner Cartridge.
Admix Auger - distributes the developer from the Toner Entrance Port to the full length of
the Developer Housing Assembly.
Supply Auger - distributes the developer to the Developer Roll and remixes the recycled
carrier beads from the Photoreceptor Drum with new developer.
Developer Roll - collects the developer within the assembly by internal magnets and
transfers it to the Photoreceptor Drum for developing the latent image.
Trim Bar - scrapes of excess developer from the Developer Roll, leaving a metered
amount of developer on the Developer Roll.
Trickle Shutter - a small gate that opens to allow waste carrier beads to be dispensed
into the Trickle Auger, which empties into the Waste Developer Bottle.
Each Developer Housing Assembly has a unique registration pin to prevent it from being
placed in the wrong color location.
Figure 2 Developer Rotor Home Positioning Components
The user has the option of selecting the type of copying/printing required. These user selected
parameters include: B/W and color copying, single or multiple copies, duplex or simplex, different paper sizes, and LEF or SEF. These variables can impact the rotation sequence for the
Developer Rotary.
Table 3 represents the development sequence for the Developer Assemblies for different types
of print jobs.
Each Developer Housing Assembly holds approximately 420 grams of developer. Two augers
mix the toner and carrier which make up the developer, This helps evenly distribute the developer throughout the length of the assembly. The augers also transport the old developer to the
discharge gate as part of the trickle development system.
A new type of developer is used for this machine. The color toners are smaller 6.5 micron diameter courser cut particles. The courser cut allows more pigment to be carried, compensating for
their smaller size. The black toner particles are 8.5 microns in diameter. The average carrier
bead size for all toners is 35 microns.
The Developer Roll is hollow Aluminum with five magnet poles inside. The magnet polarity is
designed to draw the metal carrier beads, covered with toner, onto the Developer Roll and hold
the beads on this roll as it passes the development point. The magnetic draw on the beads is
minimized after passing the development point, allowing the used beads to drop off the Developer Roll into the Developer Housing Assembly.
Table 1 Developer Assembly sequence

Type of Print/Copy Job
Rotary Sequence for laying colors *
Black only copy, single sheet

(1 image on IBT)
Home Black Home
Black only copies, multiple sheets

(2 images on IBT)
Home Black / Black Home
Any or all Colors, single sheet

(1 image on IBT)
Home Yellow Magenta Cyan Black Home
A Trim Bar in the Developer Housing Assembly scrapes off the excess developer and is set for
a trim gap of 0.7 mm for all colors. There is a gap of 0.5 mm in the Photoreceptor Drum to
Developer Roll spacing (DRS). This is factory set and will be field adjustable, if required.
Any or all Colors, multi-sheet

81/2x11 LEF or smaller
(2 images on IBT)
Home Yellow / Yellow Magenta / Magenta

Cyan / Cyan Black / Black Home
The Developer Roll rotates at 1.75 times the speed of the Photoreceptor Drum. In addition, the
Developer Roll rotates counter clockwise while the Photoreceptor Drum rotates clockwise.
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Developer Bias and Power Supply
Toner Supply
The Developer Bias High Voltage Power Supply (PSHV-L1) provides a DC voltage with an AC
signal superimposed on it. This composite voltage is provided to the developer before it is presented to the Photoreceptor Drum to form the image. These voltages are derived from interlocked +24 VDC provided by the IOT Drive PWBA. The power supplys DC output level is
typically in the range of -510 VDC to -560 VDC, but can be set over the range of -205 VDC and
-800 VDC. The AC component is 1.0 KV peak-to-peak with a frequency of 9 kHz. As shown in
Figure 4, signals from the IOT Drive PWBA control the voltage of the DC component, the voltage of the AC component and the frequency of the AC component. Figure 3 shows the location
of the Developer Bias High Voltage Power Supply (PSHV-L1).
The developer composition (toner and carrier beads) and how the carrier beads are reused in
this machine is different from other color machines. The developer that is supplied in the Toner
Cartridges consist of both toner and carrier beads mixed together. As the toner is used to
develop the electrostatic image, the carrier beads are recycled back into the developer to be
remix with new toner and carrier beads. New developer is added to the system as determined
by Process Controls using ADC (Automatic Density Control) readings. As new developer is
being added to the toner supply system and as the carrier beads are recycled, excess waste
carrier beads can accumulate which needs to be siphoned off. The excess waste carrier beads
are disposed of to the Waste Carrier Bottle. This Trickle System for developer supply (referred
to here as toner supply) is unique to this color machine.
Because the Develop Rotor has four Developer Assemblies that are not stationary, the system
suppling the developer to the Developer Assemblies is complex.
The four colors of developer are stored in individual Toner Cartridges. For each of the four colors, the developer is moved from the Toner Cartridges to the Toner Cartridge Housing, through
the Conveyor Auger, to the Rotary Dispenser, out through the Rotary Auger and into the Developer Housing Assembly.
The following will explain this process in detail, starting with the Toner Cartridge Unit.
Toner Cartridge Unit
The Toner Cartridge Unit contains 4 Toner Cartridges and their motors. This unit can be
removed from the machine as one complete assembly. This Toner Cartridge Unit contains the
following components: (Refer to Figure 4.)
Figure 3 Developer Bias Block Diagram

As the AC component of the Developer Bias swings through its high negative values, toner is
driven from the Developer Roll to the image areas on the Photoreceptor. As the Bias swings
lower negative, excess toner is retrieved from the Photoreceptor.
4 Toner Cartridges (one each for yellow, magenta, cyan and black)
4 Cartridge Motors
4 Toner Dispenser Motors
4 Toner Cartridge Housings
3 Conveyor Augers (Yellow does not use this auger)
4 Toner Sensors
Associated drive gears
A wire carries the Developer Bias voltage from the Developer Bias PWBA to a Bias Plate at the
front of the Developer Rotary Assembly. The center shaft of the Developer Roll makes direct
contact with the Bias Plate when the Developer Housing Assembly is in the development point.
This direct contact transfers the bias charge to the Developer Roll.
Developer Clutch
The Developer Clutch is a reversal-type clutch. When the clutch is de-energized, the Main
Motor through a gear meshing drives both the magnetic Developer Roll and the internal augers
in the Developer Housing. The internal augers mix the toner and carrier beads while the magnetic Developer Roll moves the developer (toner plus carrier) to the Photoreceptor Drum for
developing the latent image.
The drive from the Developer Clutch to the Developer Roll and augers occurs only when two
conditions are met: (1) the roll is in the development point, and (2) there is a latent electrostatic
image on the Photoreceptor Drum to be developed.
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Development
Table 2 Developer Mixture in Toner Cartridges

Y Developer
M/K/C Developer
Toner by weight
284 g
284 g
Carrier Beads by
weight
37.9 g
66.3 g
Total Developer in new 321.9 g

Toner Cartridge
350.3 g
The Cartridge Motors is powered by 24 VDC derived from Interlocked +24 VDC and controlled
by enable signals from the IOT Drive PWBA. When the Low Toner Sensor in the Toner Cartridge Housing is activated, the Cartridge Motor runs for:
Toner Cartridge Housings (4)

(Magenta)
C
Dispense Motors (4)

(Cyan)
M
Y
10 second intervals when the machine is actively making prints.
20 second intervals when the Low Toner Sensor senses low toner levels and when
machine power is on and the front Door Interlock is closed.
Toner Cartridge Housing
The Toner Cartridge Housing contains:
Agitator
Auger
Paddle
Low Toner Sensor (Piezo type, located outside the Toner Cartridge Housing unit)
The agitator and paddle help prevent the developer from becoming compacted. The auger
moves the developer to the outlet where the developer falls into the conveyor. These components are driven by a Toner Dispense Motor, one motor for each of the four colors. This motor
also drives a Conveyor Auger for transporting the developer out of the Toner Cartridge Housing.
Cartridge Motors (4)

(Yellow)
Figure 4 Toner Cartridge Assembly (Back View)
Toner Cartridge
Each Toner Cartridge has an Agitator driven by a unique Cartridge Motor. The Agitator serves
two functions; it prevents the developer from becoming compacted, and it moves the developer
to the outlet port where it falls through to the Toner Cartridge Housing. This Cartridge port
shutter closes when the Toner Cartridge is rotated for removal from the machine. Each Toner
Cartridge holds a mixture of toner and carrier beads. Table 2 show the composition by weight
for each developer that are within the new Toner Cartridges.
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CARTRIDGE
MOTOR
The Conveyor Augers are driven by the Dispense Motors. The Dispense Motors are energized
when the IOT CPU PWBA senses low reflective readings from the ADC Sensor for the patch
on the IBT.
AGITATOR
DISPENSE
MOTOR
TONER
CARTRIDGE
LOW
TONER
SENSOR
CONVEYOR
AUGER
CARTRIDGE
HOUSING
(LOWER)
Figure 5 Toner Cartridge and Cartridge Housing

A piezo electric Low Toner Sensor located under the shutter opening monitors the level of toner
in the Toner Cartridge Housing.
The IOT CPU PWBA samples the Low Toner Sensor status every 0.1 second while the
machine is making and moving the Developer out of the Toner Cartridge Housing into the conveyor. When a low developer level is detected 5 times in succession, the Toner Cartridge Motor
is energized for 10 seconds. This moves additional developer from the Toner Cartridge to the
Toner Cartridge Housing.
When a low developer level is detected 20 times in succession or for longer than 25 seconds, a
low toner message is displayed. If the Toner Cartridge is replaced, the low toner message is
removed as soon as a low toner level is no longer detected by the sensor 10 times in succession.
If 100 seconds of low toner is sensed while the Toner Dispense Motor is running, then the
controls will not allow another copy job to be stated. At the end of the current job, a do not
copy message is displayed and the copier will not start another job.
Conveyer Auger
The 4 toner Cartridge Housings are different distances from the Rotary Dispenser. For that
reason, there are different lengths of Conveyor Augers and one Cartridge Housing (Y) does not
use a Conveyor Auger. Refer to Figure 6.
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Figure 6 Developer Distribution Path

Rotary Dispenser
The Rotary Dispenser accepts the four different developers and deposits them into their appropriate Developer Housing Assembly within the Developer Rotary. Figure 7 shows the Rotary
Assembly for one color system.
As toner is deposited into the Rotary Dispenser by the Conveyor Auger, it is transported out to
the Developer Housing Assembly by a Rotary Auger.
The Rotary Augers have a Axel shaft that goes to the back side of the Developer Housing
Assembly. This shaft has a gear that is driven whenever the Developer Clutch is energized and
is powered by the Main Drive. The Rotary Auger rotates at 345 rpm to move the toner quickly
from the Rotary Dispenser to the Developer Housing Assembly.
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The carrier beads are brought back into the Developer Housing and remixed with the existing
developer. New developer is added to the Developer Housing (see Toner Supply) at a rate
determined by readings taken from the ADC patch on the Photoreceptor Drum.
DEVELOPER ROTARY
ASSEMBLY
Excess waste carrier beads for each Developer Housing are trickled out automatically through
a shutter gate into a center Waste Auger when the Developer Housing is at 90 above the
development point.
DEVELOPER INLET
When performing black only copying, the black Developer Housing needs to rotate up to the
90 location to remove the depleted waste carrier beads into the center Waste Auger. This is
done when:
The copy job is completed
The Toner Dispense Motor runs continuously for 17 seconds.
Waste Carrier Bottle
AXEL SHAFT
The Waste Carrier Bottle receives the waste developer from all four Developer Housings. A
magnetic sensor is used to detect a full Waste Carrier Bottle. The sensor is monitored once
every second. When the waste carrier full status is detected by the sensor five times in succession, then a caution notice (09-423) for the status of this bottle is sent to the User Interface
screen.
ROTARY
AUGER
The machine monitors both the sensor status and the rotating time of the Toner Dispense
Motor from this caution status. When a specific accumulated NVM value for the Toner Dispense Motor is reached, then a Waste Carrier Bottle fail signal (09-379) is sent to the User
Interface.
ROTARY
DISPENSER
Toner Supply Control

Figure 7 Rotary Dispenser and Developer Housing Assembly (Example)
Trickle System
This machine uses a Trickle System for replenishing the developer. This system increases the
usable life of the Developer Assemblies. It includes the following:
New developer (toner plus carrier beads) is supplied to the Developer Housings by the
Toner Supply system.
Used carrier beads from the Developer Roll are remixed back in with the new developer at
the Developer Housing.
Any excess waste carrier beads that accumulates in the Developer Housing is discharged
into a central Waste Auger and transported to the Waste Carrier Bottle. This Waste Auger
and Waste Carrier Bottle accepts the excess developer from all four colors.
Toner supply is controlled by the IOT CPU PWBA, through the IOT Drive and Dispense
PWBAs. The Low Toner Sensor output is routed to an input port on the IOT Drive PWBA,
where it can be read by the CPU on the IOT CPU PWBA. Likewise, the CPU controls a port
output from the IOT Drive PWBA for both the Cartridge and Dispense Motor control lines.
These control lines enable Dispense PWBA circuitry which converts Interlock +24 VDC to 24
VAC, 60 Hz power for the motors. Note that in Figure 9, only the black control and status lines
are shown. The yellow, magenta and cyan circuitry is exactly the same.
This system starts with the Toner Cartridges which carry a mixture of both toner and carrier
beads. The different colors of developer are transported to the appropriate Developer Housing
within the Developer Rotary Assembly. When the latent image on the Photoreceptor Drum is
developed, the toner is electrostatically attracted to the drum and the metal carrier beads
remain on the magnetic Developer Roll.
Development
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Figure 8 Toner Supply Control Simplified Block Diagram (Black)
ADC (Automatic Density Control)

The ADC Sensor is a Polarized Color Densitometer (PcDM) consisting of a Light Emitting
Diode (LED), a phototransistor and a polarizing filter. The ADC Sensor is located in the IBT
Assembly. This sensor reads the reflected light from a toner patch placed on the IBT Belt. This
reflective reading is used by Process Controls to determine the density level of the image
which will then determine the required running times for toner dispensing.
TR0 SENSOR
ADC SENSOR
The current through the phototransistor is proportional to the amount of light reflected from the
developed patch. The current is converted to a voltage level on the ADC Sensor PWB and that
voltage signal is sent as two analog signals through IOT Drive PWB to the IOT CPU PWBA
where it is used for process control functionality. The ADC Sensor and ADC Sensor PWB are
part of the ADC Sensor Assembly. Refer to Figure 10 for a block diagram of the ADC Sensor
control.
STEERING
ROLL
(INSIDE
BELT)
IBT BELT
DRIVE ROLL (INSIDE
BELT)
Figure 9 IBT and Selected Subassemblies Locations

ADC patches are made and read:
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Development
During Max Setups (in Diagnostics)
During Mini Setups
During run mode after every 26th copy for A4 or 8 1/2 x 11 inch copies
During run mode after every 13th copy for A3 or 11 x 17 inch copies
The readings are used by Process Controls to determine the developer dispensing run time.
Refer to Process Controls for more information on this function.
The dynamic range of the ADC Sensor is from 0% to about 80% area coverage. The ADC
patches are made at area coverage of 60% (for black toner) or 65% (for yellow, magenta and
cyan toner). In addition, for a given coverage, the black patch reflects less light than the
remaining colors. These two factors result in differences in sensor outputs: Vpatch, and affects
the ratio Vpatch / Vclean. Later circuitry compensates for these differences.
The physical positioning of the ADC Sensor is critical.
The distance between the ADC Sensor and the IBT Belt must be 8mm, 0.5 mm
The sensor angle with the IBT Belt must be less than 2 in the process direction and
less than 1 across the belt.
Figure 10 ADC Sensor Simplified Block Diagram
Intermediate Belt Transfer (IBT)

Toner Transfer Overview
Intermediate Belt Transfer (IBT) is new technology for this type of machine. This technology
permits increased color print speed and higher image quality. Using an IBT results in two
image transfer points.
1.
The first image transfer point is from the Photoreceptor Drum to the IBT (the colors transfer one at a time from the Drum to the IBT.)
2.
The second image transfer is the complete image for the IBT to the copy material. (All
color layer transfer in one pass.)
When making color images, one color at a time is developed on the Photoreceptor Drum and
then transferred to the IBT before the next color is used to develop the latent image on the Photoreceptor Drum. The IBT Belt accumulates all four separate color images from the Photoreceptor (PR) Drum. During a four color image copy job, the IBT Belt cycles four times to accept
the individual colors from the Photoreceptor Drum.
Because the toner transfer process occurs in two steps (PR Drum to IBT Belt, then IBT Belt to
copy material), the image and the layers of toner on the IBT are reversed from what the finished copy is.
Development, Intermediate Belt Transfer (IBT)
After each image is developed on the Photoreceptor Drum, the Drum rotates clockwise to
make contact with the IBT Belt, which is rotating counter clockwise. This contact occurs at the
First Bias Transfer Roll (1st BTR) position on the Belt. The 1st BTR and Photoreceptor Drum
create a nip, through which the IBT Belt passes. The 1st BTR roll always remains in contact
with the back side of the IBT Belt, and the IBT Belt is always in contact with the Photoreceptor
Drum. (The 1st BTR Roll is cammed away from the Photoreceptor Drum by the IBT lever on
the IBT Drawer. This is done when sliding this drawer open or closed.)
The 1st BTR inside the IBT Assembly is charged to +32 microamps at +1200 VDC by the 1st
BTR HVPS. This causes the negatively charged toner on the PR Drum to be attracted to the
surface of the IBT Belt at this 1st BTR point. The charge to the 1st BTR remains on from the
start to the end of a job.
When all four color image components have been transferred to the IBT, this image is transferred to the final copy material using one pass. This second image transfer takes place where
the IBT Belt contacts the Second Bias Transfer Roll (2nd BTR).
The 2nd BTR is part of a separate assembly, below the IBT Assembly. This 2nd BTR Assembly
includes:
Inlet Plate
Pre IBT Sensor (for the paper path)
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Cleaning Blade Assembly
Second BTR Roll
Camshaft Assembly and Cam Sensor
Detack (DTS) Comb
Lubricating Brush
Pre Fuser Sensor (for the paper path)
Exit Chute
IBT Assembly
CAUTION
The IBT Belt is fragile. It can be damaged by handling with bare hands or having items (i.e.
screws, tools or even excess dust/dirt) dropped on it.
The IBT Assembly has its own tray with slide tracks which allow this assembly to be pulled out
for access and servicing. Figure 2 shows some of the components in the IBT Assembly.
Detailed descriptions of the components follow.
IBT Belt
The 2nd BTR Roll cams up to make contact with the IBT Belt. The Main Motor drives both the
2nd BTR Roll and the 2nd BTR Retract Clutch and Shaft. The Shaft with cams rotates, raising
and lowering the 2nd BTR Roll when energized by the IOT CPU and Drive PWBAs. A Flag on
the Shaft passes through a 2nd BTR Retract Home Position Sensor. The status of the Sensor
is as follows:
Sensor blocked - 2nd BTR Roll is down (retracted from the IBT)
Sensor transmits - 2nd BTR Roll is up (contacting the IBT)
The 2nd BTR HVPS (PSHV-L3) is located in the back of the machine and supplies a charge of
approximately -2.2 kVDC to the Contract Roll inside the IBT Assembly (NOT the 2nd BTR
Roll). The Contact Roll transfers this charge to the Back Up Roll by contact. The Back Up Roll
inside the IBT Assembly remains in contact with the inside of IBT Belt at all times. It is this Back
Up Roll that repels the toner image off the IBT Belt onto the copy material. The 2nd BTR cams
up to the IBT Belt to create a nip with the IBT Belt and the Back Up Roll behind the Belt. The
copy material has the image transferred to it at this 2nd BTR and IBT nip. The copy material
holds the toner by a residual static charge.
A Detack Comb (DTS) is located on the 2nd BTR Assembly. The purpose of this Detack Comb
is to neutralize the copy material and assure the copy material does not tack to the IBT Belt. A
DTS HVPS within the Registration Roll Assembly provides a negative charge to the Detack
Comb.
Most of the machine timing and image quality controls are generated from readings taken of
the IBT. The belt has two TR0 marks which pass under a TR0 sensor to provide a timing reference pulse. Also, toner patches are laid down onto the PR Drum, are passed to the IBT Belt,
then measured for density by the ADC (Automatic Density Control) Sensor. This allows the
machine to maintain a consistent toner level for the same input color.
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The IBT uses a carbon-impregnated polyamid belt that carries the image toner from the Photoreceptor (PR) Drum to the paper. This belt holds a residual charge from the First Bias Transfer
Roll (BTR), which attracts the toner particles and holds them until that part of the belt reaches
the nip between the Second BTR and the Back Up Roll. At that point, the voltage from the Back
Up Roll causes the toner particles to be expelled from the Belt to the blank copy material. The
Belt has a circumference of 527.91 mm, which is twice the circumference of the PR Drum. At a
process speed of 220 mm/sec., the belt takes 2.399 sec. to complete one complete revolution.
The belt has two TR0 strips, separated by one-half the belt circumference and located on the
back edge of the belt. As shown in Figure 2, there are eight rolls inside the belt:
Steering Roll keeps the IBT on track and centered on the rolls.
Tension Roll keeps the belt taut.
First Idler Roll is passive and directs the belt towards the Photoreceptor Drum. It is
located between the Tension Roll and the First BTR Roll.
First BTR Roll holds the charge which attracts the toner from the Photoreceptor Drum to
the belt
Drive Roll is driven by the PR Drum Motor, which causes the IBT Belt to turn. It also
helps keep the belt on track.
Contact Roll receives the charge from the 2nd BTR HVPS and transfers this charge to
the Back Up Roll.
Back Up Roll provides a charge for toner transfer from the IBT Belt to the copy material.
It also creates a nip with the Second BTR Roll, through which both the IBT Belt and the
copy material passes through.
Second Idler Roll is passive and positions the belt between the Steering Roll and the
Backup Roll/Second BTR nip.
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Intermediate Belt Transfer (IBT), IBT Assembly
Figure 1 IBT Belt Rolls and Assemblies

Figure 2 HVPS for IBT Assembly
Drive Roll
The Drive Roll is driven by the Drum Motor. As such, Its speed changes to conform to nominal
process speeds of as the 220 mm/sec., 130 mm/sec. and 60 mm/sec. depending upon to the
copy material in use.
Tension Roll
The Tension Roll is constantly being forced upward, against the IBT Belt, by an arm-and-spring
arrangement. This is done to keep the belt tight.
IBT Cleaning Assemblies

After the toner has been passed from the IBT Belt to the blank copy media, the residual toner is
removed from the belt by a plastic blade in the IBT Cleaner Assembly. This blade is retracted
by the Main Motor when the IOT CPU and Drive PWBAs engage the Cleaner Retract Clutch.
For color images, the blade touches the belt only one belt rotation in four. The toner falls into
the IBT Waste Toner Auger, part of the Waste Toner Auger Junction. (See Cleaning Systems.)
IBT Assembly
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TR0 Sensor
As shown in Figure 10 and Figure 3, the TR0 Sensor is mounted on the back left side of the
IBT Frame Assembly. This sensor monitors two TR0 patches on the IBT to monitor cycle
speed. As shown in Figure 4, the sensor output goes to the IOT Drive and Control PWBAs.
There, it forms the basis for synchronizing all paper transport activities.
Figure 3 TR0 Circuit Block Diagram
IBT/Media Transport Sensors

There are two sensors to detect IBT paper jams.
The Pre-IBT Sensor monitors for paper jams between the Registration Roll and the 2nd
BTR. Located on the 2nd BTR Inlet Chute.
The Pre-Fuser Sensor detects the print as it reaches the Vacuum Transport. An abnormal
indication is that the leading edge of the print is not detected by this sensor within approximately 400 msec (at 220 mm/sec. process speed) after the 2nd IBT Sensor detects the
same edge. Located in the 2nd BTR Exit Chute.
Figure 4 IBT/Media Transport Sensor Locations
Figure 5 Partial electrical schematic for IBT Sensors

In addition to the paper jam sensors for the IBT, there is the ADC (Automatic Density Control)
Sensor and the TR0 Sensor. Refer to these sections for more information on these two sensors.
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IBT Assembly
Motors
Cleaning Systems
Xerographics Motors
Residual toner is removed from the Photoreceptor Drum by using a Preclean Corotron, a
Cleaning Blade and a Brush. The IBT uses a camming Cleaning Blade. A Waste Toner Auger
system is used to transport the waste toner to a Waste Toner Bottle.
Table 1 lists the motors associated with the Xerographic function.

Table 1 Xerographics Drive Motors
Motor
Activated By
Deactivated By
Cartridge Motors (4) Each motor drives a

Toner Cartridge Agitator
Low Toner Sensor is

activated.
Ten seconds after

being activated
Toner Dispense
Motors (4)
Low Density ADC

patches on IBT Belt,
Mini Set-up or normal
toner supply
Acceptable ADC
patches on IBT Belt.
Main Motor
Function
Drives the following in

the Toner Cartridge
Housing:
Cartridge Agitator
Paddle
Cartridge Auger
Conveyor Auger
Drives the following

within the Developer
system:
Trickle Auger
The carrier beads that come back off each Developer Roll during the development process are
recycled into the corresponding Developer Housing Assembly and are remixed with the other
developer for reuse.
Photoreceptor Cleaning
The components of the cleaning system for the Photoreceptor Drum includes: (See Figure 1.)
Start of Job
End of Job
Bead Pickup Roll (BPO)
Preclean Corotron (PCC)
Photoreceptor Clean Brush
Flicker Bar
Blade
IBT Cleaner
Retract
Auger
Duct
IBT Cleaner
Auger (Front)
Erase Lamp (Located in the machine, not mounted on Photoreceptor Drum)
IBT 2nd BTR
IBT 2nd BTR

Retract
Waste Toner
Auger
Bottle Entrance
Auger
Bottle Inner Auger
IBT Cleaner
Auger Rear
Drum Cleaner
Auger Rear
IBT Oil Roll

Retract
Rotary Motor
Drives the following:
Developer Rotary
Assembly
Drum Motor
Photoreceptor
Drum
In addition, there is a Developer Waste Bottle which accumulates overflow developer from the
Developer Assemblies. This is a part of the Trickle System. Refer to that section for more information on that function.
After the Drum has transferred the image to the IBT, the Drum turns past a Preclean Corotron.
This single wire Corotron neutralizes any charge on the Drum so that the Clean Brush and
scraper Blade can clean the Drum more easily. The rotating Brush cleans off the Drum and
carries toner residue away that the Blade scrapes off. A Flicker Bar cleans the toner particles
off the Brush and an auger moves this waste toner out of the Xerography module to the Waste
Toner Auger unit for transport to the Waste Toner Bottle.
Start of Job
End of Job
IBT
Motors, Cleaning Systems
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Cleaner Assembly
PHOTORECEPTOR
CLEANING BRUSH
After the Photoreceptor Drum rotates past the PCC, the residual toner is brushed and
scrapped off the Drum surface by the Photoreceptor Cleaning Brush and a plastic Cleaning
Blade. The Cleaning Brush picks up the loose toner from the Drum and the Clean Blade. This
brush is 19mm in diameter. It is driven by the Main Motor and rotates counterclockwise at
approximately 249 RPM. It forms a nip measurement with the Photoreceptor Drum of 6 to 9
mm. After the brush contacts the drum, it rotates past the Flicker Plate, which dislodges the
toner from the Brush. This toner residue falls onto the Drum Auger, part of the Waste Toner
Auger Junction.
CLEANING
BLADE
PHOTORECEPTOR
DRUM
After contacting the brush, drum is cleaned by a plastic blade. The Cleaning Blade is 22 mm
thick polyrethane and makes a 20 to 24 angle with the Photoreceptor surface. The blade is
always against the drum and does not retract. This blade angle was selected to provide effective cleaning without filming.
Erase Lamp
BPO ROLL
AUGER
The Erase Lamp is mounted in the machine and is not a part of the Photoreceptor Drum CRU.
The Lamp is an LED array and is used to irradiate the Drum, which erases the remaining electrical charge.
Photoreceptor Drum Cleaning Electrical Control
All of the mechanisms to clean the Photoreceptor Drum are either passive or are constantly
driven by the Main Motor. This motor is activated by the IOT CPU and Drive PWBAs whenever
a job is started.
PRECLEAN COROTRON
IBT Cleaning
After the IBT has transferred the image to the copy material, it rotates counter clockwise past a
IBT Clean Blade. Refer to the IBT Cleaning Assemblies section for more information.
Waste Toner System

This machine uses a cleaning system to dispose of waste toner from both the Photoreceptor
Drum and the IBT. The residue cleaned from both of these components is transported by one
common system and disposed of into one common waste bottle.
Figure 1 Photoreceptor Cleaning Components and Location

Bead Pick Off Roll (BPO)
The first cleaning function on the Photoreceptor Drum takes place after the latent image has
been developed with toner and before the image transfers to the IBT. A metal Bead Pick Off
Roll is used to pick off the toner agglomerates. This is an 8 mm diameter Stainless Steel roll
the rotates counter clockwise at 44 rpm, against the direction of the Photoreceptor Drum. This
roll is driven by the Main Motor during the print job. The drum-to-roll space is 0.5 mm 0.1 mm.
Preclean Corotron
The Waste Toner System consist of the following:
Waste Toner Bottle with internal Coil Auger
Waste Bottle Sensor (photo sensor)
Waste Bottle Full Sensor (photo sensor)
Waster Toner Auger Junction Assembly components -
After the Drum has transferred the image to the IBT, the Drum turns past a Preclean Corotron.
The Preclean Corotron (PCC) is a single wire corotron which neutralizes any charge on the
Photoreceptor prior to the cleaning zone so that the Photoreceptor can be more easily cleaned
of residual toner.
Preclean Corotron power comes from the CC/PCC-HVPS (HVPS-L2 - see Figure 3) that supplies the Charge Corotron. Energy to the PCC is supplied as a constant current type DC bias.
Machine Run Control regulates the DC current based on the humidity level. In actual operation,
the DC current is controlled within the average operation at -300 microamps constant currant.
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Jointed Slanting Auger
Jointed auger from the Photoreceptor
Jointed auger from the IBT
Bottle Auger
Drive gears and timing belt
Auger Sensor (photo sensor)
Photoreceptor Drum cleaning components
Photoreceptor Cleaning Brush

Cleaning Systems
Photoreceptor Scraping Blade
Flicker Bar
Bead Pick-off Roll (BPO)
Pre-Clean Corotron
Photoreceptor Waste Auger
Figure 3 shows part of the Waste Toner Auger Junction Assembly which is located in the back
of the machine. This system uses separate jointed augers to acquire waste toner from the Photoreceptor Drum and the IBT. These augers transport the waste toner the Slanting Auger,
which transports the toner to the Bottle Auger. The Bottle Auger transports the waste toner into
Waste Toner Bottle.
IBT cleaning components
The Waste Toner Bottle is a CRU with the capacity to hold 2600cc of toner residue with full volume at 80% (expected bottle life to full at 40Kpv). As shown in Figure 1, two augers are used to
fill the bottle:
IBT Scraping Blade (cammed)
IBT Waste Auger
Film Blade (thin Mylar seal)
The Toner Recovery Auger rotation is monitored by an Auger Sensor. A semi-circle flag
attached to the end of the Auger rotates through the Sensor as the Auger rotates. The Sensor
is sampled 10 times (0.1 sec. cycle) every 2 seconds while the Drum Motor rotates. An Auger
caution (09-424) is indicated at the User Interface when the Sensor does not detect movement (high/low status of rotating flag) 4 times continuously.
An Auger Broken fail status (09-358) is indicated when the number of copies reaches a specified value after the caution status is activated and remains.
Bottle Auger - This feeds the waste toner into the bottle and is a part of the Auger Junction
Assembly.
Coil Auger - This is inside the bottle and is part of it. It helps distribute and pack the waste
toner within the bottle.
The Main Motor drives the jointed augers, the Slanting Auger the Bottle Auger and the Coil
Auger. This motor is energized at the start of a copying or printing job.
The Waste Toner Sensor is a photoelectric sensor that checks for the presence of the Waste
Toner Bottle. This is done when the machine is powered on and the Front Interlock Switch is
closed. A No Waste Bottle failure (09-374) is indicated when the sensor does not see the Bottle.
The Waste Toner Bottle Full Sensor is monitored 3 times a second while the Drum Motor
rotates. When the sensor detects a full status continuously for 3 seconds, then a near full caution (09-420) is indicated at the User Interface.
After the caution status, the machine counter monitors and compares to an NVM value the
following cycles to determine a Waste Bottle Full statusfail (09-376):
Toner Dispense Motor run time
Number of copies
The near full and full status for the Waste Toner Bottle is reset by using the same bottle
sampling method, and the bottle is sensed empty 2 or more times per second.
Figure 2 Junction Assembly for Waste Toner Disposal
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Air Flow
The air flow system used in this machine performs the following functions:
WASTE TONER
BOTTLE AUGER
COIL AUGER
WASTE TONER
BOTTLE
Eliminates the toner and dust particles that float around inside the machine
Discharges the ozone generated by the Corotrons
Provides machine cooling
Provides suction for paper transport
There are a total of five fans used to vent or cool various parts of the machine. In addition to the
fans, this system consists of ducts to channel the air flow, filters to collect particle contaminants
and safety interlock switches. In general, the air is drawn into the machine from the front and it
exits the back. The five fans in this machine are:
Charge Corotron Intake Fan
Fuser Intake Fan
Fuser Exhaust Fan
Suction Blow
IIT Fan (See Imaging)
Charge Corotron Intake Fan

The located on the inside of the front door, closest to the door hinge. It draws the room air into
the machine, directing it through a filter that is attached to the Waste Toner Bottle and into the
Charge Corotron Duct system. This Duct system for the Photoreceptor Drum draws the ozone
away from both the Charge Corotron and the Preclean Corotron. A duct is also around the Seal
Roll to extract any stray toner residue prior to the Drum transferring the developed image to the
IBT.
Fuser Intake and Exhaust Fans
Figure 3 Waste Toner Bottle and Associated Augers
Two fans remove heat generated by the three heated rollers of the Fuser Assembly. The Fuser
Intake Fan is located on the inside of the front door, furthest away from the hinge. It draws room
air into the Fuser Duct system. The Fuser Exhaust Fan is located by the top right side of the
machine, at the exit side of the Fuser Duct System. The Fuser Duct sits above the Fuser
Assembly drawing the radiant heat generated by the Fuser away from the other components
within the machine.
Suction Blower
The Suction Blower is located on the bottom, right side of the back of machine. It is a 24 VDC
fan that draws the air out of the machine, taking the air from the ducts for the Photoreceptor
Drum and the Vacuum Transport. The duct before this fan contains a three part ozone and dust
filter.
Air System Electrical Control

As shown in Figure 1, the Fuser Fan is powered by unswitched +12 VDC directly from the AC
Driver PWBA. Therefore, anytime that the machine is plugged in and the machine circuit
breaker is closed, the fan is running. The FAN HI/LO speed control originates from the IOT
Drive PWBA and is routed to through the AC Driver PWBA.
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Cleaning Systems, Air Flow
The Suction Blower, Rotary Fan, Fuser Intake Fan and Charge Corotron Fan are all controlled
by the IOT CPU and Drive PWBAs. +12 VDC, +24 VDC and +5 VDC power originates at the
IOT Low Voltage Power Supply, but is routed through the IOT Drive PWBA. Fan power is not
interlocked. Therefore, when machine doors are open, the fans still run.
Figure 1 IOT Fans Simplified Block Diagram
Air Flow
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Process Controls
The Set Up procedures are as follows:
Overview
1.
The purpose of Process Controls is to maintain consistent image density and color balance.
Control of the image density is more critical for color images then it is for black copies. Slight
variations in any color density (C, M, Y) can result in a significant hue shift in the final color
image.
Setting Target Values: Accounting to the number of Photoreceptor Drum cycles and the
humidity as sensed by the EVN Sensor, the machine sets target values for Drum Surface
electrical potential (Vh and Vm), Development Bias for each color, ASG Bias, and density
of the ADC Patch.
2.
Setting Grid Voltage: The Grid voltage of the Charge Corotron is calculated so that the
Drum surface electrical potential meets the target values as established in step 1.
3.
Setting ROS LED Quantity: An electric potential background voltage (Vh) Patch is created
on the Photoreceptor Drum and read by the ESV Sensor in step 2. The light quantity of
the ROS LED is calculated so that the exposed image voltage (Vm) of that Patch meets
the target values as established in step 1.
4.
Correction of ASG Bias: The ASG Bias target values for each color established in step
one is corrected by the actual readout value of the Patch on the Drum.
5.
Setting the Target Value for the ADC Density Patch: The target electrical potential of the
ADC Density Patch, as read by the ADC Sensor on the IBT Assembly is done.
Process Controls has two primary monitoring and control functions:
Electrostatic and ROS LED Quantity Control - The surface electrical potential of Photoreceptor Drum monitored by the ESV sensor. And setting the intensity of the ROS LED so
that the Electrostatic patch on the Drum is within the target value for the exposed background charge (Vm).
Developability Control - The supply of developer and the control of toner density and gradation on the IBT as monitored by the ADC Sensor.
Electrostatic and ROS LED Quantity Control

The basic purpose of Electrostatic Control is to maintain the Photoreceptor Drum unexposed
background voltage (Vh) and the exposed image voltage (Vm) constant over time.
This function monitors and controls the electrostatic charge level on the Photoreceptor Drum
and the level of exposure to create the latent electrostatic image. This drum charge level is
read by the Electrostatic Voltmeter (ESV). The drum charge is applied by the Charge Corotron,
with the Corotron Wire suppling a constant voltage and the Corotron Grid Bias adjusting the
voltage to various levels in order to maintain a constant background voltage on the drum.
A background charge (Vh) is to be maintained by Electrostatic Control at the Photoreceptor
Drum. This is done by adjusting the Charge Corotron Grid Bias (Vg). During setups, Electrostatic Control adjusts the Charge Corotron Grid Bias (Vg) to various levels and reads the
resulting Photoreceptor voltage using the Electrostatic Voltmeter (ESV). With a Developer Bias
of -500 VDC, this results in a cleaning field (Vclean) of 150 volts. This cleaning field is the
potential difference which causes toner particles to return to the Developer Roll from the background areas of the electrostatic latent image.
The exposed image charge (Vm) is the electrostatic voltage level on the Drum image area with
a 50% density. Electrostatic Control is always trying to maintain Vm by adjusting the Laser
Diode power level after the Vh is set.
Developability Control
This function monitors and controls the dispensing of developer in order to control the density
of the developed image. The monitoring is done from two inputs:
Automatic Density Control (ADC) - This measures the density of the developed reflective
patch on the IBT by the ADC Sensor. The Gain of the ADC Sensor is adjusted during the
Set Up cycle.
Image Count Dispensing Control (ICDC) - This provides a pixel count for an image to help
determine the demand for the various color developers. This is done during the copy
cycle.
The supply of developer to the Xerographics process is controlled by Image Coverage Dispense Control (ICDC), and the reflective readings off the IBT Belt by the ADC Sensor. The following steps are performed for the Toner Supply Control:
1.
2.
During the machine Set Up Cycle, target values are established for Charge Corotron Grid voltages and the light quantity of the ROS LED, accounting to both temperature and humidity variables as sensed by the Environmental Sensor (EVN). Once these target values are
established, then the following are set:
Development Bias for each color
ASG Bias
Electrical potential of the ADC Density Patch
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ADC Sensor set up for the Automatic Gain Control (AGC)
The ADC Sensor reads the reflective density of the clean IBT Belt (non-developed).
This density reading is check in LUT to be in range or the high and low limit values.
The gain of the ADC sensor is adjusted when the density readings are too high or
low.
Image Coverage Dispense Control (ICDC) is implemented during the copying cycle.
When the ROS Laser exposes the Photoreceptor Drum, the number of pixels is calculated for each color.
These pixel counts is converted to a rotation time of the Developer Dispense Motor
for each color.
ADC Set Up Cycle is performed by reading the actual reflective density of the developed
patch on the IBT Belt. This reading is used to calculate the demand for the Developer.
An ADC Patch is formed on the IBT in a location between the copying images. All
colors are laid down in the same patch and each is read by the ADC Sensor.
The densities for the ADC Patch on the Belt is read and calculated against the reading in the non-developed part of the IBT (clean IBT).
Process Controls
The calculated ADC Density from the IBT is converted to a rotation time of the
Developer Dispense Motor for each color.
Refer to the following Figure 1 for an illustrative overview of how Electrostatic and Developability Controls function.
Figure 1 Process Controls overview
Process Controls
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There are several different control routines which Process Controls runs in order to maintain
consistent image density and color balance. The following Table lists the routines and shows
when and what is performed.
Table 1 Process Controls routines

CONTROL ROUTINE
WHEN PERFORMED
WHAT IS PERFORMED
Run Mode Control
Runs automatically during all

jobs
CONTROL ROUTINE
WHEN PERFORMED
WHAT IS PERFORMED
Max Set Up
Performed in Diagnostics by
the Service Representative
At machine install
Any or all the following subroutines can be performed:
ESV Sensor check
Environmental Sensor
(ENV) check
The following items are controlled:
Vm patch is made and

laser diode (LD) power is
adjusted about every 12
IBT cycles and at the
end of every job,
depending upon paper
size.
Vh/Vm Setup
Toner dispensing is controlled by pixel count

(ICDC) and periodic
ADC readings (approx.
every 13 copies, depending upon paper size)
Using the same patch

readings a in previous
reading, set TRC Cont2
Table 1 Process Controls routines
Mini Setup
Checkup
After changing the ADC

Sensor, ENV Sensor,
Developer Housings or
developer materials
During repair or cleaning

of the xerographics
During any service call
as a precaution measure
Adjust color density
Runs automatically at the start

of the first job after:
Power up, if the Fuser

temperature has
dropped below 120C
ADC Automatic Gain

Control (AGC) Setup
ADC Setup
IOT Hi-light Setup
Color Balance Setup
Two subroutines run in the

order listed:
Vh/Vm Setup
Rest (Stand-by Mode) of

more than 4 hours
When Fuser temp is less
than 120C
Two patches are made

for each color and read
by the ADC to determine
the amount of toner to
dispense
Using the same patch
readings as in previous
routine, set TRC Cont 1
Runs automatically at the start One Subroutine runs:
Vh/Vm Setup
of the first job after:
Power up, if the Fuser

temperature is above
____C
Setup Mode
Most of the Process Controls routines run as setup routines. There are other routines that run
during Run Mode or during Standby Mode.
The Setup Mode will be split into two groups:
Setup routines in Diagnostics - These are procedures that are performed by the Service
Representative while running Diagnostics routines.
Setup routines that run automatically - These are procedures which Process Controls will
run automatically and are a subgroup of Diagnostics.
A paper jam
Setup routines in Diagnostics
30 minutes of elapsed
time since the last
Checkup
The Service Representative enters Max Set Up from the Diagnostics menu to perform the balance of the Setup routines. The Max Set Up menu includes nine (9) routines:
end of a job run
Table 2 Max Setup Routines

Diagnostic Code
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DocuColor 12/DCCS50
Description
Contents
dC945
IIT Calibration
IIT and CCD Calibration, and White Reference Adjustment
dC934
ADC/AGC Setup
Adjusts ADC Sensor gain to get a constant

Vclean
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Process Controls
Table 2 Max Setup Routines

Diagnostic Code
dC933
dC918
Description
VH/VM Setup
Checkup
Contents
There is only one routine in the automatic Checkup routine. This routine is Vh/Vm Setup
described previously. This runs because the electrostatics need to be checked more often than
developability. There are three separate conditions which will cause a Checkup to run:
Adjusts VG/LD/BIAS to achieve the target

VH, VM
Changes VH/VM target to extend Development and Photoreceptor life.
Changes ADC target by Environmental Sensor (humidity)
Changes ASG Bias to keep V10% constant
1.
When power is switched on to the machine and the Fuser temperature is above 120C, a
Checkup will run automatically. This condition occurs when the power has been off for a
short time and the Fuser has not had the time to cool down. A full Mini Setup is not
required for this condition.
IOT Highlight
Setup
Adjusts Highlight legible and in/out balance

by ASG Bias
2.
A Checkup will run after a paper jam has occurred.
dC923
ProCon PG
Print PCON pattern (w/o LUT) and shows

ADC patch values.
3.
Whenever 30 minutes has elapsed since the last Checkup.
Run Mode
dC922
TRC CONT
Makes a TRC LUT based on 2 ADC patches

on the IBT Belt. If ADC is >D60% (0.3) Tone
Up/Tone Down is required (w/o paper)
dC924
TRC Adjust
Adjusts density by TRC LUT offset manually
dC939
TRC Check PG
Print PCON pattern with LUT for TRC adjustment
dC919
Color Balance
Adjusts a center value of user color balance

mode (for Digital Copier only)
There are 3 routines which run while copies are being made. Process Controls uses these routines to monitor and adjust the electrostatics and developability parameters in order to maintain
copy quality. These routines are: LD CONT, Toner Dispense Control and TRC Control.
Standby Mode
When the machine is resting in Standby, there are no setup routines running and none of the
electrostatic or developability parameters need to be controlled. The only function Process
Controls is doing during Standby is keeping track of elapsed time. This is done to track the time
between jobs to determine if a Checkup or Mini Setup is required.
Setup routines that run automatically

Process Controls must automatically perform setup operations at frequent intervals in order to
maintain image quality. The setup routines which run automatically are one of two types,
depending on the conditions: Mini Setup or a Checkup.
Mini Setup
The Mini Setup consist of three subroutines:
1.
Vh/Vm Setup
This electrostatic routine is the same as DC933. This routine may result in new set values
for the Charge Corotron Grid Voltage (Vg) and Laser Diode power (LD) to maintain a Vh
equal to -650 volts and a Vm approximately equal to -350 volts (voltage varies with humidity and Photoreceptor Drum cycles).
2.
ADC Patch readings

This developability routine causes ADC patches to be made for each color. The patches
are measure by the ADC and if the values are different than the target values, the Run
time dispensing algorithm is adjusted. See Run time toner dispensing for more information.
3.
TRC CONT 1
Process Controls
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Overview
The Fusing Process
The Fuser bonds the toner to the copy material (paper or transparency) by applying heat and
pressure to the toner and copy material.
The copy with the unfused toner is transported from the Intermediate Belt Transport (IBT) by
the Vacuum Transport. The Vacuum Transport moves the copy to the Inlet Chute where the
lead edge of the copy is guided into the nip of the Fuser. The Pressure Roll is cammed up into
the Heat Roll to create a nip or a Contact Arc between the two rollers. This Contact Arc serves
two functions:
Functions of the Fuser Subassembly

This Fuser chapter will describe the following functions:
The Fusing Process
Mechanical Drives
Copy Transport and Sensors
Temperature Control and Power Usage
Camming of Rollers
Fuser Release Agent
Web Cleaning of the Heat Roll
Copy Exit
Creates a relatively large roller contact area (about 10.3 mm) in which to apply heat and
pressure to the copy for the fusing process.
Directs the lead edge of the copy down to assist in releasing it from the Heat Roll.
Both the Heat Roll and Pressure Roll apply heat and pressure to the copy. This action fuses the
toner into the paper. The Heat Roll and Pressure Roll are heated from the inside by their own
Quartz Lamp. There is also a metal External Heat Roll that is heated internally by a Quartz
Lamp. The External Heat Roll cams into contact with the top of the Heat Roll to help maintain a
consistent surface temperature on the Heat Roll.
This machine can handle a wide variety of paper weights and material types. The different
materials and weights often require different dwell times in the Fuser Contact Arc to correctly
fuse the toner to the various materials. To achieve these different dwell times, three different
transport speeds are used in the Fuser. The three Fuser transports speeds are:
220 mm per second (nominal) - Normal Paper Mode providing normal fusing speed for
copy weights up to 105 gsm (28 lb bond). B/W, B/W Transparencies and all Color. Note,
this speed equals approximately 1 revolution per second of the Heat and Pressure Rolls.
130 mm per second (nominal) - Heavy Weight Paper Mode providing slower fusing
speed for copy weights of 106 - 163 gsm (28 lb - 90 lb index), plus other special materials.
Both B/W and Color. Note, this speed equals approximately 1 revolution per 2 seconds of
the Heat and Pressure Rolls.
60 mm per second (nominal) - Extra Heavy Weight Paper Mode providing the slowest
fusing speed for copy weights of 164 - 250 gsm (>90 lb - 140 lb index or 90 lb cover), Both
B/W and Color, plus Color Transparency. Note: this speed equals approximately 1 revolution per 3 seconds of the Heat and Pressure Rolls.
Contact Arc
The Pressure Roll is raised into the Heat Roll to form the Contact Arc. The outer core of both
rolls are covered with silicon rubber. Because the Heat Roll rubber layer is thicker (3 mm) than
the Pressure Roll (2 mm), the Pressure Roll sinks into the Heat Roll. This forms a Contact Arc
(a Heat Roll indentation) that curves away from the Heat Roll. When the copy leaves the Fuser
nip, the copy curls towards the Pressure Roll because the Contact Arc is curved in that direction. This paper curl towards the Pressure Roll helps strip the fused copy from the Heat Roll.
The size of the Contact Arc (nip widths of 9.8 mm at the center and 10.3 mm at the ends) provides a relatively large surface area for fusing. This increased surface area enables for a faster
copy transport speed.
Figure 1 Fuser Cross Section View
Reissue
DocuColor 12/DCCS50
The width of the Contact Arc is critical for proper fusing. When the Contact Arc is too narrow,
there is not enough heat and pressure applied to the copy for fusing to occur, and there is a
tendency for the copies to wrap around the Heat Roller. A Contact Arc that is too wide results in
excessive fusing and a tendency for the copy to wrap around the Pressure Roll, creating a
paper jam.
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Overview, The Fusing Process
The Contact Arc adjustment is done by raising or lowering the end support brackets on the
Pressure Roll with two adjustment screws. This bracket and the Pressure Roll cam up into the
Heat Roll. See the Contact Arc adjustment procedures in the Service Manual.
The Heat Roll has a light coating of oil applied to its outer surface. The oil helps prevent the
toner and paper from sticking to the Heat Roll. The metering of the oil is important in preventing
toner contamination on the rollers, copy jams and an excessive coating of oil on the copy. Refer
to Fuser Release Agent section for more information.
Functional Description of Fuser Subassemblies

Mechanical Drives
There are four motors that operate the Fuser functions. The motors, their functions and what
activates/deactivates the motors are listed in Table 1
Table 1 Fuser Drives
Motor
Fuser Motor
Exit Motor
Function
Heat Roll
Pressure Roll
Vacuum Transport
Oil Pick-up Roll
Fuser Exit Rolls
Inverter 1 Roll
Pressure Roll
Camming
Machine Exit
Roll
Activated By
Deactivated By
TR0 signal for first Trail edge of last

color
sheet passing the
Fuser Exit Sensor
or the Heat Roll
warming up to
Ready Temperature for the next
color job.
Print Start Button
Drum Motor off signal
Retract Motor
External Heat Roller

Cam
TR0 signal for first Trail edge of last

color
sheet passing the
Fuser Exit Sensor
or the Heat Roll
warming up to
Ready Temperature for the next
color job.
Web Motor
Web Take-Up Roller
Fuser Exit Sensor

ON
ON time ended by
S/W timer
The Fuser Motor is controlled by the IOT Control and Drive PWBAs. Motor operation is synchronized with the TR0 signal from the IBT Belt.
Through gearing, the Fuser Motor drives the Heat Roller, Pressure Roller, Vacuum Transport,
Fuser Exit Rollers and Oil Pick-up Roll. Therefore, the Fuser Motor drives all of the copy transport mechanisms entering, within and exiting the Fuser Assembly. This means that the three
different copy transport speeds will always be synchronized in the Fuser area.
The Exit Motor drives the Pressure Roller Cam and the Exit Rollers for the machine. Through
gearing and a clutch, the Exit Motor rotates a shaft with eccentric cams at each end. These
cams lift the Pressure Roll up into the Heat Roll forming the Fuser Nip. Brackets and adjustment screws at each end of the Pressure Roll Assembly allows for Fuser Nip adjustment without having to remove an of the Fuser Assembly from the machine. Refer to the Contact Arc
adjustment in your service manual for this procedure.
The Fusing Process, Functional Description of Fuser
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The Pressure Roller Cam is a clutch-driven shaft with cams on each end. When rotated, it
raises and lowers the Pressure Roller. Attached to the shaft is a flag that passes through an
optical sensor. The sensor is blocked by the flag and indicates the Pressure Roller is cammed
up and in contact with the Heat Roller. The normal position of the Pressure Roll is away from
the Heat Roll when the fusing process is not required. For the 220 mm/sec. transport speed),
the Pressure Roll remains in contact with the Heat Roll during the print run. For the 130 mm/
sec and 60 mm/sec transport speeds, the Pressure Roll cams away from the Heat Roll
between copies within a print run.
The Retract Motor rotates an eccentric cam shaft that is used to raise and lower the External
Heat Roll against the Heat Roll. A flag on the end of this shaft actuates an optical sensor to signal that the External Heat Roll is in the correct position. See Camming of Rollers section for
more details.
The Web Motor drives the Take-up Roll on the Web Assembly. This motor pulls the Web material across the Heat Roll and Cleaning Roll. Refer to the Web Cleaning of the Heat Roll for
more information on the Web subassembly.
Figure 1 Fuser Motors Electrical Block Diagram

Table 2 Fuser Motor Control Lines and Condition
Reissue
DocuColor 12/DCCS50
On
Sel 1
Sel 2
CLK
Fuser Motor Operating Condition
N/A
Motor Off
545.37 Hz
N/A
Not used
1182.31 Hz
130 mm/sec process speed
2000.8 Hz
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Copy Transport and Sensors
Table 3 Fuser Thermistor Resistance Values
The unfused print is transported from the IBT Belt to the Fuser by the Vacuum Belt. A Fuser
Entrance Sensor just before the Vacuum Transport Assembly is used to detect paper jams from
the IBT by sensing the lead edge and trail edge of the copy. The lead edge of the copy is
guided into the Contact Arc of the Fuser by the Inlet Chute.
Stripper Fingers on the Pressure Roller and Heat Roller help prevent the copy from wrapping
around these Rollers. As the copy leaves the Fuser nip, the lead edge enters the nip of the
Fuser Exit Rollers. A Fuser Exit Sensor detects the lead edge of the copy as it leaves the Fuser
Exit Rollers. This sensor looks for the lead edge of the copy as it exits the Fuser. If the lead
edge is more than 20 ms late to this sensor, the Fuser will stop, the Fuser nip will open and a
jam error code will be generated. The quick stopping of the Fuser helps prevent the copy from
getting wrapped around the Heat or Pressure Rolls. Copy jams of this type can always be
cleared from the Fuser entrance area.
Thermistor Temperature (C)
Thermistor Resistance (kOhms)
50
10 - 40
100
5.7 - 6.9
130
2.46 - 2.95
160
1.22 - 1.35
180
0.78 - 0.87
The Heat Roll (HR) is 65mm in diameter, with a 4.5mm aluminum thick wall and 3mm Silicon Rubber base coating and a layer of Viton on the outside. The Heat Roll has priority
over the other two rolls for power required for the heat lamp. The Heat Roll has its own
drive motor for copy transport.
The Pressure Roll (PR) is 65mm in diameter, with a 4.5mm aluminum thick wall and a
2mm Silicon Rubber base coating and a layer of Viton on the outside. The Pressure Roll
is mounted on brackets, which cam up to the bottom of the Heat Roll to create the Fuser
Contact Arc. The Pressure Roll is gear driven by the Fuser Motor.
The External Heat Roll (EHR) is a 23mm diameter stainless steel roll with a 2.5mm thick
wall. Its purpose is to help regulate the surface temperature of the Heat Roll by applying
additional heat directly to the surface of the Heat Roll. This reduces variations in temperature of the Heat Roll surface. The External Heat Roll rotation comes from direct contact
with the motor driven Heat Roll.
Refer to Standby Power, Section 1 for information on machine safety interlocks.
Temperature Control and Power Usage

The Fuser Assembly includes three heated rollers. Each of these rollers have Tungsten Halogen Quartz Lamps in their centers, and the heat generated by the lamp migrates to the surface
of the roller for the fusing process.
Fuser temperature control is complicated and as shown in Figure 3. there are four classes of
required components:
1.
Thermistors to measure the temperature of each Fuser roll.
2.
Lamps to heat the rolls
3.
Control hardware and software to read the temperature and switch the lamps on and off.
4.
Thermostats to prevent the Fuser from catastrophically overheating due to a component

failure.
To monitor and regulate the Fuser heating cycles, each roll has two thermistors (Table 3) and a
thermostat on or near the external surfaces of the rolls. The functions of each are as follows:
Control Thermistors - These determine the nominal set and run temperatures of the
associated roll. The current through these devices is monitored by the IOT Drive and Control PWBAs. These are in direct contact with each roll.
Overheat Thermistors - These are also monitored by the IOT Drive and Control PWBAs.
When the current through one of these devices reaches a particular value, the IOT Control and Drive PWBAs attempt to completely shut off the heater for the associated roll.
This occurs when the thermistors sense a temperature of 230 C or more. These Thermistors are in direct contact with each roll.
Overheat Thermostats - These are Fail-Safe switches. When a Thermostat senses an

overheat condition (>230 C), it opens and disconnects power from the associated heat
lamp. the Thermostats are spaced approximately 3 mm from the surface of each Roll.
These thermostats cannot be reset.
Table 3 Fuser Thermistor Resistance Values
Thermistor Temperature (C)
Thermistor Resistance (kOhms)
20
102 - 150
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Fuser Not Ready - At least one of the HR, PR and/or EHR is below its Not Ready Temperature. (See Table 4.)
The Fuser Ready state can be divided into two substates:
Standby - The Fuser Motor isnt running.
Run - The Fuser Motor is running.
The Fuser Not Ready state can be divided into three substates:
Preheat - The Fuser lamps are heating the rolls to their Preheat Temperatures. (See Table
4.) These temperatures are below the Ready Temperatures. This is done as a means of
reducing First Copy Out time.
Warm-up - The Fuser lamps are heating the rolls to their Ready Temperatures.
Stop - All Fuser lamps are shut off due to a paper jam, a machine failure has occurred or
a machine interlock is open.
Heat Roll Empty Rotation - When printing small copy media sizes, heat will be transferred
to the media from isolated parts of the Heat Roll. Over time, this may cause the temperature of the HR surface to become uneven. Therefore, under certain conditions, the Fuser
will perform a Empty Rotation Operation for approximately 40 seconds. This allows the
EHR to make the HR surface temperature more uniform. This only occurs if the HR temperature is above the HR Empty Rotation Operation Floor Temperature.
Primary and Secondary Control Temperatures - Control temperatures are the temperatures that the IOT Control PWBA attempts to maintain during Fuser Run. Each of the rolls
has both Primary and Secondary Control Temperatures. Primary temperatures are the
starting target temperatures. Secondary Control Temperatures are calculated values
which depend on the NVM values shown in Table 4 and the difference between maximum
and minimum temperatures measured in ten consecutive samples (Table 5). If the temperature difference is small enough, then the heat lamp can be switched on less often
than normal, and the Secondary Control Temperatures can be used. This reduces the
likelihood of the roll temperature will overshoot its maximum temperature after a job
because its heating lamp is unnecessarily switched on immediately before the end of the
job.
Table 4 IOT Control NVM Fuser Roller Temperature Entries
Temp No. Min
Nominal Max
Description
130
160
200
HR Primary Control Temperature
70
120
180
PR Primary Control Temperature
160
190
220
EHR Control Temperature (Primary)
100
115
180
100
150
180
EHR Not Ready Ceiling Temperature
100
130
150
HR Preheat Temperature
80
100
150
PR Preheat Temperature
10
100
120
150
EHR Preheat Temperature
11
100
140
160
HR Empty Rotation Operation Floor Temperature
12
150
155
170
HR Ready Floor Temperature
4
5
PR Not Ready Temperature; Formula-based
6
Figure 2 Fuser Heaters and Heater Control Block Diagram
All aspects of Fuser operation, including its temperature, are controlled by the IOT Control and
Drive PWBAs. At the highest level, the Fuser has two operating states:
Fuser Ready - The HR, PR and EHR have all reached their Ready Temperatures. (See
Table 4.)
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PR Secondary Control Temperature

HR Not Ready Temperature; Formula-based
Table 4 IOT Control NVM Fuser Roller Temperature Entries

Temp No. Min
Nominal Max
Description
13
110
115
150
PR Ready Floor Temperature
14
180
185
200
EHR Ready Floor Temperature
15
140
155
170
HR Nip Width Adjustment Floor Temperature
16
100
115
130
PR Nip Width Adjustment Floor Temperature
17
150
170
190
EHR Nip Width Adjustment Allowed Temperature
18
160
195
220
EHR Secondary Control Temperature when

using normal paper for 4-color
19
160
210
220

using normal paper for B&W
20
160
210
220

using OHP material for B&W
21
160
190
220

using OHP material or heavyweight or very
heavyweight paper for 4-color
22
160
190
220

using heavyweight or very heavyweight paper
for B & W
24
155
165
170
EHR temperature Control Determination Temperature
22
10
20
30
PR Post-Job Temperature Difference
Table 5 Fuser Warm up Sequence
Fuser Motor
Fuser Intake Fan
Fuser Duct
Fuser Exhaust Fan
630W
481W
379W
P/R Lamp
350W
350W
350W
350W
Ext H/R Lamp
62W
218W
340W
340W
on
There are two rolls in the Fuser that use camming action:
Pressure Roll - Cams up to contact the Heat Roll to create the Fuser nip (Contact Arc)
for the copy fusing process.
External Heat Roll - Cams down to contact the Heat Roll to provide supplemental heating to the surface of the Heat Roll.
When the External Heat Roll and the Pressure Roll are cammed away from the Heat Roll, there
is a 3 mm gap between the Heat Roll and the other two rollers.
PR/HR Nip (Pressure Roll Camming)
The IOT Control PWBA creates a PR/HR nip by engaging the Fuser Nip Clutch and the Exit
Motor. This combination rotates a shaft with an eccentric cam attached that forces the Pressure Roll up into the Heat Roll.
Two factors combine to determine when this nip is created. The first factor is the TR0 pulse
which starts movement of blank print media from a tray. The second factor is delay interval
stored in the IOT NVM. This is shown as B in Figure 4 and Figure 5. There are actually 7 intervals stored in the IOT NVM. Which one is used depends on three factors:
630W
on
Camming of Rollers
The temperature control and sequence for Fuser warm up is a four stage process. Refer to
Table 5 for this sequence.
H/R Lamp
off
The Fuser Intake Fan is mounted on the front door of the machine. This fan draws room air into
the Fuser Duct, which is attached to the top of the Fuser Assembly. The Fuser Duct has metal
panel on its bottom which absorbs the radiant heat generated by the Fuser. The circulating air
in the duct passes over this metal panel and draws this heat out of the machine as the air exits
through the Fuser Exhaust Fan on the right side of the machine.
Warm up time for the Digital Copier is about 7.5 minutes. Warm up time for the Copier/Printer is
about 8 minutes, and for the Printer, about 9.5 minutes.
Step3: Fuser Step 4:

Drive
Fuser Ready
off
The Fuser has an air circulation system to prevent excess heat build up in the machine. This
system consists of:
Fuser Warm Up Sequence
Step 2:
Initialize
Step3: Fuser Step 4:

Drive
Fuser Ready
Fuser Cooling System
Each rolls temperature is read by the IOT Drive and Control PWBAs every 500ms. Power to
the rolls is changed only after ten consecutive readings.
Step 1:
Power On
Step 2:
Initialize
The user is given a ready indication when the Heat Roll reaches 160 and the Process Control
Setup routines are complete.
The IOT Control and Drive PWBAs manage power to the three heated rolls to reduce maximum energy usage within the machine. The energizing cycles vary, depending upon the
machines operating status (warm-up, stand-by or running) and the type of copy job running
through the machine (standard weight, heavy weight, or larger quantities of copies to run). At
no time during the copy run cycle are the Heat Roll and Pressure Roll energized for heat at the
same time.
Table 5 Fuser Warm up Sequence
Step 1:
Power On
The type of blank media being used.
The thickness of the blank media being used
Whether the job is color or B & W
Whether the Fixing Surface is on the top or bottom.
Default values of interval B range from 01 seconds for B & W jobs on normal paper and transparency material to 10 seconds for color jobs on extremely heavyweight paper.
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EHR/HR Fuser Nip (External Heat Roll Camming)

The IOT Control PWBA creates a nip between the External Heat Roll and the Heat Roll by
energizing the Retract Motor. This motor rotates a eccentric shaft that is above the External
Heat Roll. This rotating shaft cams the External Heat Roll into or away from the Heat Roll.
As with the PR/HR nip, two factors combine to determine when the External Heat Roll is moved
into contact with the Heat Roll. The first factor is the TR0 event which starts the movement of
the copy material from the Trays. The second is 1 of 5 delay intervals stored in the IOT NVM.
This delay interval is shown as D in Figure 4.
As shown in Figure 5, for B & W jobs on normal paper, there is no delay. However, for color
jobs on extremely heavyweight paper and transparency material, the default delay is 10 seconds.
Figure 3 Fuser Nip Timing Diagram (Color, 11 X 17)
The status of this nip is monitored by the External Heat Roll Retract Sensor. This is an optical
sensor which is blocked with the two rolls in contact, and unblocked in the retracted position
(approximately 3 mm away from the Heat Roll). To correctly read this sensor, the External Heat
Roll Retract Motor must be stopped for 100 msec after a change is sensor state is detected.
Rotation of the External Heat Roll is done by contact with the motor driven Heat Roll.
Fuser Release Agent

The Heat Roll is lubricated with fuser oil which acts as a release agent to prevent the toner and
copy from sticking to the roll. (See Figure 1.) Amino Silicone oil is used as the fuser oil.
Figure 4 Fuser Nip Timing Diagram (B & W, 8-1/2 X 11)
The Fuser Oil Pump is turned ON whenever the Fuser Drive Motor is on. There is no way to
adjust the oil pump ON time. The pump takes the oil from the Oil Tank to the Drip Pipe. The oil
drips onto the Oil Wick from eleven (11) evenly spaced holes in the Drip Pipe. The holes in the
drip pipe increases in size from front to rear to ensure uniform oil flow at the rear end.
A PR/HR nip is removed:
For simplex jobs in color - when the trailing edge of the print passes the Fuser Exit Sensor
For duplex jobs in color - when the trailing edge of the each even numbered print passes
the Fuser Exit Sensor
For B & W jobs - never during the job run.
For all Black only jobs, the Pressure Roll remains in contact with the Heat Roll during the entire
print run. For all Color jobs, the Pressure Roll cams away form the Heat Roll between each
sheet in 1 pitch mode (i.e. 11x17), and cams away between each pair of sheets in 2 pitch
mode (i.e. 8.5x11). These modes of operation apply for both paper and transparencies.
Brackets with adjustment screws on each end of the Pressure Roll allows for Fuser nip adjustment without having to remove any of the Fuser Assembly from the machine. Refer to Contact
Arc adjustment in your service manual for this procedure.
The status of this nip is monitored by the Nip Sensor. This is an optical sensor that is blocked
when the two rolls are in contact, and unblocked when the rolls are in the retracted position.
However, the design of the sensor is such in order to accurately detect its state, the IOT Control
PWBA must disengage the Fuser Nip Clutch for approximately 100 msec after detecting a
change in sensor state. When fusing is not required, the normal position of the Pressure Roll is
approximately 3 mm away from the Heat Roll.
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The oil moves by capillary action through the Oil Wick to the Pick-up Roll. A Metering Blade
regulates the thickness of the oil coating on the Pick-up Roll. Any excess oil from the Metering
Blade or Oil Wick is caught by the Oil Pan. The oil pan contains a replaceable oil filter to collect
contaminants that get into the oil. A Return Tube takes this oil back to the Oil Tank for reuse.
The Pick-up Roll transfers the oil to the Donor Roller. The Donor Roller then delivers the final
thin coating of oil to the surface of the Heat Roller. The system dispenses a constant volume
(microliters) of oil per letter size copy.
The Fuser Motor drives the Pick-up Roll through a geared connection. The Donor Roller is
freewheeling and is rotated by its contact with the Pick-up Roll and the Heat Roller.
A customer replaceable (CRU) Oil Cartridge is used to supply a permanent Oil Tank that is in
the bottom of the Fuser Assembly. A new Oil Cartridge contains approximately 350 ml of oil.
The Oil Tank capacity is 150 ml. An Oil Sensor is located within the Oil Tank to sense when the
oil level becomes low. The IOT Control PWBA checks the status of this sensor every 500 msec.
When the Photo Coupler type of sensor detects the absence of oil on its surface, the sensor
triggers a Replace Fuser Oil Cartridge Soon message on the User Interface.
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The low oil signal from the sensor also starts a software timer in the machine. The timer will
allow approximately 2000 additional copies to be run during this warning period before the
machine will shut down. During this warning period, if the front door interlock is opened, the
Replace Fuser Oil Cartridge Soon message will disappear from the UI for 10 minutes. If after
the 10 minutes, the Oil Sensor still detects a low oil condition, the message will be displayed
again on the UI.
When the software timer expires (approximately 2000 copies), a Replace Fuser Oil Cartridge
message is displayed on the UI. When this condition occurs, the machine shuts down. Installing a new Oil Cartridge will enable the machine to run jobs again.
Oil usage rates vary, depending upon the types of images and media being run. Under normal
conditions, an Oil Cartridge should last approximately 25-40K copies/prints. Oil rates can be
much higher when the oil metering system is in need of service.
Web Cleaning of the Heat Roll

The Web Assembly is a Customer Replaceable Unit (CRU). The Web material is a low fiber,
paper-like material that removes toner and paper particles which may adhere to the Heat Roll
during the fusing process. A metal Cleaning Roller is also used to remove toner residue from
the Heat Roll. The Cleaning Roller is driven by direct contact with the Heat Roll.
The Web material is held in constant contact with both the Heat Roll and the Cleaning Roll.
Furthermore, the Cleaning Roll is held in constant contact with the Heat Roller by two foamcovered Web Pressure Rollers. The Web Pressure Roller holding Web against the Heat Roller
is spring loaded. The Web Pressure Roller holding the Web against the Cleaning Roll and the
Cleaning Roller against the Heat Roll is held by gravity.
The Web material moves in the opposite direction as the surface of the Heat Roller as it travels
from a Supply Roll to a Take-up Roll. The IOT Control and Status PWBAs can approximately
determine how much of the Web Material has been used. Through a hard stop circuit, the
machine is shut down when the Web material runs out.
Figure 5 Web Assembly circuit

The IOT Control and Drive PWBAs advances the Web Material by activating a dedicated Web
Motor. This causes Web Material to pass from the Web Supply Roll to the Web Take-up Roll.
The interval that the motor is activated can vary between one and four seconds. How long the
motor is activated depends on two factors.
There are three physical stages to metering the Web usage; New, In Use, and Empty. There is
also a non-physical stage where the machine software determines a Web Low warning state
on the UI. These stages are detailed below.
The motor is on for twice as long for color jobs than B & W jobs.
The period that the motor is on decrease with the amount of Web Material that has been
used in the current Web Assembly
First, as shown in Figure 5, the Web Assembly has an electrical circuit that contains a fuse.
When a new Web Assembly is installed, the fuse is immediately opened. This transition indicates to the Control Logic that a new Web Assembly has been installed. The IOT Control
PWBA resets to 0 a variable indicating how many copies have occurred for this Web Assembly. As copies are made, this variable is incriminated.
As more material is used, the effective diameter of the Take-up Roll core increases. Therefore,
the Web Material is transferred between rolls more rapidly. The IOT Control PWBA uses a copy
count variable to estimate the amount of Web material that has been used. This determines the
amount of Web Motor activation time for each copy, based upon a rough estimate of the Takeup Roll core diameter.
Once the total Web Motor ON time reaches 1458 minutes (approximately 40,000 copies), a
Replace Cleaning Web Soon message is displayed on the UI. This message will remain displayed for approximately 3,000 - 5,000 copies until the Web Assembly circuit detects the Web
Supply Roll is empty. When empty, two metal contacts touch the metal Supply Roll core and
completes a circuit. When this occurs, the machine becomes disabled and a Replace Cleaning Web message is displayed on the UI. This condition ends when a new Cleaning Web
Assembly is installed.
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In addition to the general Web advancement described above, the Web will also advance for
two minutes after any jams that occurred in the Fuser Assembly. This is done to clean any
excess toner that might be left from the jam.
Copy Exit
As the fused print leaves the nip (Contact Arc) between the Heat and Pressure Rolls, Stripper
Fingers on both rolls keep the copy from wrapping around these two rollers. A Fuser Exit Sensor looks for the leading edge of the copy material and stops the Fuser Motor if the lead edge
is not detected within a designated time. This feature prevents sheets from wrapping around
the Fuser Rolls and enables all Fuser jams to be cleared from the entrance side of the Fuser
Assembly.
The copy material then proceeds through Fuser Exit Rolls and past a Exit Path Sensor to either
the paper duplex/inverter path or out of the machine to the Exit Tray or the Mailbox/Sorter. If a
jam is detected by any of the paper path sensors in the Exit or Inverter areas, the Fuser will
immediately stop to prevent accordion jams from damaging the Fuser.
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Functional Description of Fuser Subassemblies,
Functional Description of Fuser Subassemblies,
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Overview
This chapter describes the electrical and mechanical components of the Mailbox/Sorter and
Offset Catch Tray optional accessories. The Mailbox/Sorter is a single set of hardware whose
functionality is determined by the configuration of the machine to which it is connected.
Mailbox/Sorter Bins (1-10)
The Mailbox/Sorter performs these primary functions:
Decurls finished copies for easier paper stacking and handling
When attached to the DocuColor 12/Document Centre Color Series 50 (DC) it:
Collates finished copies by stacking them into bins
Collates finished copies by sorting into bins
Stacks into one pile or into an offset pile finished copies onto an Offset Catch Tray
(OCT)
When attached to the Digital Networked Copier/Printer (DC/P) or the Digital Networked
Printer (PR), the Mailbox/Sorter can function as:
A printer, stacking finished copies into bins (mailboxes) assigned by a user
A copier/printer, stacking finished copies onto the Offset Catch Tray (OCT) in one
pile or in offset piles
The Mailbox/Sorter, shown in Figure 1, always includes a Decurler Assembly and a Mailbox/
Sorter Assembly.
The Offset Catch Tray (OCT) is another optional accessory that can be used with a machine
alone or combined with the Mailbox/Sorter.
Decurler
This Chapter will cover the following:
Overview
Mailbox/Sorter Electrical Connections
Mailbox/Sorter PWBAs
Print Transport through the Mailbox/Sorter
Offset Catch Tray (OCT)
Mailbox/Sorter Operation.
Offset Catch Tray

(OCT)
Mailbox/Sorter Assembly
Figure 1 Mailbox/Sorter attached to the machine
The Mailbox/Sorter is an optional accessory to the DC, CP and LP machines. It connects to the
right (output) side of the machine using a sliding rail which attaches to the lower front frame of
the machine. This rail provides a sliding track that allows for 300 mm of separation between the
Mailbox/Sorter and the machine for clearing of paper jams.
This same hardware accessory can function either as a Sorter or as a Mailbox. The function of
this accessory is determined by the type of machine and the software configuration installed.
Table 1 shows the different types of machine configurations, which then determines the type of
function for the Mailbox/Sorter accessory.
Table 1 Machine Configurations for Mailbox/Sorter
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Machine
Type
Machine
Configuration
Sorter / Mailbox
Function
Digital Copier (DC)
Image Input Terminal (IIT)
Sorter
Digital Network Printer (PR)
Digital Front End (DFE)
Mailbox
Digital Copier (DC)

and
Digital Network Printer (PR)
Image Input Terminal (IIT)

and
Digital Front End (DFE)
Mailbox
Overview
Sorter
When the Mailbox/Sorter is being used as a Sorter, it receives finished copies from the copier
and collates them into different bins. This collation process can be done in either Sort Mode or
Stack Mode. The Sorter has ten (10) bins for this collating function. Each bin can hold 100
sheets (1,000 sheet total capacity for the bins). When a bin contains approximately 100 sheets,
a switch is activated which causes a Bin Full message on the machine UI screen. Any additional copies for that bin are directed to the Catch Tray until the prints are removed from the bin.
A single connector provides all electrical connections between the basic machine and the Mailbox/Sorter. The connections include power, serial communications links, and discrete control
and status lines. The Mailbox/Sorter operates entirely on either +24 VDC or +5 VDC power,
which originates in the IOT PWBA LVPS in the basic machine.
Both Catch Trays can accept up to 500 prints in a single stack, and each contains a sensor to
indicate when it is full. The OCT provides offsetting capability of finished copies for all sizes
except 12x18 and 12.6x18 papers.
The Sorter function is available only when the machine is configured as Digital Copier. When
the machine is configured as a Copier/Printer, the hardware can only function as a Mailbox.
Refer to Sorter Operation Overview for more information.
Figure 1 shows power lines, discrete command and status lines, and serial communication
links between the Machine IOT and both the Mailbox/Sorter and OCT. Figure 2 shows the
block diagram of the Mailbox/Sorter. Figure 3 shows the block diagram of the Decurler.
Both the IOT CPU PWBA and the Mailbox/Sorter Control PWBA include microcontrollers.
Therefore, much of the command and status information passed between these assemblies
uses their shared command and status serial data link. The IOT CPU PWBA becomes aware
of the Mailbox/Sorter by detecting the proper level on the Output Detect line. It also passes a
discrete line (Sys Reset) indicating that the Mailbox/Sorter processor should reset itself to a
start-up condition.
Mailbox
When the Mailbox/Sorter is being used as a Mailbox, the bins can be assigned independently
for individual users or groups of users. These bin assignments are programmed into the IOT
CPU NVM (Non-Volatile Memory) by the printer network system administrator. The capacity for
each bin is the same as the Sorter: 100 sheets/bin. A Bin Full indication is sent to the sender
of the document, and any extra copies designated for that bin go to the Catch Tray.
When the copier/printer machine is used as a walk-up copier, all finished copies go to the
Catch Tray.
When attached to either the Printer (PR) or the Copier/Printer (CP), the Mailbox does not provide sorting capabilities.
Refer to Mailbox Operation Overview for more information on the operation of this accessory.
Offset Catch Tray

The Offset Catch Tray (OCT) accepts finished copies in a single stack, providing an offsetting
function for most size papers. The OCT is an optional accessory for a machine with or without
a Mailbox/Sorter installed.
Decurler
The Mailbox/Sorter includes a dual Decurler Assembly. The Decurler Assembly removes the
upward or downward paper curl that typically results from the toner fusing process. Because a
print can exit from the machine either face-up or face-down, the assembly has separate
upward and downward decurling mechanisms. Prints are decurled by creating a nip between a
pair of Decurler Rolls. One roll has a soft surface and the other roll has a hard surface. If the
paper requires decurling in a downward direction, a Cam moves the Lower Decurler Roll
toward the Decurler Entrance Roll, increasing the nip. To decurl paper in a downward direction,
the Cam moves the Upper Decurler Roll toward the Decurler Exit Roll. At the same time, the
nip in the opposite pair of rolls becomes neutral. The size of the nip and the transport speed
are adjustable, depending upon the type of material being processed. Refer to Decurler control
for more information.
Overview, Mailbox/Sorter Electrical Connections
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Figure 2 Mailbox/Sorter Subassembly Simplified Block Diagram

Figure 1 Mailbox/Sorter Connections to IOT
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Offset Catch Tray Electrical Connections

The Offset Catch Tray (OCT) does not have a control processor. Discrete lines from one of two
assemblies provide direct control of the OCT. If a Mailbox/Sorter is not installed, the OCT is
connected to the IOT Drive PWBA, as shown in Figure 1. If the OCT is installed with a Mailbox/
Sorter, the OCT is connected to the Mailbox/Sorter Control PWBA as shown in Figure 1. These
PWBAs become aware of the OCT by detecting the level on the OCT Det line. The OCT Mot
Fwd and OCT Mot Rev control lines directly control the OCT motor and cause it to move the
tray toward the front or back of the machine. The OCT Full status line indicates that the OCT
paper capacity has been reached. The OCT Home Sensor indicates when the OCT is in the
front-most (Home) position, while the OCT Position Sensor indicates that the tray is in the rearmost position.
Figure 3 Decurler Simplified Block Diagram
Mailbox/Sorter Electrical Connections, Offset Catch
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Mailbox/Sorter Interlocks
The Mailbox/Sorter has four (4) pairs of interlock switches:
Two Docking Interlocks that detect when the Decurler is connected to the basic machine.
Mailbox/Sorter Front Cover Interlock
The Decurler Front Cover Interlock is actually two switches. When the cover is off, one pole of
this switch disconnects +24 VDC supply voltage from the Decurler Stepper Motor. The other
switch and all of the remaining interlock outputs are all normally at +5 VDC, but are grounded
when opened. The microcontroller on the Mailbox/Sorter Control PWBA reads the voltage signals. An open interlock causes the microcontroller to send a message to the IOT CPU PWBA,
informing it of the interlock condition. An appropriate message displays on the machine User
Interface.
Sorter Front Cover

Interlock
Decurler Front Cover

Interlock
Docking Interlocks (2)
Figure 1 Interlock Switch locations for the Mailbox/Sorter
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Mailbox/Sorter Interlocks
Mailbox/Sorter PWBAs
The Mailbox/Sorter has two PWBAs:
The Mailbox/Sorter contains three (3) motors. Table 1 shows the Mailbox/Sorter motor functions.
The Mailbox/Sorter Control PWBA, shown in Figure 2, monitors paper path sensors, interlock switches, bin full switches, OCT full switch and OCT present and home position status.
The Decurler PWBA, shown in Figure 3, monitors the paper path through the Decurler
and controls the decurling function and communicates with the Mailbox/Sorter Control
PWBA.
The Mailbox/Sorter Control PWBA includes four (4) LEDs. The IOT CPU PWBA has LEDs that
light to indicate active communication between the two PWBAs.
Table 1 Mailbox/Sorter Control PWBA LEDs
LED
Color
CR1
Signal
Comment
Vcc
Lit indicates that digital logic power is available
Table 1 Mailbox/Sorter Motors and Functions

Motors
Drives:
Transport Speed
Decurler Motor
(+24 VDC Stepper)
Decurler In Roll
350, 220, 130, 60 mm/sec.
2nd Decurler Roll

Decurler Exit Roll
Sorter Motor
(+24 VDC Stepper)
Sorter Entrance Roll

1-10 Vertical Bin Rolls
Sorter Exit Roll
CR2
RxD
Flickering indicates command data being

received from IOT CPU PWBA
OCT Motor
(+24 VDC Bi-directional)
(optional with printer)
CR3
Reset
Lit indicates that PWBA microcontroller is

being reset by IOT CPU PWBA
CR4
/Lock
Lit indicates that Mailbox/Sorter Assembly

Motor is locked.
Decurler control
A self-test is performed on the Mailbox/Sorter Control PWBA during power on.
1st Decurler Roll
Offset Catch Tray
The Decurler neurtralizes paper curl that results from the Xerographic process. The basic concept of decurling is to force a smaller diameter metal roll with a hard surface into the much
softer foam surface of a larger diameter roll. This creates a valley in the larger roll, and the print
is forced into this valley in the opposite direction of its natural curl. Prints curl toward the side
having fused toner.
Paper curl and the decurling process is dependent upon these variables:
Paper weight and type
Single or two sided copies
Black-and-white or Color copies
Pixel density
Humidity
To address the different amount and directions of paper curl, the Decurler Motor operates at
different speeds and one of the two Decurling Rollers cam up or down by different distances to
decurl the paper.
The Decurler Motor has the following adjustable parameters:
The distance by which the harder roll is forced into the surface of the softer roll, called the
Nip Shift
The speed at which the paper travels through the decurler
Which decurler (upper or lower) is active
Refer to Figure 1 and Table 2 for details of the components for this function.
Mailbox/Sorter PWBAs, Print Transport through the
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OCT Gate Control

The OCT Gate is moved up or down by the OCT Solenoid. This gate diverts the copy material
to either the bins or to the OCT. The status of the OCT Gate is determined by the IOT CPU
PWBA, which sends an appropriate message to the Mailbox/Sorter Control PWBA. The Mailbox/Sorter Control PWBA enables or disables the OCT Solenoid as required.
Mailbox/Sorter Control
The sorter and mailbox functions use the same hardware. The difference between them results
from the configuration of the attached machine and the type of print or copy job being performed. These differences result in different control messages from the IOT CPU PWBA and
different control signals from the Mailbox/Sorter Control PWBA. In particular, the machine configuration determines whether sorter or mailbox functionality is available. Table 3 shows the
types of collating functions that are available for the different machine configurations.
Table 3 Functions for different configurations
Figure 1 Paper Decurling components and function
The Decurler transport speed is to match the transports speed of the copy job through the
xerographics process. The speed of the Decurler Motor is determined by the IOT CPU PWBA.
Table 2 Decurler Shift Requirements & Motor Speeds
Decurler Roll Nip Shift
Image Type
Transport Speed
2 mm
Transparency
Black and White
160 mm/sec
X
X
Copier
(DC)
Only
Mailbox
Sorter
Output Functions
Therefore, prints exiting with image side down are forced through the Upper Decurling Nip with
2, 6 or 10 mm of shift and through the Lower Decurling Nip with no nip shift. The controls
required for this function originate in the machine IOT CPU PWBA. This information is then
sent through the Mailbox/Sorter Control PWBA to the Decurler Control PWBA. This last PWBA
regulates the amount of Nip Shift and which nip is shifted. Table 2 shows the distance of the
Nip Shift in the Decurling Roll for various paper types and copy modes.
Media Type
Printer
(PR)
Only
6 mm
10 mm
Copier/Printer
(DC/PR)
Mailbox
functioning as a:
Copier
Sorts into bins

(1,2,3...1,2,3...etc.)
Stacks into bins

(1,1,1...2,2,2...etc.)
Printer
Sorts into bins by user

(User A: 1,2,3...User B: 1,2,3...etc.)

straight stack

offset stacks
Sorter Functions
Transparency
4-Color
60 mm/sec
Lightweight Plain
Paper
Black + 1 Color
160 mm/sec
NOTE: Sorter operation is possible only when the Mailbox/Sorter is attached to the Digital
Copier machine (DC).
Lightweight Plain
Paper
4-Color; Image
Density < 50%
160 mm/sec
When a Sorter is connected to the Digital Copier, four (4) different finishing outputs are available. See Table 3 for these outputs.
Lightweight Plain
Paper
4-Color; Image
Density > 50%
160 mm/sec
Heavyweight Plain
Paper
Black + 1 color
60 mm/sec
Heavyweight Plain
Paper
4-Color; Image
Density < 50%
60 mm/sec
Heavyweight Plain
Paper
4-Color; Image
Density > 50%
60 mm/sec
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When the Mailbox/Sorter is configured as a Sorter, the user can select from the User Interface
screen either Sort Mode or Stack Mode for outputs to the bins. Copies for bin output are
diverted into the Vertical Transport area of the Sorter by the OCT Gate. At the appropriate bin
level, a bin solenoid energizes to push a Bin Diverter Gate (one gate per output bin) into the
paper path. This directs the copy into that bin. The selection of the Bin Diverter Gate is made
by the Sorter Control PWBA in response to control messages from the IOT CPU PWBA. The
appropriate Bin Solenoid is energized only as the copy enters the vertical transport area. When
the trailing edge of the copy passes the Bin Sensor, the Bin Solenoid deenergizes to close the
Bin Gate.
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Refer to Offset Catch Tray (OCT) for the finishing functions of this component.
Mailbox Configuration
Bin In Sensors (10)
NOTE: When this device is attached to the Digital Network Copier/Printer or the Digital Network Printer, it operates as a Mailbox. The OCT is an optional accessory to the Mailbox.
For Mailbox bin outputs when working with the Printer mode, the user sends a print job to the
printer. The bin addresses are programmed by the printer system administrator and stored in
the NVM associated with the IOT CPU PWBA.
The copies for the Mailbox bin are diverted into the Vertical Transport area of the Mailbox by
the OCT Gate. At the appropriate bin level, a Bin Solenoid energizes to push a Bin Diverter
Gate (one gate per output bin) into the paper path. The selection of the Bin Diverter Gate is
made by the Sorter Control PWBA in response to control messages from the IOT CPU PWBA.
The appropriate Bin Solenoid is energized only as the copy enters the vertical transport area.
When the trailing edge of the copy passes the Bin Sensor, the Bin Solenoid deenergizes to
close the Bin Gate.
Jam Sensing
The Mailbox/Sorter has thirteen (13) sensors for detecting the leading and trailing edges of
copies:
Sorter Front Cover Interlock
Vertical Transport In Sensor

Docking Interlocks (2)
Machine Exit
Sensor
Vertical Transport-In Sensor
Ten (10) Bin-In Sensors (one for each bin)
OCT Exit Sensor
Figure 2 shows the sensor locations.

The IOT Machine Exit Sensor is also used by the Decurler PWBA or the Sorter Control PWBA.
OCT Exit Sensor
Figure 2 Mailbox/Sorter and Decurler Sensor Locations
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Mailbox/Sorter Operation.
The Offset Catch Tray (OCT) is an optional accessory. The OCT can be attached directly to the
machine or to the Mailbox/Sorter. If connected to a Mailbox/Sorter, the OCT replaces the standard non-offsetting catch tray.
This device can operate as either a Sorter or as a Mailbox, depending upon what type of
machine it is attached to. Refer to Overview at the beginning of this Chapter for information on
the Sorter and Mailbox functionality with the different machines.
The OCT is used to compile copy output into a single stack or to provide offsetting stacks onto
a single tray. The OCT does not provide offsetting for paper sizes of 12x18 or larger.
Sorter Operation Overview
The OCT can attach to a machine or to the Mailbox/Sorter by two (2) Thumb Screws. A multipin plug connects the OCT to the machine or the Mailbox/Sorter for communications and DC
power needs.
A +24 VDC bi-directional motor shifts the OCT toward the front of the machine or toward the
back of the machine when performing the offset stacking function. The OCT straight stack or
home position is with the catch Tray toward the front of the machine.
Two (2) sensors monitor the offset paper stacking function:
The Offset Home Sensor indicates when the OCT is in the straight stack or home position.
The Offset Position Sensor indicates when the OCT is in the offset position.
An OCT Motor moves the tray between the two positions. The OCT Motor is controlled by discrete control lines from the IOT CPU and Drive PWBAs.
Single stacks of copy are discharged within a paper alignment of approximately 20 mm of
scatter. Offset stacks will have approximately 10 mm offset between sets of stacks.
When copy output is to be stacked in offsetting piles, the first stack is always placed with the
OCT in the Home Position. Additional stacks are placed with the tray alternating between the
Home and Offset Positions. When a copy job is complete, the OCT always returns to the Home
Position.
The OCT can hold 500 sheets of standard weight paper. When the tray capacity is reached, the
Full Stack Sensor is activated, and a status line is asserted to the IOT CPU PWBA.
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The Sorter can collate copy output in the following modes:
Stack mode into bins (1,1,1... 2,2,2... 3,3,3...etc.)
Sort mode into bins (1,2,3... 1,2,3... 1,2,3...etc.)
Straight stack into the Catch Tray
Offset stack into the optional OCT, if connected
The user selects the type of output on the UI touch pad of the copier. Depending upon the copy
material used or selected, the control logic will determine if the user selection is valid (i.e. the
selected paper weight is within the operational range of the Sorter).
Mailbox Operation Overview

The Mailbox can collate copy output in the following modes:
Sort mode into bins assigned to users or group addresses (1,2,3... 1,2,3... 1,2,3...etc.)
Straight stack into the Catch Tray when one or more mailbox bins are full.
Offset stack into the optional OCT, if connected
The system administrator for the printer network assigns the addresses used for the Mailbox
function. The address data are stored in the NVM associated with the IOT CPU PWBA.
When the machine is used as a networked printer, the user sends a print job to the machine
from a workstation terminal to the Digital Front End (DFE). The address is sent to the IOT CPU
PWBA, which uses data stored in the NVM to correlate the address to a bin. The bin address is
then sent to the Mailbox/Sorter Control PWBA, which activates the appropriate motors and
solenoids to route the prints into the correct bin.
When the machine is configured as a copier/printer and is being used as a copier, the local
user can only send the job to the catch tray. If the OCT is attached, the user can choose to single stack or offset stack the job.
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Offset Catch Tray (OCT), Mailbox/Sorter Operation.
Offset Catch Tray (OCT), Mailbox/Sorter Operation.
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Finisher Power
The Finisher requires +5VDC and +24VDC for normal operation. The Finisher receives these
voltages from the Distribution PWB in the IOT (Figure 1).
The Finisher PWB uses these voltages to run internal logic, sensors, solenoids, and the Finisher Motors. The Distribution PWB +24VDC output is controlled by the Decurler Door Interlock, the Stapler Door Interlock, the Compiler Cover Interlock, and the Mailbox Door Interlock
switches. The +24VDC from the Distribution PWB is cut whenever any of these door interlocks
are opened.
Figure 1 DC Power Circuits
Finisher Interlocks
The interlocks on the doors of the Finisher have two circuits, a +24VDC circuit and a +5VDC
circuit. Generally speaking, the +24VDC side of the interlock is used to interrupt Finisher power
when a door is opened, and the +5VDC side of the interlock controls interlock fault declaration.
The door interlocks work by interrupting power to the finisher. When a door is opened, the
+24VDC side of the switch is opened and the finisher functions that use +24VDC are shut
down. The +5VDC side of the interlock is also opened, resulting in a fault declaration (Figure
1).
The Docking Interlocks are located on the left side of the Finisher assembly. These are magnetic interlocks that are held open when the Finisher is docked. When the Finisher is
undocked, the switches will close, completing a path to ground. The resulting drop in voltage is
sensed on the Finisher PWB, and will result in an indication that the Finisher is undocked.
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Finisher Power, Finisher Interlocks
Finisher Power Components

WARNING
In the undocked condition, +24VDC to the finisher is NOT interrupted.
Figure 1 +5 VDC Interlock Circuit
Finisher Interlocks, Finisher Power Components
1.
Distribution PWB
Provides +24VDC and +5VDC to the Finisher PWB.
2.
Finisher PWB
The Finisher PWB controls all Finisher functions, executes commands sent from the IOT
CPU PWB, and sends information back to the Printer Engine Controller PWB. All Finisher
components are connected to the Finisher PWB.
3.
Stapler Door Interlock

Monitors the state of the Stapler door and cuts +24VDC to the Finisher when the Stapler
Door is open.
4.
Compiler Door Interlock

Monitors the state of the Compiler door and cuts +24VDC to the Finisher when the Compiler Door is open.
5.
Mailbox Door Interlock

Monitors the state of the Mailbox door and cuts +24VDC to the Finisher when the Mailbox
Door is open.
6.
Decurler Door Interlock

Monitors the state of the Decurler door and cuts +24VDC to the Finisher when the
Decurler Door is open.
7.
Docking Interlock 1 and 2

Magnetic interlocks that indicate an undocked condition. These interlock switches are
open in the docked position, and closed in the undocked position.
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Finisher Control
Finisher Control is a term used to describe the resources that monitor and control the actions
and operations of the Finisher -- from paper entrance to paper stacking.
The Finisher PWB controls all Finisher functions, executes commands sent from the IOT CPU
PWB, and sends information back to the IOT CPU PWB. All Finisher components are connected to the Finisher PWB. The IOT CPU PWB provides the logic and information processing
that is necessary for the printer to function, and the Finisher PWB provides the logic and information processing that is necessary for the Finisher to function.
Every electrical component within the Finisher is connected to the Finisher PWB. Sensors in
the Finisher send status information to the Finisher PWB. The Finisher PWB processes this
information, shares it with the IOT CPU PWB, and compares it to timing tables stored in ROM.
Acting on the results of the processing, the Finisher PWB sends commands to the various Finisher components; for example, switching on a motor or switching off a solenoid (Figure 1).
Figure 1 Finisher Control Paths

Table 1 Input and Output Devices
Input Devices
Output Devices
SCT Full Sensor
Decurler Stepper Motor
Decurler Door Interlock Switch
Finisher Transport Motor
Docking Interlock Switch
Mailbox Drive Motor
Mailbox Gate Solenoid
Stapler Door Interlock Switch
Mailbox Solenoid
Mailbox Door Interlock Switch
Finisher Gate Solenoid
SCT Exit Sensor
Finisher Gate Solenoid
Mailbox Entrance Sensor
Compiler Tray Solenoid
Compiler Entrance Sensor
End Wall Motor
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Finisher Control
Table 1 Input and Output Devices

Input Devices
Output Devices
Compiler Cover Safety Switch
Tamper Motor
Compiler Cover Interlock Switches
Stapler Position Motor
Unload While Run Switch
Eject Motor
Tamper Home Sensor
Eject Paddle Motor
Compiler Paper Sensor
Eject Clamp/Offset Motor
End Wall Open Sensor
Gate Solenoid
Stapler Position Sensors
Stacker Motor
Eject Paddle Home Sensor

Offset Home Sensor
Eject Clamp Sensor
Stack Height Sensor
Stacker Upper Limit Sensor
Stacker Full (Mixed Size) Sensor
Stacker Full Sensor
Stacker Lower Limit Sensor
Stacker Paper Sensor
Finisher Control
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The Finisher Paper Path

The Finisher Paper Path is the physical route that paper takes through the Finisher, from leaving the IOT to arriving at the Finisher Bin, the Simple Catch Tray, or a bin in the Sorter/Mailbox
(Figure 1).
There are two major diversion points for paper traveling through the subsystem. The first is the
Finisher Gate. At this gate, the paper can be directed toward the Finisher, or the Sorter/Mailbox. The second gate is the Mailbox Gate, where paper that has been directed to the Sorter/
Mailbox can be sent either to the Simple Catch Tray, or to the Sorter/Mailbox bins.
Figure 1 Finisher Paper Path
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The Finisher Paper Path
The Decurler
The Finisher Gate
Paper exiting the fuser is fed first through the Decurler. The Decurler is capable of correcting
curl up, or curl down. This is achieved through the use of two sets of rollers (Figure 1).
The Finisher Gate is the first point at which the paper in the path can be diverted to either the
Finisher or the Sorter/Mailbox (Figure 1).
The first set of rollers in the Decurler Assembly will correct for curl up. This is accomplished
through the use of two rollers, one larger and made of a soft, foam material, and the other is a
metal rod. The foam roll is positioned over the top of the paper path. The metal rod is located
below the path. When the paper enters the decurler, and if it is to be processed for curl up, the
two rolls will come together with the paper between them. Because the top roll is soft, the lower
rod will slightly deform it, and the paper will pass through the nip created at this point. The
shape of the nip will remove the curl from the paper as it passes through.
The gate consists of a rod with fingers that is controlled by the Finisher Gate Solenoid. The Finisher Gate Solenoid is a latching solenoid. When a signal is received from the Finisher PWB,
the solenoid will either lift the gate to send paper to the Finisher, or lower it to send paper to the
Sorter/Mailbox.
To reduce curl down, the second set of rolls in the Decurler are used. In this set of rolls, the
foam roll is on the bottom of the path and the metal rod is on the top. The rolls come in contact
with each other and the paper is passed through the resulting nip.
The decurled media is then passed into the Finisher.
Figure 1 Finisher Gate
Figure 1 Decurler Assembly and Paper Path
The Decurler, The Finisher Gate
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The Mailbox Gate
Finisher Path for Stacking without Stapling
The Mailbox Gate provides diversion to either the Sorter/Mailbox, or the Simple Catch Tray
(SCT). Lie the Finisher Gate, the Mailbox Gate is a plastic rod with fingers that is positioned
across the paper path (Figure 1). The gate is controlled by the Mailbox Gate Solenoid. The
solenoid will latch the gate up to divert the paper to the Simple Catch Tray, or down to divert the
paper to the Sorter/Mailbox.
The Finisher options that are available depend upon whether a Print or Copy job has been
sent. The table below indicates which options are available for each type of job.
The explanation below assumes the following:
1.
The job is a print job.
2.
No stapling was requested.
3.
The paper has been decurled.
4.
The paper has passed through the Finisher Gate and was directed to the Finisher.
The Transport Rolls within the Compiler continue driving the paper into the Compiler (Figure 1).
The Compiler Transport Rolls drive the paper further into the Compiler where the leading edge
of the paper actuates the Compiler Entrance Sensor. The Exit Rolls and Paddle Assembly
drive the paper to the Eject Roll. The Eject Roll and Paddle Assembly drive the paper out into
the Stacker Tray.
Figure 1 Mailbox Gate

Figure 1 Compiler Paper Transport
Exit/Eject Paper Path Components
1.
Transport Rolls and Pinch Rolls
2.
Complier Entrance Sensor
3.
Exit Roll and Paddle Assembly
Drives paper through the Compiler.

Monitors paper entering and leaving the Compiler entrance.
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The Mailbox Gate, Finisher Path for Stacking with-
Finisher Paper Path for Stapling and Stacking
Drives paper to the Eject Roll.

4.
Eject Roll and Paddle Assembly
The following explanation assumes the following:
Drives paper into a Finisher Bin Tray.
1.
The Eject Roll assembly is shifted from side-to-side so that each set entering the Finisher Bin
Tray is offset slightly from the previous set.
For additional information, see Eject Paddle Motor
The job is a print job.
2.
Stapling was requested.
3.
The paper has been decurled.
4.
The paper has passed through the Finisher Gate and was directed to the Finisher.
The Exit Chute uses rolls and rubber paddles to move the paper into the Eject area. If the
paper is to be collected into sets and stapled, the Eject Rolls rotate in reverse and drive the
paper back into the Compiler Bin (Figure 1). When the correct number of sheets has entered
the Bin, the Tamper aligns the edges of the paper sheets to form a neat paper set. The Stapler
then drives a staple through the set. As the Eject Rolls drive the paper set out of the Stapler,
they offset each paper set slightly from the previous set as they are delivered into the Stacker
Tray.
Finisher Path for Stacking without Stapling, Finisher
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Figure 1 Paper Path Through Stapler
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Finisher Paper Path for Stapling and Stacking
Compiler/Tamper Functional Description

The Compiler arranges paper into sets.
1.
Tamper Motor
2.
Tamper Home Sensor
Drives the paper stack Tamper.

Monitors the position of the Tamper (Figure 1).
Figure 1 Tamper Assembly

3.

Tilts the Compiler Bin when the paper stack reaches 25 sheets (Figure 2).
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Figure 2 Compiler Tray End Wall

4.
End Wall Motor
5.
End Wall Open Sensor
6.
Compiler Entrance Sensor
Controls the opening and closing of the End Wall.

Monitors the position of the End Wall.
Monitors paper entering the Compiler. The signal from the Sensor is used by the Finisher
logic to start and stop the Transport Motor and the Eject Motor.
7.
Compiler Paper Sensor
8.
Compiler Cover Interlock Switch
Monitors paper on the Compiler Tray.

Monitors the position of the Compiler Cover.
The Eject Roll reverses rotation and drives the sheet of paper back into the Compiler Tray. A
motor raises the End Wall to block the end of the Compiler Tray. When a set of paper (maximum of 25 sheets) is transported to the Compiler Tray, the Tamper taps the side of the paper to
square up the set (Figure 3).
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Figure 3 Paper Being Compiled for Stapling

The End Wall Motor lowers the End Wall and the Compiler Tray Solenoid tilts the Tray, causing
the paper set to move into the Stapler (Figure 4).
For additional information, see End Wall Motor and Tamper Motor.
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Figure 4 Paper Set Positioned for Stapling

Compiler /Tamper Paper Path Components
1.
Eject Roll
2.
Compiler Tray
3.
End Wall
6.

Tilts the Compiler Tray so the paper set slides into the Stapler.
Drives paper into the Compiler Tray

Staging area used to collect sheets of paper into sets for stapling.
Closes the end of the Compiler Tray so paper can be collected into sets. Is moved out of
the way when the set is ready to be sent to the Stapler.
4.
5.
End Wall Motor

Tamper
Taps the sides of every sheet to square up the edges before stapling.
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Stapler Functional Description
Monitors the position of the Stapler Head for stapling at the front edge of a paper set.
3.
The Stapler staples sets of paper.

1.
Stapler Front Corner Sensor
2.
Stapler Front Straight Sensor
Stapler Rear Straight Sensor

Monitors the position of the Stapler Head for stapling at the rear edge of a paper set.
Monitors the position of the Stapler Head for stapling in the front corner of a paper set.
4.

Moves the Stapler Head into position (Figure 1).
Figure 1 Stapler Unit and Position Motor

5.
6.
Eject Paddle Home Sensor
7.
Eject Paddle Motor
8.
Eject Paddle Drive Belt
Drives the Stapler Head while it is stapling a paper set.

Monitors whether or not the Eject Paddle is in the home position.
Drives the Eject Paddles to clamp a paper set onto the Compiler Tray prior to stapling.
Drives the Eject Paddles to clamp a paper set onto the Compiler Tray prior to stapling.
(Figure 2)
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Figure 2 Eject Paddle Assembly

For additional information, see Eject Paddle Motor.
The Stapler Position Motor slides the Stapler Unit along a fixed rail. Set locations along the rail
place the Stapler in position to perform one of four possible staple configurations; front corner,
front straight, rear corner, and rear straight. Sensors along the rail monitor the position of the
Stapler Unit. Once the stapler is in position, it drives a single staple at a selected area of the
set (Figure 3).
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Figure 3 Staple Position Options

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1.
Stapler Paper Path Components
1.
Stapler Front Corner Sensor

Monitors the position of the Stapler Head for stapling in the front corner of a paper set.
2.
Stapler Front Straight Sensor
Eject/Offset Functional Description

The Eject and Offset transport and offset compiled sets of paper into the Stacker Bin.
1.
Monitors the position of the Stapler Head for stapling at the front edge of a paper set.
3.
Stapler Rear Straight Sensor
2.
Eject Clamp Sensor
3.
Offset Home Sensor
4.
Eject Motor
Monitors the position of the Stapler Head for stapling at the rear edge of a paper set.
4.
Stapler Assembly

Raises and lowers the Eject Chute and Pinch Roll, and drives the Offset Actuator.
Monitors whether the Eject Roll is in the up or the down position.
Contains the Stapler Head and Stapler Cartridge.
Monitors whether or not the Eject Roll is in the home position.

Drives the Eject Shaft Assembly.
After the set is stapled, the Eject Roll rotates clockwise and drives the set out of the Compiler
Tray and toward the Offset Rolls (Figure 1).
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Stapler Functional Description, Eject/Offset Func-
Figure 1 Stapled Paper Set Eject

A cam and gear set shift the Offset Pinch Rolls and Paddle Assembly back and forth across the
Eject paper path, shifting the exiting sheet of paper so each sheet of paper entering the Finisher Tray is offset slightly from the previous sheet (Figure 2).
For additional information, see Eject Clamp/Offset Motor.
(Figure 2.)
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Figure 2 Set Offest Mechanism

Eject/Offset Paper Path Components
1.
Helps drive paper out of the Compiler Tray and into the Stacker.
Pinch Roll Assembly

Shifts alternate paper sets back and forth so they are offset as they stack in the Stacker.
2.
Pinch Roll Assembly
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Stacker Functional Description
Mechanical Drive
Provides the mechanism for sensing paper in the Stacker Tray.
Mechanical Drive is the term used to describe the various motors, solenoids, gears, and belts
that are used to generate, control, and transmit drive to the various paper path components
within the Finisher.
1.
Stacker Full Sensor
2.
Stacker Full (Mixed Set) Sensor
Monitors the Stacker Tray and detects when the stacker is full.
Monitors the Stacker Tray and detects when the stacker is full if mixed sets are being sent
to it.
Stacker Functional Description, Mechanical Drive
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The Finisher Transport Motor is located in the Compiler section of the Finisher. The Finisher
PWB sends power to the Transport Motor, which uses gears and pulleys to drive the Stapler
Entry/Exit, and the paper Exit functions (Figure 1). +5 VDC voltages from the Finisher PWB are
used to switch the Transport Motor on, and to control its speed. The Transport Motor is powered by +24 VDC.
Eject Motor
Figure 1 Finisher Transport Assembly
The Finisher PWB switches the Eject Motor clockwise to Eject paper into the Stacker. The Finisher PWB switches the Eject Motor counter clockwise to drive the paper back into the Compiler Tray. The Eject Motor Drive Belt transmits drive from the Motor to Eject Gear B. Gear B
drives Eject Shaft 2. Eject Shaft 1 is driven by the Eject Paddle Motor, while the Eject Rolls on
Eject Shaft 1 are independently driven by gearing from Eject Shaft 2 (Figure 1, Figure 2).
Finisher Transport Mechanical Drive Components

1.
2.
Transport Gears
3.
Compiler Transport Drive Belt
A +24 VDC stepper motor. Provides drive for the Transport.

Transmits Motor drive to Pulley.
Transmits Finisher Transport Motor drive to the Eject Shaft, Exit Shaft, and the Paddle
Shaft.
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Finisher Transport Motor, Eject Motor
Figure 1 Eject Motor and Its Associated Components
Eject Motor
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Figure 2 Eject Paddle Motor and Its Associated Components
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Eject Motor
End Wall Motor
The End Wall Motor raises and lowers the Compiler Tray End Wall (Figure 1). When paper is
sent to the Compiler Bin, the Finisher PWB switches on the End Wall Motor. The End Wall
Motor raises the End Wall of the Compiler Tray. When a set of paper is collected in the Compiler Bin and the set is ready to be sent to the Stapler, the End Wall Motor lowers the End Wall
to allow the paper set to move to the Stapler.
Figure 1 Compiler End Wall and Its Associated Components

End Wall Mechanical Drive Components
1.
End Wall Motor
2.
End Wall
A +24 VDC stepper motor. Raises and lowers the End Wall.
Raised to close off the end of the Compiler Tray. Lowered to open the end of the Compiler
Tray and allow the paper set to move to the Stapler.
End Wall Motor
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Tamper Motor
The Finisher PWB switches on the Tamper Motor when a paper set in the Compiler Tray is
ready to be sent to the Stapler. The Tamper is attached to the Tamper Drive Belt (Figure 1).
When the Tamper Motor is switched on, it pulses, which in turn taps the Tamper against the
side of the paper set. The Tamper Home Sensor monitors the position of the Tamper.
Figure 1 Compiler Tamper and Its Associated Components

Tamper Mechanical Drive Components
1.
Tamper Motor
2.
Tamper Drive Belt
A +24 VDC stepper motor. Drives the Tamper Drive Belt.

Drives the Tamper.
3.
Tamper
Attached to the Drive Belt. The side of the Tamper taps the edge of each sheet of paper to
align the set before stapling.
4.
Tamper Home Sensor

Monitors the position of the Tamper when it is not activated.
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Tamper Motor
Eject Paddle Motor

The Finisher PWB switches on the Eject Paddle Motor (Figure 1). The Eject Paddle Drive Belt
transmits drive to the Paddle Shaft Assembly. Paddles on the Assembly drive a stapled set of
paper into the Finisher Tray. The Eject Paddle Home Sensor monitors the home position of the
Paddle Shaft Assembly (Figure 2).

Eject Paddle Mechanical Drive Components
1.
Eject Paddle Motor
2.
Eject Paddle Motor Drive Belt
3.
Eject Paddle Home Position
A +24 VDC motor. Provides drive for the Paddle Shaft Assembly.
Transmits Set Clamp Motor drive to the Paddle Shaft Assembly.
Monitors the home position of the Paddle Assembly.
Eject Paddle Motor
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Eject Paddle Motor
The Eject Clamp/Offset Motor drives the Offset Cam. As the Cam rotates, the high and low
points of the Cam drive the Eject Clamp Rolls back and forth across the paper path. The Eject
Clamp/Offset Motor also drives the Eject Clamp Cam. As the Cam rotates, the high and low
points of the Cam drive the Eject Clamp Pinch Rolls up and down (Figure 1).
Figure 1 Eject/Offest Mechanical Details 1
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Offset Mechanical Drive Components

1.
3.
Driven by the Eject Clamp Offset Motor. As the cam rotates, the high and low points move
the Eject Clamp Pinch Rolls up and down.

A +24 VDC motor. Provides drive for both the Eject Clamp Pinch Rolls and the Eject Rolls.
2.
Eject Clamp Cam
4.
Eject Clamp Sensor
Offset Cam
Monitors the position of the Eject Clamp Cam.
Driven by the Eject Clamp Offset Motor. As the cam rotates, the high and low points slide
the Offset Rolls across the paper path.
(See Figure 2.)
Figure 2 Eject/Offset Mechanical Details 2
Stacker Tray Motor and Sensors

The Stacker Tray has a separate Motor that raises or lowers the Tray to accommodate the
amount of paper sent to it. The Stacker Tray is moved by Stacker Tray Drive Belts that are
driven by the Stacker Motor. As the Belts rotate, the Tray raises or lowers depending on the
direction of Belt rotation. Sensors monitor the presence of paper and the position of the Tray.
(See Figure 1.)
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Eject Clamp/Offset Motor, Stacker Tray Motor and
Figure 1 Stacker Tray Details

Stacker Tray Mechanical Drive Components
Stacker Tray Sensors
1.
Stacker Motor: A +24 VDC stepper motor. Provides forward and reverse drive for the Eject
Roll.
1.
Stacker Upper Limit Sensor: Monitors when the Stacker Tray has reached the highest
point that it can safely travel.
2.
Pulleys, Belt, Worm Wheel, and Shaft: Transmits Motor drive to the Stacker Tray Drive
Belts. The Shaft drives the belts and pulleys on the opposite side of the Stacker from the
motor.
2.
Stacker Full (Mixed Size) Sensor: Monitors when the Stacker tray has received all the sets
of mixed sizes that it can hold.
3.
3.
Stacker Tray Drive Belts: Raise and lower the Stacker Tray.
Stacker Full Sensor: Monitors when the Stacker tray has received all the sets of uniform
size that it can hold.
4.
Stacker Lower Limit Sensor: Monitors when the Stacker Tray has reached the lowest point
that it can safely travel.
5.
Stacker Paper Sensor: Monitors the presence of paper on the Stacker Tray.
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Overview
Electrical and Mechanical Operation of the IDFE
The Splash Integrated Digital Front End (IDFE) is a color server option that provides an integrated link between the DC CS50 (IOT) and the Local Area Network (LAN) of the customer.
The server transforms the DC CS50 into a network-based printer and scanner, capable of
working with a variety of high-end graphics and color printing applications.
This section describes the electrical distribution and mechanical operation of the IDFE. For
more information describing AC and DC Power distribution to the DC CS50, refer to Stand-By
Power, Chapter 1 in the Principles of Operation for the DocuColor 12.
The IDFE uses a process called Raster Image Processing (RIP) to translate PostScript print
files into raster images specifically formatted for the DC CS50. The IDFE then sends images to
the IOT for printing.
Customers can generate and submit jobs to the IDFE for printing. The IDFE supports print drivers for Windows 95, Windows 98, Windows NT 4.0, Mac OS v7.x and the MAC OS v8.x operating systems. In addition, a web browser such as Netscape Communicator or Microsoft Internet
Explorer allows customers to access the IDFE Web client.
NOTE: The job files are PostScript ready files only.
The web client allows customers to submit jobs to the IDFE for printing, to view the current status of the IDFE, to view the current status of the DC CS50, to set-up scanning jobs, to perform
job and device management, and to perform color calibration. The web client also allows the
system administrator to configure the IDFE network settings.
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Overview, Electrical and Mechanical Operation of
Power Distribution - Solid State Relay

The AC Driver PWB supplies +5 VDC to the Coil of the Main Switch (BSD 1.1). When the Main
Switch is pressed, the Coil for the Switch is energized, providing +5 VDC to Connector J83 Pin
1 of the Printer Solid State Relay (SSR) (BSD 16.1). To complete the DC circuit, Connector J84
Pin 1 provides the return path to ground from the SSR to the AC Driver PWBA at Connector
J20 Pin 2.
From Connector J2 (BSD 16.1), the AC Driver PWBA (PL 9.3) provides 120 VAC @ 16
amperes (220/240 VAC @ 10 Amperes) to Connector J81 Pin 1 of the Printer SSR (PL9.3).
When this DC circuit is energized, the SSR will switch on, allowing high voltage AC from the AC
Driver PWBA to pass through the Printer SSR to Connector J82 Pin 1 and onto Connector J4
Pin 4 of the Printer Low Voltage Power Supply (LVPS).
NOTE: When an operator removes power from the IOT by switching off the main switch, an
RC network located on the AC Driver PWBA delays release of the Coil for the Main Switch for
18-22 seconds. This delay is used to allow the IDFE Hard Disk Drive to safely shut down (Figure 1).
Power Distribution - Printer Low Voltage Power Supply

(LVPS)
When energized, the Printer SSR provides 120 VAC @ 16 Amperes (220/240 VAC @ 10
Amperes) to the Printer LVPS at Connector J4 Pin 4 (BSD 16.1). The Printer LVPS converts
this AC power into a regulated +5.1 VDC @ 11 Amperes Power Supply, and a regulated +12
VDC @ 1.6 Amperes Power Supply within the LVPS (BSD 16.1).
Figure 1 IDFE Power Interface Block Diagram

NOTE: There is a ground wire attached to the Chassis Frame at P/J 899 Pin 12. This is not
shown on BSD 16.1.
NOTE: The Printer and IOT LVPS are separate. The Printer LVPS is located behind the AC
Driver PWBA.
The return path to Frame Ground for the Printer LVPS is provided through Connector J4 Pin 1
(BSD 16.1).
Power Distribution - IDFE

The IDFE (PL 19.1) is an enclosed color server mounted on the back of the DocuColor 12,
which converts the IOT into a network printer. The IDFE uses +5 VDC power, supplied from the
Printer LVPS to power the following parts inside the IDFE (PL 19.1):
IDFE Motherboard
Diagnostic LEDs
CD-ROM Drive
Token Ring PWBA
Hard Disk Drive
The DC returns for the IDFE Motherboard, CD-ROM Drive, Token Ring PWBA and the Hard
Disk Drive are provided through the Connector P/J 899 Pins 5, 6, 7,and 8 (BSD 16.1) to Connector J508 Pins 3 and 4 on the Printer LVPS.
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The IDFE also uses +12 VDC power, supplied from the Printer LVPS to transfer power to the
IDFE Wiring Harness at P/J 899 Pin 9. This +12 VDC circuit is used to provide additional power
to the CD-ROM Drive, the Fan and the AUI Transceiver for the IDFE. The DC return for the CDROM Drive, the Hard Disk Drive, the Fan and the AUI TRansceiver is provided by Connector P/
J 899 Pin 11 through Connector J509 Pin 4 (BSD 16.1).
Digital Signal Distribution from the IDFE to the IOT

Two 80 pin cables provide Digital to Digital Interface (DDI) connections at Connector DPJ2 for
the Printer and Connector DSJ2 for the Scanner. These two cables provide the DDI link
between the VSEL EXT PWBA on the DC CS50 and the IDFE Interface Card contained within
the IDFE. (BSD 16.1)
The Print and Scan DDI Cables for the IOT and the IDFE are identical. The Print and Scan DDI
Cables must not be crossed.
CAUTION
To assure that the Print and Scan Cables are installed correctly and are not crossed in manufacturing or service repair, a pair of ICONS (Paper > Scanner, Printer > Paper) will be printed
onto the IOT and IDFE covers.
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Power Distribution - IDFE, Digital Signal Distribu-
IDFE Enclosure
Network Interface
The IDFE Enclosure is formed from a single piece of 22 gauge galvanized steel to provide EMI
and EME suppression for the noise sensitive components in the IDFE and the IOT. A Cover
Plate is added for the CD-ROM Drive to help suppress additional EME emissions from the CDROM Drive. The IDFE uses an internal Fan to provide air flow through the IDFE in a right to left
direction. The Internal Fan is powered by +12 VDC from the Printer LVPS. The fully assembled
IDFE weighs 13.5 lbs. (6.1 kg).
The IDFE can interface

with local area networks by use of several different protocols:
TCP/IP
Netware IPX (NDS and Bindery only)
AppleTalk
LPD network protocol stack
Banyan VINES (requires additional hardware through an external print server using a parallel port or controller)
NetBEUI
Netbios
The IDFE supports the following physical interfaces:
Parallel printer interface (For external print server to support Banyan VINES)
Ethernet (10 or 100 Mbps)
Token Ring (4 or 16 Mbps)

NOTE: Installation of the Token Ring PWBA requires optional hardware.
IDFE Enclosure, Network Interface
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Image Processing
Print Interface
Refer to Chapter 6 - Imaging, in the Principles of Operation for the DocuColor 12 and BSD 16.1
for more information on how the following PWBAs perform signal flow and Image Processing:
Half Tone PWBA
Post IPS PWBA
VSEL Base PWBA
VSEL Extension PWBA
Figure 1 IDFE Print Interface Block Diagram

The print interface between the DC CS50 and the IDFE is shown in Figure 1. The signals are
as follows:
VIDEO DATA ODD and VIDEO DATA EVEN - Each is a set of eight parallel lines which
provide the print data to the IOT.
TAG ODD and TAG EVEN - Each is a set of four parallel lines which provides auxiliary
data for images sent using YMCK color space.
nPAGE REQ - The IDFE must provide an entire print page of data to the IOT during the
active (negative) period of this signal.
nLINE REQ - The IDFE must provide a pair of data lines during the active (negative)
period of this signal.
VCLK - The IOT uses this signal to sample the video data and tag information.
nVALID - This indicates that the data on the video data and tag lines is valid and may be
sampled.
The odd and even data and tag buses are used simultaneously to pass 600 dpi images. Either
the even or odd busses can be used individually to pass a 400 dpi image.
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Image Processing, Print Interface
Scan Interface
Figure 1 IDFE Scan Interface Block Diagram

The scan interface is very similar to the print interface, except that image data flows in the
opposite direction. The interface is shown in Figure 1. The signals are:
SVDATA ODD and SVDATA EVEN - Each is a set of eight parallel lines which provide the
scan data from the IOT.
STAG ODD and STAG EVEN - Each is a set of four parallel lines which provides auxiliary
data for images sent using YMCK color space.
nSEPAGE REQ - The IOT must provide an entire print page of data to the IOT during the
active (negative) period of this signal.
nSLINE REQ - The IOT must provide a pair of data lines during the active (negative)
period of this signal.
SVCLK - The controller uses this signal to sample the video data and tag information.
nSVALID - This indicates that the data on the video data and tag lines is valid and may be
sampled.
As with the print interface, the odd and even data and tag buses are used simultaneously to
pass 600 dpi images. In addition, either the even or odd buses can be used individually to pass
a 400 dpi image.
Scan Interface
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DocuColor 12/DCCS50
11 Glossary of Terms
Glossary of Terms and Contractions...............................................................................
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11-3
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Glossary of Terms
Glossary of Terms
1/05
11-2
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DocuColor 12/DCCS50
Glossary of Terms and Contractions
Table 1 Glossary of Terms
Purpose
Term
Description
This section provides a list of acronyms and new words used in conjunction with this machine.
CCW
Counterclockwise (left-hand rotation)
CD
Circuit Diagram
CDIC
Compression Decompression Interface Controller
CD-ROM
Compact Disc Read only Memory
CGROM
Character Generator Read Only Memory
CMP
Call Maintenance Practices
Table 1 contains the terms and acronyms that are used throughout the Service Documentation.
Term
Description
A/E or AE
Auto Exposure
CPM
Copies per Minute
A3
Paper size 11.69 x 16.54 inches (297 x 420mm)
CPU
Central Processing Unit
A4
CQ
A4 Cover
Copy Quality, refers to characteristics that are xerographic and\or

cosmetic related
A5
CRU
Customer Replaceable Unit
ACH
AC High
CRUM
AC
Alternating Current
Customer Replaceable Unit Monitor, individual CRU usage monitor (internal to each CRU)
ACL
AC Line
CRUM-COD-ID
Crum Code Identification
AC Neutral
CSDNO
Circuit Switched Digital Network
Auto Density Control
CSE
Customer Service Engineer
CSI
Called Subscriber Identification
Automatic Offset Control
CTC
Continue to Correct
Auto Paper Sensor
CVT
Constant Velocity Transport
(American Standard Code for Informational Interchange) A 7-bit

code providing 128 possible character combinations.
CW
Clockwise (right-hand rotation)
DAD
Discharge Area Development
(Application Specific Integrated Circuit) A chip that is designed for

a specific purpose within a highly vertical application.
DADF
DATAMAN
Data Management Application
ATS
Auto Tray Selection
DC
Direct Current
Auditron
Electronic counters for tracking customer usage of the machine.
dC
Diagnostic Routine
B4
DC COM
Direct Current, Common
B5
DFE
Digital Front End
BBS
Bulletin Board System, Electronic Bulletins can be downloaded to

the PWS via this system.
DMM
Digital Multi-meter
Dog Ear
A condition when the corner or corners of the paper are curled or

folded
ACN
ADC
AGC
AOC
APS
ASCII
ASIC
BCO
Bead Carryout
BCR
Bias Charge Roll
DOS
Disk Operating System) A generic term for operating system.
BIOS
Basic Input/Output System
DPI
Dots Per Inch
Bit
Binary digit (1 or 0), representing an electrical state.
DPM
Duplex Copies per Minute
BSD
Block Schematic Diagram
DRAM
Dynamic Random Access Memory
BTR
Bias Transfer Roll
DSS
Disk Stacker Stapler
BUS
An electrical connection that allows data flow in two directions at

the same time.
DTS
Detack Saw
ECM
Error Correction Mode
EDOC
Electronic Documentation
EEPROMS
(Electronically Erasable Programmable Read Only Memory) A

memory chip that holds its content without power.
Cyan
CB
Chute Bias
CCD
Charge Coupled Device
CCITT
International Telegraph and Telephone Consultative Committee
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Glossary of Terms
Term
Description
Term
Description
ELOG
Electronic Service-Log, an electronic tool used to track machine

service history.
IOT
Image Output Terminal
IPS
Image Processing System
EME
Electromagnetic Emissions
IQ
Image Quality
EPC
Electronic Page Collation
IQ defects
Image Quality defects (see CQ)
EPROM
Erasable Programmable Read-Only Memory. A ROM that can be

erased and then programmed again with new software.
ISDN
Integrated Services Digital Network
ISDN1
ISDN Channel 1
ISDN-CSDN1
Circuit Switched Digital Network
ISDNO
ISDN Channel 0
IVCM
Integrated Video and Control Module
Black
KO
Key Operator
Low
LAN
Local Area Network
Laser SOS
Laser Start of Scan
LCD
Liquid Crystal Display
EQM
Eye Quality Monitor
ES
Expert System
ESD
Electrostatic Discharge. A transfer of charge between bodies at

different electrostatic potential. Could be damaging to sensitive
devices.
ESV
Electro Static Voltage
Executive
FAX
Facsimile Product, the conversion of paper media to electronic

impulses that are transmitted over the phone lines and then recompiled at the receive end
FCC
Federal Communications Commission
LD
Laser Diode Driver
FIP
Fault Isolation Procedure
LDD
Laser Diode Driver
FRU
Field Replaceable Unit
LE
Lead Edge
FX
Fuji Xerox
LED
Light Emitting Diode
PPM
Prints Per Minute
Ledger
Paper size 11 x 17 inches (297 x 420mm)
G4M
Group 4 Module
LEF
Long Edge Feed; Portrait orientation
GFI
Ground Fault Interrupter
Legal
Paper size 8.5 x 14 inches (216 x 356mm)
GND
Ground
Letter
Paper size 8.5 x 11 inches (216 x 279mm)
GSM
Grams per Square Meter
Letter Cover
Paper size 9 x 11 inches (229 x 279mm)
High
LP
Laser Printer
HCF
LVPS
Low Voltage Power Supply
HDD
Hard Disk Drive
M/C
HDIF
Hard Disk Interface
Machine Clock or Mean Copies or Machine (Depending on context)
HFSI
High Frequency Service Items (parts in a machine that have an

anticipated known life)
Magenta
MB
Megabyte
HVPS
High Voltage Power Supply
Mbps
Mega bits per second
HZ
Hertz, cycles per second
MBX
Mailbox
I/F
Interface
MBX P(s)
Mailbox Passwords
I/O
Inputs and Outputs
MMB PWBA ID
Main Mailbox
IB
Inboard; the side of the paper path closer to the rear of the
machine; toward the inside of the machine.
MMR
Modified Read
MN
Multi-National
IBT
Intermediate Belt Transfer
Moire
IDFE
Integrated Digital Front End
Patterns on the image areas of the output copy or print that have
the appearance of a screen or grid overlaying the image.
IE
Image Enhancement
MPSX
MPS Xerox Signal
IIT
Integrated Input Terminal, or Image Input Terminal
MR
Modified Read
IIT/IPS
Integrated Input Terminal/Image Processing System
MRC
Machine Run Control
Glossary of Terms
1/05
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DocuColor 12/DCCS50
Term
Description
Term
Description
MRD
Machine Resident Diskette, 3.5-inch floppy diskette stored on the

bottom rear cover of the machine. Used to store NVM (backup)
and ELOG files.
RTC
Return to Control
RTN
Retrain Negative
RTP
Retrain Positive
RX
Rank Xerox (obsolete term, see XL)
SA
System Administrator
SCSI
Small Computer Systems Interface
SEF
Short Edge Feed; Landscape orientation
SIMM
Single Inline Memory Module
Skew
Angular error between the xerographic image and the copy paper,
measured at the lead edge.
SOS
Start of Scan
SPI
Spots per Inch
SR
Service Representative
SSR
Solid State Relay
SW
Switch or Software
T/A
Takeaway
TAG
Hardware upgrade information
TMB
Tower Mailbox
TP
Test Point
TRC
Toner Reference Control
TRC RADC
Toner Reference Control Random Access Density Control
TRN
Train
TTL
Transistor Logic: A digital circuit with transistor input and transistor

output.
msec.
milliseconds
MSI
Multi-Sheet Inserter
NASG
North American Solutions Group
NSF
Non-Standard Facilities
NVM
Non-Volatile Memory. Random Access Memory device (RAM)
OB
Outboard; the side of the paper path closer to the front of the
machine; toward the outside of the machine.
OCT
Offset Catch Tray
Ohms
a unit of measurement of electrical resistance
OPC
Organic Photo Conductor
PC
Personal Computer
PCL5
Printer Control Language
PCMCIA
Personal Computer Memory Card International Association
PIX
Picture data (pixel)
PL
Parts List
PMC
Preventive Maintenance Call
PO/PO
Power Off/Power On the machine.
POST
Power On Self Test
PPI
Pixels per Inch
PPM
Prints per Minute
PPM
Pages per Minute
PROM
Programmable Read Only Memory
TTM
Tray Turn Module
PS
PostScript
UART
Universal Asynchronous Receiver Transmitter
PSTN
Public Switched Telephone Network
UI
User interface
PWB(A)
Printed Wiring Board Assembly
USCO
United States Customer Operations
PWS
Portable Workstation
VAC
Voltage Alternating Current
RADC
Random Access Density Control
VCE
Video Compression and Expansion
R/E
Reduction/Enlargement
VDC
Voltage Direct Current
RAM
Random Access Memory. A digital memory circuit from which

information can be accessed or where software information can be
stored.
Xero
Xerographics
VRAM
Volatile Random Access Memory
XE
Xerox Europe (formerly RX, or Rank Xerox)
XVDC
Generic Voltage DC
XPC ASIC
X direction pixel count application specific integrated circuit
Yellow
RAP
Repair Analysis Procedure
R/H
Right Hand
RE
Reduction, Enlargement
Regi.
Registration
RGB
Red Green Blue
ROM
Read Only Memory. A digital memory circuit that is designed to

contain permanent software information.
ROS
Raster Output Scanner (name given to a laser unit)
Reissue
DocuColor 12/DCCS50
1/05
11-5
Glossary of Terms

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DocuColor 12/DCCS50

Photoreceptor Drum Light Shock

Electrostatic Discharge Damage

Toner, Developer and Drum

Disconnecting and Reconnecting Electrical Connectors.

Figure 1 Laser Hazard Symbol

About This Documentation

Section 1. Service Call Procedures

Detailed Maintenance Activities

Section 2. Status Indicator Repair Analysis Procedures (RAPs)

Section 3. Image Quality Repair Analysis Procedures (IQ RAPs)

Section 4. Repairs and Adjustments

Section 5. Parts List

Section 6. General Procedures

Section 7. Wiring Data

Section 8. Accessories / Options

Section 9. Installation and Removal

Section 10. Principles of Operations

Figure 1 General Information

Figure 2 General Information

Figure 3 General Information

AC and DC Voltage Nomenclature

Actual Voltage Ranges

+4.5 to +5.3 VDC

0.0 to +1.0 VDC

+3.0 to +4.2 VDC

0.0 to +1.0 VDC

+10.0 to +13.2 VDC

0.0 to +1.5 VDC

-10.0 to -13.2 VDC

0.0 to -1.5 VDC

+11.0 to +14.2 VDC

0.0 to +1.5 VDC

+22.0 to +25.7 VDC

0.0 to +3.0 VDC

DANGER: Lors de certaines installations (particulirement en Europe), le neutre peut

3 Image Quality RAPs

IQ 37 Developer Bias HVPS RAP

IQ 38 Charge Corotron HVPS RAP

IQ 39 Preclean Corotron HVPS RAP

DANGER: Mettre la machine sur Arrt et dbrancher le cordon d'alimentation.

IQ 40 2nd BTR HVPS RAP

Turn the power off and disconnect the power plug.

REP 2.1.2 Tray 2/3/4 Size Sensor

IQ 41 1st BTR HVPS RAP

Turn power off and disconnect the power plug.

REP 2.4.1 Tray 1/2/3/4 Feeder

Turn power off and disconnect the power plug.

4 Repairs and Adjustments

REP 2.5.1 Tray 1/2/3/4 Feed/Nudger Roll Assembly

REP 1.3.1 Belt (Developer Drive)

DANGER: Mettre la machine sur Arrt et dbrancher le cordon d'alimentation.

REP 2.6.1 Feed Lift Motor

Turn power off and disconnect the power plug.

DANGER: Mettre la machine sur Arrt et dbrancher le cordon d'alimentation.

Turn power off and disconnect the power plug.

REP 1.4.1 Belt (2nd BTR, Auger)

DANGER: Mettre la machine sur Arrt et dbrancher le cordon d'alimentation.

REP 2.6.2 Retard Roll

Turn the power off and disconnect the power plug.

DANGER: Mettre la machine sur Arrt et dbrancher le cordon d'alimentation.

Turn power off and disconnect the power plug.

REP 1.5.1 Tray 5/Regi. /Tray 1 Take Away Drive

DANGER: Mettre la machine sur Arrt et dbrancher le cordon d'alimentation.