01 Service Call Procedures

Service Call Procedures

rvice Call Procedures

July 20051-1WorkCentre Pro 275 Family (CC232-WCP275F)

1 SeSCP 1 Initial Actions........................................................................................................ 1-3SCP 2 First Call Actions.................................................................................................. 1-4SCP 3 Normal Call Actions ............................................................................................. 1-4SCP 4 Fault Analysis ...................................................................................................... 1-5SCP 5 Subsystem Maintenance ..................................................................................... 1-7SCP 6 Final Actions ........................................................................................................ 1-8SCP 7 Machine Features ................................................................................................ 1-9

WorkCentre Pro 275 Family (CC232-WCP275F)
July 2005
1-2


SCP 1Service Call Procedures

SCP 1 Initial ActionsUse the Service Call Procedures to find a problem with the machine.

To display the active messages on the UI, perform the steps that follow:

1. Press the Status Key on the UI.

n the UI.


Use the Initial Actions to collect the information on the machine performance.

Also refer to SCP 7 Machine Features.

Initial ActionsSwitch off the machine, then switch on the machine, GP 14.

ProcedureWARNING

Switch off the electricity to the machine, GP 14. Disconnect the power lead from the customer supply while tasks are performed that do not need the electricity. The electric-ity can cause the death or injury of persons. The moving components can cause the injury of persons.

WARNINGDo not work in a small area. 1 m (39 inches) of space is needed to work safely.

1. Take note of problems, error messages or error codes. If necessary, refer to Machine Sta-tus.

2. Ask the operator to describe or demonstrate the problem.

3. If the problem is the result of an incorrect action by the operator, refer the operator to the user documentation.

4. Check the steps that follow:

a. The power lead is connected to the wall outlet and to the machine.

b. The documents are not loaded in the DADH or on the document glass.

c. The paper is loaded correctly.

d. All paper trays are closed.

e. All covers are closed or installed.

f. If a telephone line cable is installed, make sure that the cable is connected between the line socket and the wall jack.

g. If a telephone line cable is installed, make sure that the customer telephone line is good.

5. Check the machine service log book for previous actions that are related to this call.

6. If this service call is the first service call to this machine, go to SCP 2 First Call Actions. If this service call is not the first call, go to SCP 3 Normal Call Actions.

Machine Status

To display a list of all fault codes on the UI, perform the steps that follow:


2. Touch the Fault tab on the UI.

3. Touch the All Faults button on the UI.

To display the event log on the UI, perform the steps that follow:


2. Touch the Fault tab on the UI.

3. Touch the Event Log button on the UI.

2. Touch the Fault tab on the UI

3. Touch the Active Messages button o


sason for the service call.

e machine, GP 14.

o the RAP for the error message. If necessary refer to

ples.

are correct. If necessary refer to the user documenta-

omer information and soft machine settings, perform P 5.

or clear the memory, check for a customer job in the

nter.

contamination. Refer to the OF11 Waste Toner Con-

July 20051-4SCP 2, SCP 3


SCP 2 First Call ActionsUse the First Call Actions for the first service call.


Procedure1. Check the machine configuration with the customer. Check that all the required hardware

and software is installed. Check that all the required hardware and software is enabled.

2. Check that all the machine settings are entered correctly.

3. Mark off the hardware options, software options or Tags installed on the Tag matrix cards and dC111.

4. 32-55 ppm Only. If the machine has a OCT, install the OCT fingers. Go to REP 12.1.

NOTE: The OCT fingers are supplied with the OCT but must be installed by a CSE at the first service call. They are located in a plastic wallet on the rear of the machine. The OCT fingers improve feeding to the OCT.

5. If a fault is found, go to SCP 3 Normal Call Actions. If a fault is not found, go to SCP 6Final Actions.

6. Check the machine for waste toner contamination. Refer to the OF11 Waste Toner Con-tamination RAP.

7. Save NVM to the machine resident diskette. Refer to GP 5 Portable Workstation and Tools.

8. Enter the machine information and the customer information in the service logbook.

SCP 3 Normal Call ActionUse the Normal Call Actions to find the re

Initial ActionsSwitch off the machine, then switch on th

Procedure

NOTE: If an error message appears, go tOF4 Status Codes and Messages RAP.

Perform the steps that follow:

1. Review the copy, print and Fax sam

2. Make sure the user access settings tion.

3. To prevent the deletion of the custNVM Save and Restore. Refer to G

4. Before you press the on/off switch memory.

5. Check and record the total print cou

6. Check the machine for waste tonertamination RAP.

7. Go to SCP 4 Fault Analysis.


SCP 4 Fault AnalysisUse the Fault Analysis to identify a fault.

Messages, Fault Codes and Status Codes

• If the machine has the problems that follow, go to the 19-401, 19-402, 19-403 Out of

ough memory to complete the job.

omplex job.

print speed is slow.

yed, but not a fault code, go to OF4 Status Code and

Status Indicator RAP for that code.

rk Service Unavailable’ is displayed, perform the Sta-e fault continues after you performed the RAP, go to AP.

the features for output devices that are installed, per-w:

18 IOT to Output Device Error RAP.

Head Operation Failure RAP.

cuments in the DADH input tray, go to 05B Document

ult code, go to the 05A DADH Other Faults RAP.

nt of the wrong size. Perform the procedures that fol-

RAP.

ilure RAP.

s

do not have a fault code, perform the correct proce-

Level RAP.

Level RAP.

Paper RAP.

per RAP.

o to the OF8 Multifeed RAP.

Failure RAP.

T, go to the OF6 Ozone and Air Systems RAP.

t, but not a fault code, perform the correct procedure

AP.

ibution RAP.

Communication Interface RAP.

witch Settings RAP.



ProcedureUse the machine in all modes until you find the fault.

Go to the correct procedure for the machine fault. When the fault is fixed, go to SCP 5 Sub-system Maintenance.

• Power Up Problems

• Sleep Mode Problems

• User Interface Problems

• Messages, Fault Codes and Status Codes

• DADH Problems

• Paper Supply and Paper Feed Problems

• OCT Problems

• 1K LCSS Problems

• 2K LCSS Problems

• HCSS Problems

• HCSS BM Problems

• Fax Problems

• Other Problems

Power Up Problems

• If the machine has the problems that follow, go to the OF3 Dead Machine RAP.

– The machine will not power up.

– There is no information on the user interface.

– There is no LED illumination on the user interface.

• If all the panel lights are on, the UI touch screen is illuminated and the machine then pow-ers off. Go to the OF3 Dead Machine RAP.

• If the UI displays ‘system unavailable’ or the machine does not come to a ‘Ready to scan your job’ state. Go to the OF5 Boot Up Failure RAP.

Sleep Mode Problems

• If the machine fails to enter or exit sleep mode, go to the 01K Sleep Mode RAP.

User Interface Problems

• If the machine has the problems that follow, go to the OF3 Dead Machine RAP.

– The machine is silent.

– There is no information on the user interface.

– There is no LED illumination on the user interface.

• If the user interface is not illuminated, go to the OF2 UI Touch Screen Failure RAP.

• If the user interface is illuminated, but there is no information, go to the 02-309 UI Control Panel Button or Touch Screen RAP.

Memory Resources RAP.

– A message that there is not en

– The machine does not print a c

– The customer reports that the

• If a status code or message is displaMessage RAP.

• If a fault code is displayed, go to the

• If a fault code and the message ‘Matus Indicator RAP for that code. If ththe 03B Mark Service Unavailable R

• If the user interface does not displayform one of the procedures that follo

– 03-360, 03-408 to 03-410, 03-4

– 11-050-110, 11-360-110 Staple

DADH Problems

• If the DADH does not detect the doPresent Failure RAP.

• If the DADH has a fault, but not a fa

• If the DADH has detected a documelow:

– 14A Scanning Document Size

– 05C Document Size Sensor Fa

Paper Supply and Paper Feed Problem

• For the paper supply problems thatdure that follows:

– 07A Tray 1 and 2 False Paper

– 07B Tray 3 and 4 False Paper

– 07C Bypass Tray RAP.

– 07D Tray 1 and 2 Wrong Size

– 07E Tray 3 or Tray 4 Out Of Pa

– 07F Tray Out of Service RAP.

• If the machine makes a multifeed, g

OCT Problems

• Go to the 12-301 Offset Catch Tray

• If the prints bond together in the OC

1K LCSS Problems

• If the machine has a 1K LCSS faulthat follows:

– 11A-120 Bin 1 Overload RAP.

– 11B-120 Initialization Failure R

– 11C-120 1K LCSS Power Distr

– 11D-120 1K LCSS to Machine

– 11E-120 1K LCSS PWB DIP S


– 11F-120 1K LCSS PWB Damage RAP. HCSS BM Problems

S BM, but with no fault code, perform the correct pro-

n Failure RAP.

tribution RAP.

Communication Interface RAP.

re RAP.

HCSS BM RAP.

apled and Unstapled Sets RAP.

ing RAP.

tion, perform ADJ 11.2-170 Hole Punch Position.

he compiler are not correct, go to the 11-364-170, 11- Failure RAP.

rrect, perform the correct procedure that follows:

BM Staple Unit 1 Failure RAP,

BM Staple Unit 2 Failure RAP.

SS BM bins, go to OF6 Ozone and Air Systems RAP.

, perform the correct procedure that follows:

P.

Some Machines RAP.

RAP.

P.

RAP.

age Checkout.

and Air Systems RAP.

etwork Controller RAP.

e OF12 Convenience Stapler RAP.

tem Administration password. Go to dC001 Reset

password and the Auditron password are the same

age Quality Entry RAP.

le Noise RAP.

e and Air Systems RAP.

03-374 Power Off Failure RAP.

stic Entry, Facilities and Exit.

n Device Checkout.

July 20051-6SCP 4


– 11G-120 Copy Damage in the 1K LCSS RAP.

– 11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.

– 11J-120 1K LCSS Poor Stacking RAP.

• If the machine has the problems that follow, go to the 11E-120 1K LCSS PWB DIP Switch Settings RAP:

– False jam clearance messages.

– Communication errors between the LCSS and the machine.

• If the staples of a stapled set are not correct, go to the 11-364-120 Stapling Failure RAP.

• If the prints bond together in the LCSS trays, go to OF6 Ozone and Air Systems RAP.

2K LCSS Problems

• If the machine has an 2K LCSS fault, but not a fault code, perform the correct procedure that follows:

– 11A-110 Offline Stapling Faults RAP.

– 11B-110 Bin 1 Overload RAP.

– 11C-110 Initialization Failure RAP.

– 11D-110 2K LCSS Power Distribution RAP.

– 11E-110 2K LCSS to Machine Communications Interface RAP.

– 11F-110 2K LCSS PWB DIP Switch Settings RAP.

– 11G-110 2K LCSS PWB Damage RAP.

– 11H-110 Copy Damage in the 2K LCSS RAP.

– 11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.

– 11K-110 2K LCSS Poor Stacking RAP.

• If the punched holes are out of position, perform ADJ 11.3-110 Hole Punch Position.

• If the machine has the problems that follow, go to the 11F-110 2K LCSS PWB DIP Switch Settings RAP:

– False jam clearance messages.

– Communication errors between the LCSS and the machine.

• If the staples of a stapled set are not correct, go to the 11-364-110 Stapling Failure RAP.

• If the prints bond together in the LCSS trays, go to OF6 Ozone and Air Systems RAP.

HCSS Problems

• If the machine has a HCSS fault, but with no fault code, perform the correct procedure that follows:

– 11A-130 Offline Stapling RAP.

– 11B-130 HCSS Initialization Failure RAP.

– 11C-130 HCSS Power Distribution RAP.

– 11D-130 HCSS to Machine Communications Interface RAP.

– 11E-130 Copy Damage in the HCSS RAP.

– 11F-130 Mis-Registration in Stapled and Unstapled Sets RAP.

– 11G-130 HCSS Poor Stacking RAP.

• If the punched holes are out of position, perform ADJ 11.2-130 Hole Punch Position.

• If the staples of a stapled set are not correct, go to the 11-364-130, 11-370-130 Stapling Failure RAP.

• If the prints bond together in the HCSS bins, go to OF6 Ozone and Air Systems RAP.

• If the machine has a fault in the HCScedure that follow:

– 11A-170 Offline Stapling RAP.

– 11B-170 HCSS BM Initializatio

– 11C-170 HCSS BM Power Dis

– 11D-170 HCSS BM to Machine

– 11E-170 HCSS BM Bin 2 Failu

– 11F-170 Booklet Quality RAP.

– 11G-170 Copy Damage in the

– 11H-170 Mis-Registration in St

– 11J-170 HCSS BM Poor Stack

• If the punched holes are out of posi

• If the staples of a stapled set from t370-170 Compiler Carriage Stapling

• If the staples of a booklet are not co

– 11-063-170, 11-411-170 HCSS

– 11-403-170, 11-413-170 HCSS

• If the prints bond together in the HC

Fax Problems

• For Fax problems with no fault code

– 20A Fax Entry RAP.

– 20B Unable To Send A Fax RA

– 20C Unable To Send A Fax To

– 20D Unable To Receive A Fax

– 20E Fax Will Not Print RAP.

– 20F Fax Tab Not Available RA

– 20G Embedded Fax Checkout

– 20H Embedded Fax PWB Volt

Other Problems

• Hot machine. Go to the OF6 Ozone

• Network print faults. Go to the 16A N

• Convenience stapler faults. Go to th

• If the customer has lost the SysAuditron Master PIN.

NOTE: The System Administration item.

• Image quality fault. Go to the IQ1 Im

• Machine noise. Go to the OF1 Audib

• Machine odour. Go to the OF6 Ozon

• The machine will not turn off. Go to

• Check the fault history. GP 1 Diagno

• Foreign device. Go to ACC 1 Foreig


SCP 5 Subsystem MaintenanceUse the Subsystem Maintenance to maintain the machine.

NOTE: If a range of machine speeds are specified within Table 1, the life expectancy for the part will be specific for the parts that are built for those particular machines.

fe expectancy for the part apply to all machines within

own in Table 2. To change HFSI settings, refer to GP

frequency service items

ion

The recommended life for new component installation

Parts list reference

fed from tray 1 HFSI reset

1,500k feeds PL 8.26 Item 5







feeds from tray after last HFSI


feeds from tray ter the last HFSI


feeds from tray the last HFSI


bypass tray r the last HFSI

100k feeds PL 7.30 Item 21

DADH feeds in after the last

et

180k feeds PL 5.15 Item 1

turned and eds after the last et

2,500k feeds (32-55 ppm) PL 10.13 Item 4 or (65-75 ppm) PL 10.11 Item 4

count of the nsor actuator

last HFSI reset

1,000k actuator counts

PL 8.20 Item 4


ProcedureWARNING

Switch off the electricity to the machine, GP 14. Disconnect the power lead from the customer supply while tasks are performed that do not need the electricity. The electric-ity can cause the death or injury of persons. The moving components can cause the injury of persons.

Go to the correct procedure:

• Installation of New Parts

• HFSI

• Lubrication

• How to Clean the Machine

Installation of New PartsThe design life of the major components are shown in Table 1.

If the speed has not been specified, the lithe product family.

HFSIThe High Frequency Service Items are sh17 High Frequency Service Items.

Table 1 Component design life

Part Life Parts list reference

Fuser module32-55 ppm65-75 ppm

400k prints400k prints

PL 10.8 Item 1PL 10.10 Item 1

Ozone filter32-55 ppm65-75 ppm



Xerographic module32-38 ppm45-75 ppm



Toner cartridge32-55 ppm65-75 ppm

30k prints at 6% area coverage45k prints at 6% area coverage


Waste toner bottle 100k prints at 6% area coverage PL 9.10 Item 1

DADH feed roll assembly 150k feeds PL 5.15 Item 1

1K LCSS staple cartridge 2k staples PL 26.10 Item 26

2K LCSS staple cartridge 5k staples PL 26.10 Item 11

HCSS staple cartridge 5k staples PL 26.10 Item 11

HCSS BM staple cartridge 5k staples PL 26.10 Item 11

BM staple cartridge 2k staples PL 26.10 Item 24

Developer assembly32-38 ppm45-55 ppm65-75 ppm

1000k prints2500k prints5000k prints

PL 9.17 Item 2PL 9.17 Item 2PL 9.15 Item 2

Table 2 High

Item Component Descript

Tray 1 feed Feed rolls All sheetsafter last




Tray 1 trans Transport roll The total1, 2, 3, 4reset

Tray 2 trans Transport roll The total2, 3, 4 afreset

Tray 3/4 trans Tray 3 and 4 transport roll

The total3, 4 afterreset

Bypass feeds Bypass tray feed roll and retard pad assembly

The totalfeeds aftereset

DADH feeds Feed roll assembly

The totalall modesHFSI res

Inverter feeds Nip split shaft assembly

The totalduplex feHFSI res

Duplex sen-sor

Duplex sen-sor actuator

The totalduplex seafter the


peration of the system. Use the Final Actions to com-

identified, go to SCP 4 Fault Analysis:

chine from the machine resident diskette. Go to GP 5

ce.

1.

. Make the copies and prints from all trays, use the

omer document.

were changed, return the selections to the previous

are options or Tags installed on the Tag matrix cards,

resident diskette. Go to GP 5 Portable Workstation

onfiguration or options were added, print the configu- report with the machine log book. Discard the previ-rt.

st patterns.

area are clean.

ith training.

Table 2 High frequency service items

July 20051-8SCP 5, SCP 6


LubricationTo lubricate the machine, refer to ADJ 4.1 Machine Lubrication.

How to Clean the Machine• Perform ADJ 9.4 Xerographics Cleaning.

• Clean the takeaway roll idlers, PL 5.20 Item 3. Refer to ADJ 5.4 DADH Cleaning Proce-dures.

• Clean the upper surfaces of the CVT glass and document glass. Refer to (32-55 ppm) ADJ 14.1A or (65-75 ppm) ADJ 14.1B Optics cleaning procedures.

• Clean the tray 4 feed sensor and the area around the sensor.

• Clean the registration sensor and the surrounding area, PL 8.15 Item 3.

• For special tools and consumables, refer to GP 8 Special Tools and Consumables.

• Go to SCP 6 Final Actions.

SCP 6 Final ActionsUse the Final Actions to verify the total oplete the service call.

ProcedurePerform the steps that follow. If a fault is

• If necessary, restore NVM to the maPortable Workstation and Tools.

• Go to SCP 5 Subsystem Maintenan

• To clear all fault counters, go to GP

• Operate the machine in all modesDADH and the document glass.

• Make a proof copy or print of a cust

• If some of the customers selectionssettings.

• Mark off the hardware options, softwdC111.

• Save NVM changes to the machineand Tools.

• If some changes were made to the cration report. Store the configurationous version of the configuration repo

• Remove and destroy all copies of te

• Make sure the machine and service

• If necessary, provide the customer w

Bias foam Bias contact The total sides of copies and prints after the last HFSI reset

500k impres-sions

PL 8.15 Item 23

Developer Developer drive gear / pulley and the main drive gear

The total sides of copies and prints after the last HFSI reset

2,500k impres-sions

(32-55 ppm) PL 9.17 Item 2 or (65-75 ppm) PL 9.15 Item 2

Post Fuser Tri-roll shaft assembly and Post fuser exit roll.

The total sides of copies and prints after the last HFSI reset

1,200k impres-sions

(32-55 ppm) PL 10.14 Item 4, PL 10.14 Item 10 or (65-75 ppm) PL 10.12 Item 4, PL 10.12 Item 10.

Item Component Description

The recommended life for new component installation

Parts list reference


SCP 7 Machine FeaturesConfiguration Options

Development HistoryThe CC232-WCP275F machines have been developed from the DC535F, CC35-WCP55F and

new features:

pm.

r (1K LCSS) available on 32ppm, 38ppm and 45ppm

er (HCSS BM) available on 32ppm, 38ppm, 45ppm

the various machine configurations:

ent cover and OCT.

d OCT.

and 1K LCSS.

and 2K LCSS.

d 3K HCSS.

and HCSS BM.

stand, document cover and OCT


The CC232-WCP275F is available as a basic machine with trays 1, 2 and a bypass tray. It is also available in various configurations using the following options:

General

For the space requirements, environment range and the print out time. Refer to:

• GP 21 Installation Space Requirements

• GP 23 Environmental Data.

• GP 25 First Copy / Print Out Time and Power On / Off Time.

Paper supply and paper handling options

• 3600 sheet high capacity feeder (HCF).

• 75 sheet duplex automatic document handler (DADH).

Output options

• 500 sheet offsetting catch tray (OCT).

• 1250 sheet 1 bin stapler stacker (1K LCSS).

• 2250 sheet 2 bin stapler stacker (2K LCSS).

• 3250 sheet 3 bin stapler stacker (HCSS).

• 1750 sheet 3 bin stapler stacker (HCSS BM).

Accessories and Kits

• 50 sheet convenience stapler.

• Foreign interface kit.

• EPC (machine) RAM upgrade.

• Image overwrite security kit.

• Nationalization kits.

• Basic network controller kit.

• Advanced network controller kit.

• NC RAM upgrade kit.

• Server FAX kit.

• 4 hole punch kit.

• USB print kit.

• Internet FAX kit.

• Embedded FAX kit.

• Network accounting kit.

• Scanning kit.

• Ad hoc e-mail kit. NASG only.

NOTE: The service manual covers all of the above configurations. Within the manual, ignore any references to options that are not installed.

CC165-WCP175F and offer the following

• New models speeds of 32 and 38 p

• Wider choice of output modules:

– 1250 sheet 1 bin stapler stackemachines.

– 1750 sheet 3 bin stapler stackand 55ppm machines.

Machine IdentificationThe following diagrams illustrate some of

• Figure 1, CC232 with stand, docum

• Figure 2, WC238 with DADH, NC an

• Figure 3, WCP245 with DADH, NC


• Figure 5, WC265 with DADH, NC an


Figure 1 CC232 with


with DADH, NC and 2K LCSS

ith DADH, NC and 3K HCSS

July 20051-10SCP 7


Figure 2 WC238 with DADH, NC and OCT

Figure 3 WCP245 with DADH, NC and 1K LCSS

Figure 4 WCP255

Figure 5 WC265 w

July 2005
1-11WorkCentre Pro 275 Family (CC232-WCP275F)

Figure 6 WCP275 with DADH, NC and HCSS BM

July 2005
1-12SCP 7Service Call Procedures

01 Service Call Procedures

Documents

Transcript of 01 Service Call Procedures