Transmittal Page

Product Title Part Number

WorkCentre 5790 Family Service Manual 708P89780

(WC5735-WC5790F)

Launch Date

February 2010

Please note the following:

This output is created from an electronic documentation (EDOC) database

and is not optimised for hard copy. Please be aware of the following:

•Text may not appear to be in the logical order when flowing around figures.
•Text may continue on a following page without indication.
•Figures may not appear on the page containing the figure reference.
•EDOC hot link references can over write text.
Service Manual binder inserts

WorkCentre 5790
Family Service Manual

Front pocket insert

WorkCentre 5790 Family

Service Manual
Spine insert
708P89780
February 2010

Xerox WorkCentre 5790 Family

Service Manual
Prepared by:
Creative and Technical Communications - Europe & Asia
Xerox Global Services
Bessemer Road,
Welwyn Garden City
Hertfordshire
AL7 1BU
United Kingdom

© 2010 by Xerox Corporation. All rights reserved. Xerox® and the sphere of connectivity design are trademarks of Xerox Corporation in the US and/or other countries.
Other company trademarks are also acknowledged.
While every care has been taken in the preparation of this manual, no liability will be accepted by Xerox Europe arising out of any inaccuracies or omissions.
All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service per-
sonnel only. Xerox does not warrant or represent that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or
modules, components or parts of such equipment may affect whether Xerox is responsible to fix machine defects under the warranty offered by Xerox with respect to such equipment. You
should consult the applicable warranty for its terms regarding customer or third-party provided service.
 Revision Control List
Product: Title: Part Number: Revision:
WorkCentre 5790 Family Service Manual 708P89780 February 2010
(WC5735-WC5790F)

Documentation compatible with this revision.

EDOC (Compact Disc) . . . . . . . . . . . . . . . . . . . . . . . . . . 708P89778

EDOC Supplement (hard copy wiring diagrams) . . . . . . 708P89779
PDF (Compact Disc). . . . . . . . . . . . . . . . . . . . . . . . . . . . 708P89780

All pages in this revision are dated February 2010.

 Introduction
About This Manual .......................................................................................................... iii
How To Use This Manual ................................................................................................ iii
Mod / Tag Identification................................................................................................... iv
Voltages Resistances and Tolerances ............................................................................ iv
Safety Information ........................................................................................................... vii
Health and Safety Incident reporting............................................................................... viii
Translation of Warnings .................................................................................................. ix

February 2010 Introduction

Xerox WorkCentre 5790 Family i
Introduction February 2010
ii Xerox WorkCentre 5790 Family
About This Manual How To Use This Manual
This manual is part of a multinational service documentation system that is structured in the Always start with the Service Call Procedures, Section 1. Perform Initial Actions and verify the
standard Xerox service manual format. problem, then follow the directions given.

Organization How to Differentiate Between Machine Variants

The service manual is the document used as the primary information source for repairing and When a procedure, parts list description or other reference is unique across different speeds of
maintaining this family of products and is available as EDOC on a CDROM, or in PDF format. machine, the appropriate speed range will be quoted. For example, 35-55 ppm, 65-90 ppm.
The information within the manual is divided into an introduction and eight other sections. Any artwork will also be specific.

Section 1 Service Call Procedures Some machines are configured as copiers only. Refer to GP 30 Copier Only Machine Identifi-
This section is used to start and complete a service call. The procedures in this section will cation.
either direct you to a Repair Analysis Procedure (RAP), or identify a faulty component or sub-
assembly. NOTE: This manual services all configurations of the machine. Ignore references to options
not installed on the machine.
Section 2 Status Indicator Repair Analysis Procedures
Warnings, Cautions And Notes
This section contains the Repair Analysis Procedures (RAPs) and checkouts necessary to
diagnose, isolate and repair faults other than image quality faults. WARNING
A warning is used whenever an operating or maintenance procedure, practice, condi-
Section 3 Image Quality tion or statement, if not strictly observed, could result in personal injury.
This section contains the Image Quality Repair Analysis Procedures (IQ RAPs), checkouts and A translated version of all warnings is in Translation of Warnings.
setup procedures necessary to diagnose, isolate and repair image quality faults. CAUTION
A caution is used whenever an operation or maintenance procedure, practice, condition or
Section 4 Repairs/Adjustments statement, if not strictly observed, could result in damage to the equipment.
This section contains the instructions for removal, replacement, and adjustment of parts within
the machine. NOTE: A note is used where it is essential to highlight a procedure, practice, condition or state-
ment.
Section 5 Parts List
This section contains the detailed and illustrated spare parts list. Any part that is spared or that
must be removed to access a spared part is illustrated.

Section 6 General Procedures / Information

This section contains all other procedures, product specifications and general information. It
also contains Tag / MOD information. The abbreviations used in this Manual are in GP 40 Glos-
sary of Terms, Acronyms and Abbreviations.

Section 7 Wiring Data

This section contains PWB locations, PJ Locations and Wiring Diagrams.

Section 8 Accessories
This section contains details of any accessories that the machine may have.

Publication Comments Sheet

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

February 2010 Introduction

Xerox WorkCentre 5790 Family iii About This Manual, How To Use This Manual
Mod / Tag Identification Voltages Resistances and Tolerances
Figure 1, shows the Mod/Tag identification symbols. For AC power specifications, refer to GP 22 Electrical Power Requirements.

DC Voltage Levels and Tolerances

DC Voltages should be measured between an available test point and a machine ground.
Table 1 shows the range of the common voltages.

These with tag symbols are used to identify the components Table 1 DC Voltage Levels
or configurations that are part of a machine change covered
Nominal voltage Voltage tolerance range RAP reference
by this tag number.
0 volts 0.00 to 0.10V 01B 0V Distribution RAP
+3.3V standby +3.23V to +3.43V 01J Power On and LVPS Control Signals RAP
+3.3V +3.23V to +3.43V 01D +3.3V Distribution RAP
+5.V +4.75V to +5.25V 01E +5V Distribution RAP
+12V +11.4V to +12.6V 01F +12V Distribution RAP
These without tag symbols are used to identify the +24V +23.28V to +25.73V 01G +24V Distribution RAP
components or configurations that are used when this
tag is not fitted. Non-standard voltage levels will be quoted on the relevant circuit diagram. All other voltage lev-
els are plus or minus 10%.

Resistance Tolerances
All resistance measurement tolerances are plus or minus 10%, unless otherwise stated in the
procedure.
Figure 1 Mod/Tag identification symbols
DC Signal Nomenclature
Figure 1 shows the signal nomenclature used in this manual.

Introduction February 2010

Mod / Tag Identification, Voltages Resistances and iv Xerox WorkCentre 5790 Family
 NOTE: The P/J links to the connector location on the PWB in a circuit diagram.

Signal description (event that NOTE: The PWB links the connector to the pin layout on the PWB, referenced in the Wir-
causes the signal level change) ing Diagram section.
• 01D +3.3V Distribution RAP.

NOTE: This links to a RAP.

Install new components as necessary:

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

Figure 1 Signal Nomenclature

Table 2 shows the signal tolerances.

Table 2 Signal tolerances

Signal voltage (H) logic level (L) logic level
+5V +3.85V or greater At or near 0.8V
+3.3V +2V or greater At or near 0.8V

Non standard signal tolerances will be quoted on the relevant circuit diagram.

NOTE: The logic level shown with the signal name will be the actual signal as measured with a
service meter. This will not necessarily be the same as the logic state shown on the diagnostic
screen.

Samples of RAP reference text

Throughout the manual there are linked references that extend the diagnostic procedure or
add more information.

Go to Flag 1. Check Q08-300. Refer to:

NOTE: This links to a particular part of the circuit diagram within a RAP.

• GP 11 How to Check a Sensor.

NOTE: This links to General Procedures information.

• Figure 1, IOT PWB

February 2010 Introduction

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

Introduction February 2010

Voltages Resistances and Tolerances vi Xerox WorkCentre 5790 Family
Safety Information Hot Surface Symbol
This symbol indicates hot surfaces. Take care when servicing the machine.
The WARNING that follows is for general guidance when live working.

WARNING
Do not work in a confined space. 1m (39 inches) space is needed for safe working.
Safety Icons
The safety icons that follow are displayed on the machine:

ESD Caution Symbol

Lethal Voltage Symbol
This symbol indicates potentially lethal voltages. Take care when servicing the machine when
the power cord is connected.

CAUTION
Certain components in this product are susceptible to damage from electrostatic discharge.
Observe all ESD procedures to avoid component damage. Ozone
Laser Radiation Warning Symbol During normal operation, this machine produces ozone gas. The amount of ozone produced
does not present a hazard to the operator. However, it is advisable that the machine be oper-
ated in a well ventilated area.

Toner Cartridge
The product contains a dry imager cartridge that is recyclable. Under various state and local
laws, it may be illegal to dispose of the cartridge into the municipal waste. Check with the local
waste officials for details on recycling options or the proper disposal procedures.

Fuses
WARNING
Follow the service procedure exactly as written. Use of controls or adjustments other
WARNING
than those specified in this manual, may result in an exposure to invisible laser radia- Do not install a fuse of a different type or rating. Installing the wrong type or rating of
tion. During servicing, the invisible laser radiation can cause eye damage if looked at fuse can cause overheating and a risk of fire.
directly. Part Replacement
Location Arrow Symbol Only use genuine Xerox approved spare parts or components to maintain compliance with leg-
The location arrow symbol points to the location to install, to gain access to, or to release an islation and safety certification. Also refer to GP 26 Restriction of Hazardous Substances
object. (R0HS).

Disassembly Precautions
Do not leave the machine with any covers removed at a customer location.

Reassembly Precautions
Use extreme care during assembly. Check all harnesses to ensure they do not contact moving
parts and do not get trapped between components.

February 2010 Introduction

Xerox WorkCentre 5790 Family vii Safety Information
General Procedures Health and Safety Incident reporting
Observe all warnings displayed on the machine and written in the service procedures. I. Summary
This section defines requirements for notification of health and safety incidents involving Xerox
Do not attempt to perform any task that is not specified in the service procedures.
products (equipment and materials) at customer locations.

II. Scope
Xerox Corporation and subsidiaries worldwide.

III. Objective
To enable prompt resolution of health and safety incidents involving Xerox products and to
ensure Xerox regulatory compliance.

IV. Definitions
Incident:

An event or condition occurring in a customer account that has resulted in injury, illness or
property damage. Examples of incidents include machine fires, smoke generation, physical
injury to an operator or service representative. Alleged events and product conditions are
included in this definition.

V. Requirements
Initial Report:
1. Xerox organizations shall establish a process for individuals to report product incidents to
Xerox Environment Health and Safety within 24 hours of becoming aware of the event.
2. The information to be provided at the time of reporting is contained in Appendix A (Health
and Safety Incident Report involving a Xerox product).
3. The initial notification may be made by any of the methods that follow:
• For incidents in North America and Developing Markets West (Brazil, Mexico, Latin
American North and Latin American South):
– Phone* Xerox EH&S at: 1-800-828-6571.
– Electronic mail Xerox EH&S at: [email protected].
– Fax Xerox EH&S at: 1-585-216-8817 [intelnet 8*219-8817].
• For incidents in Europe and Developing Markets East (Middle East, Africa, India,
China and Hong Kong):
– Phone* Xerox EH&S at: +44 (0) 1707 353434.
– Electronic mail Xerox EH&S at: [email protected].
– Fax Xerox EH&S at: +44 (0) 1707 353914 [intelnet 8*668 3914].
*Initial notification made by phone must be followed within 24 hours by a completed inci-
dent report and sent to the indicated electronic mail address or fax number.

NOTE: If sending a fax, please also send the original via internal mail.
Responsibilities for resolution:
1. Business Groups/Product Design Teams responsible for the product involved in the inci-
dent shall:
a. Manage field bulletins, customer correspondence, product recalls, safety retrofits.
b. Fund all field retrofits.

Introduction February 2010

Safety Information, Health and Safety Incident report- viii Xerox WorkCentre 5790 Family
2. Field Service Operations shall: Translation of Warnings
a. Preserve the Xerox product involved and the scene of the incident inclusive of any
associated equipment located in the vicinity of the incident.
WARNING
A warning is used whenever an operating or maintenance procedure, practice, condi-
b. Return any affected equipment/part(s) to the location designated by Xerox EH&S
tion or statement, if not strictly observed, could result in personal injury.
and/or the Business Division.
DANGER: Une note Danger est utilisée chaque fois qu'une procédure d'utilisation ou de
c. Implement all safety retrofits.
maintenance peut être cause de blessure si elle n'est pas strictement respectée.
3. Xerox EH&S shall:
AVVERTENZA: Un segnale di avvertenza è utilizzato ogni volta che una procedura oper-
a. Manage and report all incident investigation activities. ativa o di manutenzione, una pratica, una condizione o un'istruzione, se non stretta-
b. Review and approve proposed product corrective actions and retrofits, if necessary. mente osservata, potrebbe causare lesioni personali.
c. Manage all communications and correspondence with government agencies. VORSICHT: Weist darauf hin, dass ein Abweichen von den angeführten Arbeits- und
d. Define actions to correct confirmed incidents. Wartungsanweisungen gesundheitliche Schäden, möglicherweise sogar schwere Ver-
VI. Appendices letzungen zur Folge haben kann.
AVISO:Un aviso se utiliza siempre que un procedimiento de operación o mantenimiento,
The Health and Safety Incident Report involving a Xerox Product (Form # EH&S-700) is avail-
práctica o condición puede causar daños personales si no se respetan estrictamente.
able in the locations that follow:
• On electronic documentation (EDOC), located in the folder \safety. WARNING
• In the hardcopy, located at the end of the manual. Do not work in a confined space. 1 m (39 inches) space is needed for safe working.
DANGER: Ne pas travailler dans un espace restreint. 1 mètre d'espace est nécessaire
pour un dépannage en toute sécurité.
AVVERTENZA: Non lavorare in uno spazio limitato; è necessario uno spazio di almeno
un metro attorno alla macchina per la sicurezza dell'operatore.
VORSICHT: Nur mit ausreichendem Bewegungsspielraum (1 m) arbeiten.
AVISO: No trabaje en un espacio reducido. Se necesita 1 metro de espacio para trabajar
con seguridad.
WARNING
Follow the service procedure exactly as written. Use of controls or adjustments other
than those specified in this manual, may result in an exposure to invisible laser radia-
tion. During servicing, the invisible laser radiation can cause eye damage if looked at
directly.
DANGER : Les procédures de dépannage doivent être suivies à la lettre. Si les réglages
ou vérifications ne sont pas effectués suivant les instructions de ce manuel, il peut y
avoir un risque d'exposition dangereuse au faisceau laser. Celui-ci peut provoquer des
lésions oculaires s'il est observé directement.
AVVERTENZA: Eseguire le procedure di servizio esattamente come descritto. L'utilizzo
di dispositivi di controllo o di registrazione diversi da quelli riportati in questo manuale
potrebbe comportare un'esposizione a radiazioni laser invisibili. Tali radiazioni possono
danneggiare gli occhi se si guarda direttamente il fascio laser durante gli interventi di
servizio.
VORSICHT: Die Wartungsarbeiten genau den Anweisungen entsprechend durchführen.
Der Umgang mit Steuer- oder Bedienelementen, deren Verwendung nicht ausdrücklich
in diesem Handbuch angewiesen wurde, kann dazu führen, dass unsichtbare Laser-
strahlung frei gesetzt wird. Direkter Blickkontakt mit dem Laserstrahl kann bleibende
Augenschäden verursachen.
AVISO: Siga los procedimientos de mantenimiento tal como están descritos. El uso de
controles o ajustes no especificados en este manual puede tener como resultado la
exposición a radiación láser invisible. Durante las operaciones de mantenimiento, la
radiación de láser invisible puede causar daños en los ojos si se mira directamente a
ella.

February 2010 Introduction

Xerox WorkCentre 5790 Family ix Health and Safety Incident reporting, Translation of
 WARNING AVVERTENZA: Procedere con cautela durante la misurazione della tensione CA della
rete. L'elettricità può causare infortuni o morte.
Do not install a fuse of a different type or rating. Installing the wrong type or rating of
fuse can cause overheating and a risk of fire. VORSICHT: Bei der Netzspannungsprüfung stets vorsichtig vorgehen
DANGER: Ne pas installer de fusible de type ou de calibre différent. Il existe un risque AVISO: Tenga cuidado al medir la tensión de la línea de alimentación de corriente
de surchauffe voire d'incendie. alterna. La electricidad puede causar lesiones e incluso la muerte.
AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non installare un fus- WARNING
ibile di tipo o carica diversi da quelli esistenti. Do not repair or install a new fuse F1 on the IOT PWB. Repairing or installing a new fuse
VORSICHT: Keine Sicherungen anderer Art oder anderer Leistung auf dem IOT-PWB can cause overheating and a risk of fire.
installieren - Überhitzungs- und Brandgefahr. DANGER : Ne pas réparer de fusible F1 ou en installer un nouveau sur la carte d'alimen-
AVISO: No instale un fusible de potencia o tipo distinto. Un fusible de potencia o tipo tation de la machine. Il existe un risque de surchauffe voire d'incendie.
distinto puede producir sobrecalentamiento y el riesgo de incendio. AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non riparare o instal-
WARNING lare un nuovo fusibile F1 sul PWB IOT.
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord VORSICHT: Die Sicherung F1 auf dem IOT-PWB nicht reparieren oder neu installieren -
from the customer supply while performing tasks that do not need electricity. Electricity Überhitzungs- und Brandgefahr.
can cause death or injury. Moving parts can cause injury. AVISO: No repare un fusible F1 ni instale uno nuevo en la PWB de la IOT. Un fusible rep-
DANGER : Mettez la machine hors tension. Reportez-vous à GP 14. Déconnectez le cor- arado o nuevo puede producir sobrecalentamiento y el riesgo de incendio.
don d'alimentation de l'alimentation du client lorsque vous réalisez des tâches qui ne WARNING
nécessitent pas d'électricité. L'électricité peut être à l'origine de blessures, voire d'un
Do not repair or install a new fuse F1 on the power distribution PWB. Repairing or
accident mortel. Les pièces amovibles peuvent être à l'origine de blessures. installing a new fuse can cause overheating and a risk of fire.
AVVERTENZA: Spegnere la macchina. Vedere GP 14. Scollegare il cavo di alimentazione DANGER : Ne pas réparer de fusible F1 ou en installer un nouveau sur la carte de distri-
dall'alimentatore quando si eseguono attività che non richiedono elettricità. L'elettricità
bution électrique. Il existe un risque de surchauffe voire d'incendie.
può causare morte o lesioni personali. Le parti in movimento possono causare lesioni
AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non riparare o instal-
personali.
lare un nuovo fusibile F1 sul PWB distribuzione di alimentazione
VORSICHT: Schalten Sie die Stromversorgung der Maschine ab. Siehe auch GP 14. Zie-
hen Sie das Stromkabel ab, wenn Sie Aufgaben ausführen, für die keine Stromver- VORSICHT: Die Sicherung F1 auf dem Stromverteilungs-PWB nicht reparieren oder neu
installieren - Überhitzungs- und Brandgefahr.
sorgung benötigt wird. Stromschläge können Todesfällen oder Verletzungen
verursachen. Bewegliche Teile können zu Verletzungen führen. AVISO: No repare un fusible F1 ni instale uno nuevo en la PWB de distribución de
energía eléctrica. Un fusible reparado o nuevo puede producir sobrecalentamiento y el
AVISO: Apague la electricidad de la máquina. Consulte el GP 14. Desconecte el cable de
alimentación eléctrica de la toma de pared mientras esté realizando tareas que no riesgo de incendio.
necesiten corriente. La electricidad puede causar daños o la muerte. Las partes móviles WARNING
pueden causar daños. Do not repair or install a new fuse F1 on the main drive PWB. Repairing or installing a
WARNING new fuse can cause overheating and a risk of fire.
Do not switch on the electricity to the machine while a ground circuit is disconnected. DANGER : Ne pas réparer de fusible F1 ou en installer un nouveau sur la carte
Ground circuits ensure that the machine remains safe during a fault condition. d'entraînement principal. Il existe un risque de surchauffe voire d'incendie.
DANGER : Ne pas mettre la machine sous tension si un circuit de mise à la masse est AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non riparare o instal-
déconnecté. Les circuits de mise à la masse permettent de garantir la sécurité de la lare un nuovo fusibile F1 sul PWB azionamento principale.
machine lors d'un incident. VORSICHT: Die Sicherung F1 auf dem Hauptantriebs-PWB nicht reparieren oder neu
AVVERTENZA: Non accendere la macchina se uno dei conduttori di terra non è con- installieren - Überhitzungs- und Brandgefahr.
nesso. In caso di guasti elettrici, tali conduttori garantiscono la sicurezza del sistema. AVISO: No repare un fusible F1 ni instale uno nuevo en la PWB de impulso principal. Un
VORSICHT: Stromzufuhr zum Gerät nicht einschalten, wenn keine Erdung gegeben ist. fusible reparado o nuevo puede producir sobrecalentamiento y el riesgo de incendio.
AVISO: No encienda la máquina mientras esté deconectado algún circuito de tierra. Los WARNING
circuitos de tierra mantienen la seguridad de la máquina en las situaciones de averías o Avoid exposure to laser beam. Invisible laser radiation.
errores. DANGER : Eviter toute exposition au faisceau laser. Radiation laser invisible.
WARNING AVVERTENZA: Evitare l'esposizione al fascio laser. Radiazioni laser invisibili.
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury. VORSICHT: Nicht in den Laserstrahl blicken. Verletzungsgefahr durch unsichtbare
DANGER: Prendre des précautions lors du relevé de la tension de la prise de courant Laserstrahlung.
alternatif. L'électricité peut entraîner des blessures graves voire mortelles.

Introduction February 2010

Translation of Warnings x Xerox WorkCentre 5790 Family
AVISO: Evite la exposición al rayo láser. Radiación de láser invisible. AVISO: Manténgase apartado del mecanismo de la cuchilla hendedora cuando trabaje
junto al realizador de folletos si la máquina está encendida. Dicho mecanismo se activa
WARNING de forma rápida y con mucha fuerza.
Take care during this procedure. Motors will become hot during normal operation.
WARNING
DANGER : Exécuter cette procédure avec précaution. Les moteurs peuvent devenir très
Take care, a hazardous voltage is present at the XXXX. Electricity can cause death or
chauds en fonctionnement normal.
injury.
AVVERTENZA: procedere con cautela durante questa procedura. I motori si riscaldano
molto durante il funzionamento. DANGER : Faire attention, une tension électrique dangereuse est présente au niveau de
la sortie de l'inverseur de la lampe d'exposition.
VORSICHT: Bei diesem Vorgang vorsichtig vorgehen, da Motoren im Normalbetrieb heiß
AVVERTENZA: fare attenzione alla carica elettrica di uscita dell'invertitore della lampada
werden können.
di esposizione. L'elettricità può causare infortuni o morte.
AVISO: Tenga cuidado al efectuar este procedimiento. Los motores alcanzan altas tem-
VORSICHT: Achtung: Spannung am Ausgang des Belichtungslampeninverters.
peraturas durante su funcionamiento normal.
AVISO: Tenga cuidado; hay tensión peligrosa en la salida del inversor de la lámpara de
WARNING
exposición. La electricidad puede causar lesiones e incluso la muerte.
Do not touch the fuser while it is hot.
DANGER : Ne pas toucher au four pendant qu'il est encore chaud.
WARNING
Do not touch the test pads on the embedded fax PWB while the machine is switched on.
AVVERTENZA: Non toccare il fonditore quando è caldo.
Dangerous voltages may be present that could cause death or injury.
VORSICHT: Fixierbereich erst berühren, wenn dieser abgekühlt ist.
DANGER : Ne pas toucher les contacts de test de la carte de circuits imprimés du fax
AVISO: No toque el fusor mientras está caliente. intégré tant que la machine est sous tension. Ils représentent un risque de chocs élec-
WARNING triques qui sont un danger de mort ou peuvent entraîner des blessures graves.
Take care not to topple the LCSS. The LCSS is unstable when undocked from the AVVERTENZA: non toccare le aree di contatto del PWB del fax incorporato mentre la
machine. Do not show the customer how to undock the LCSS. macchina è accesa. La presenza di voltaggi pericolosi comporta il rischio di morte o
DANGER: Attention à ne pas faire tomber la trieuse/agrafeuse petite capacité. Elle n'est lesioni personali.
pas stable lorsqu'elle est détachée de la machine. Ne pas montrer au client comment VORSICHT: Die Testpads (Prüfkontakte) der Platine für das integrierte Fax nicht
détacher la trieuse/agrafeuse. berühren, solange das Gerät eingeschaltet ist. An den Pads liegt eine Spannung an; es
besteht Stromschlag- bzw. Lebensgefahr!
AVVERTENZA: fare attenzione a non destabilizzare il modulo della pinzatrice/impilatore
da 2000 fogli. Quando è sganciato dalla macchina, il modulo è instabile: non mostrare al AVISO: No toque la zona terminal de prueba que presenta el circuito impreso del fax
cliente come sganciarlo interno mientras la máquina está encendida, ya que podría haber tensiones peligrosas
que podrían provocar lesiones o incluso la muerte.
VORSICHT: Stapler nicht umstoßen. Nach Trennung des Staplers vom Document Centre
ist dieser sehr instabil WARNING
AVISO: Tenga cuidado de que no se caiga el apilador/grapadora de baja capacidad. Only use the correct plug to connect a power lead to a power outlet.
Cuando no está acoplada a la máquina es inestable. No le muestre al cliente como desa- DANGER : Toujours utiliser la fiche appropriée pour connecter le cordon d'alimentation
coplar el apilador/grapadora de baja capacidad. à la prise.
WARNING AVVERTENZA: Usare la spina corretta per connettere il cavo elettrico alla presa.
Keep away from the crease blade mechanism when working in close proximity to the VORSICHT: Nur Netzkabel mit dem für die vorhandenen Netzsteckdose geeigneten
booklet maker while the machine is powered on. The crease blade mechanism activates Netzstecker verwenden.
quickly and with great force. AVISO: Utilice solamente un enchufe apropiado para conectar el cable de alimentación a
DANGER: Ne pas s'approcher du méchanisme de la lame de pliage lors d'une activité à la toma de corriente.
proximité de la plieuse/brocheuse pendant que la machine est sous tension. Ce mécan-
isme s'active rapidement et avec force.
WARNING
Take care during this procedure. Sharp edges may be present that can cause injury.
AVVERTENZA: Quando la macchina è accesa, tenersi a debita distanza dalla lama di pie-
gatura mentre si opera in prossimità della stazione libretto. Il meccanismo della lama di DANGER : Exécuter cette procédure avec précaution. La présence de bords tranchants
piegatura si attiva con velocità e forza notevoli. peut entraîner des blessures.
VORSICHT: Wenn bei eingeschaltetem Gerät nahe am Booklet Maker gearbeitet wird, AVVERTENZA: procedere con cautela durante questa procedura. Possono essere pre-
von der Schneidevorrichtung fernhalten. Die Schneidevorrichtung wird schnell und mit senti oggetti con bordi taglienti pericolosi.
viel Druck ausgelöst. VORSICHT: Bei diesem Vorgang vorsichtig vorgehen, damit keine Verletzungen durch
die scharfen Kanten entstehen.

February 2010 Introduction

Xerox WorkCentre 5790 Family xi Translation of Warnings
AVISO: Tenga cuidado al efectuar este procedimiento. Puede haber bordes afilados que AVISO: Tenga cuidado de que no se caiga la bandeja 5. Cuando no está acoplada a la
podrían producir lesiones. máquina, la bandeja 5 es inestable.No le muestre al cliente como desacoplar la bandeja
5.
WARNING
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury.
WARNING
Take care when removing the latch. The latch contains a compressed spring, which can
DANGER : Prendre des précautions lors du relevé de la tension de la prise de courant
alternatif. L'électricité peut entraîner des blessures graves voire mortelles. cause injury when released.

AVVERTENZA: Procedere con cautela durante la misurazione della tensione CA della DANGER: Faites attention en déverrouillant le levier : il comporte un ressort comprimé,
ce qui présente un risque de blessure lors du déverrouillage.
rete. L'elettricità può causare infortuni o morte.
AVVERTENZA: Rimuovere il gancio con cura in quanto contiene una molla compressa
VORSICHT: Bei der Netzspannungsprüfung stets vorsichtig vorgehen
che può causare lesioni al rilascio.
AVISO: Tenga cuidado al medir la tensión de la línea de alimentación de corriente
VORSICHT: Beim Entfernen der Verriegelung mit Vorsicht vorgehen. Es ist eine unter
alterna. La electricidad puede causar lesiones e incluso la muerte.
Spannung stehende Feder enthalten, die bei spontaner Freisetzung Verletzungen
WARNING verursachen kann.
Do not attempt any repairs to the power cord or safety ground harness/conductor. AVISO: Tenga cuidado al soltar el enganche. Tiene un resorte comprimido, que puede
DANGER : Ne pas tenter de réparer le faisceau/conducteur de mise à la masse ou du causar alguna lesión al soltarlo.
cordon d'alimentation. WARNING
AVVERTENZA: non eseguire riparazioni sul cavo dell'alimentazione o sul conduttore di Mandatory safety warning. This procedure must be performed by 2 people. The module
terra di sicurezza. is heavy.
VORSICHT: Keine Reparaturen am Netzkabel oder am Schutzleiter vornehmen. DANGER: Avertissement obligatoire. Cette procédure doit être effectuée par 2 per-
AVISO: No intente reparar el cable de alimentación ni el conductor/mazo de tierra de sonnes. Le module est très lourd.
protección. AVVERTENZA: Avviso di sicurezza obbligatorio. A causa della pesantezza del modulo,
WARNING questa procedura deve essere eseguita da due persone.
Do not remove the DADH while the DADH is lowered. In the lowered position the coun- VORSICHT: Verbindliche Sicherheitsvorschrift - dieser Vorgang muss von zwei Per-
terbalance springs are compressed and can cause injury when released. sonen ausgeführt werden, da das Modul sehr schwer ist.
DANGER : Ne pas retirer le CAD alors qu'il est en position basse. Dans cette position, AVISO: Aviso de seguridad obligatorio. Este procedimiento debe ejecutarse entre dos
les ressorts compensateurs sont compressés et peuvent entraîner des blessures s'ils personas. El módulo pesa mucho.
se relâchent. WARNING
AVVERTENZA: non rimuovere l'alimentatore automatico documenti quando è Use safe handling procedures when removing the module. Refer to GP 16. The module
abbassato. In questa posizione, le molle del contrappeso sono compresse e possono is heavy.
causare lesioni al rilascio.
DANGER: Conformez-vous aux procédures de manipulation de sécurité pour le retrait
VORSICHT: Vorlageneinzug nicht in abgesenkter Position entfernen. Bei abgesenktem du module. Reportez-vous à GP 16. Le module est lourd.
Vorlageneinzug sind die Ausgleichsfedern zusammengedrückt und können bei Fre- AVVERTENZA: Utilizzare procedure di gestione sicure durante la rimozione del modulo.
igabe Verletzungen verursachen.
Vedere GP 16. Il modulo è pesante.
AVISO: No quite el alimentador de documentos automático si está bajado. Cuando está
VORSICHT: Verwenden Sie sichere Vorgehensweisen zum Entfernen des Moduls. Siehe
bajado, los resortes de contrapeso están comprimidos y pueden causar lesiones al
auch GP 16. Das Modul ist sehr schwer.
soltarse.
AVISO: Utilice los procedimientos de seguridad cuando elimine el módulo. Consulte el
WARNING GP 16. El módulo es pesado.
Take care not to topple Tray 5. Tray 5 is unstable when undocked from the machine. Do WARNING
not show the customer how to undock Tray 5.
Do not break the glass. Broken glass can cause injury.
DANGER : Attention à ne pas faire tomber le magasin 5. Le magasin 5 n’est pas stable
DANGER: Attention à ne pas briser la glace sous risque de blessure.
lorsqu’il est détaché de la machine. Ne pas montrer au client comment détacher le
magasin 5. AVVERTENZA: Per evitare il rischio di lesioni, non rompere il vetro.

AVVERTENZA: Fare attenzione a non destabilizzare il vassoio 5. Quando è sganciato VORSICHT: Glas nicht zerbrechen - Verletzungsgefahr.
dalla macchina, questo vassoio è instabile: non mostrare al cliente come sganciarlo. AVISO: No rompa el cristal. El cristal roto puede ocasionar daños.
VORSICHT: Behälter 5 nicht umstoßen.Der Behälter ist nach der Trennung vom Gerät
sehr instabil.Benutzer nicht im Trennen des Behälters vom Gerät einweisen.

Introduction February 2010

Translation of Warnings xii Xerox WorkCentre 5790 Family
 WARNING
Wear protective gloves when using solvents and cleaning agents, PL 26.10 Item 10 .
DANGER : Porter des gants de protection lors de l'utilisation de solvants et de produits
de nettoyage, PL 26.10 Item 10.
AVVERTENZA: utilizzare guanti protettivi durante l'impiego di solventi e soluzioni per
pulizia PL 26.10 Item 10.
VORSICHT: Beim Einsatz von Lösungs- und Reinigungsmitteln Handschuhe tragen PL
26.10 Item 10.
AVISO: Póngase guantes de protección cuando utilice disolventes y productos de limp-
ieza PL 26.10 Item 10.
WARNING
Do not use the on/off switch as a safety disconnect device. The on/off switch is not a
disconnect device. Disconnect the power cord from the supply to isolate the equipment.
DANGER : Ne pas utiliser l'interrupteur comme système d'arrêt d'urgence. Déconnecter
le cordon d'alimentation de la prise pour isoler l'équipement.
AVVERTENZA: Non usare l'interruttore di accensione/spegnimento come dispositivo di
sicurezza per il disinserimento dell'elettricità, in quanto l'interruttore non è stato diseg-
nato per questa funzione. Per isolare la macchina dalla corrente elettrica, scollegare il
cavo dell'alimentazione dalla presa a muro.
VORSICHT: Der Netzschalter reicht zur Trennung von der Netzspannung NICHT aus. Um
das Gerät von der Netzspannung zu trennen, den Netzstecker abziehen.
AVISO: No utilice el interruptor de encendido/apagado como dispositivo de desconex-
ión seguro. El interruptor de encendido/apagado no es un dispositivo de desconexión.
Para aislar el equipo totalmente, desconecte el cable de alimentación de la toma de cor-
riente.
WARNING
USA and Canada. Do not install this machine in a hallway or exit route that does not
have 1.12 m (44 inches) of space additional to the normal space requirements in front of
the machine. To conform with fire regulations this additional 1.12 m (44 inches) of space
is needed in front of the machine in hallway and exit routes.
DANGER : États-Unis et Canada. Si cette machine est installée dans un couloir ou une
voie de sortie, 1,12 m (44 pouces) d'espace supplémentaire à l'espace normal doit être
disponible devant la machine conformément aux normes de sécurité d'incendie.
AVVERTENZA: N/A
VORSICHT: N/A
AVISO: Estados Unidos y Canadá. No instale esta máquina en un corredor o ruta de sal-
ida que no tenga 1.12 m (44 pulgadas) de ancho delante de la máquina, sin incluir el
espacio que ocupe la máquina. Este espacio adicional de 1.12 m (44 pulgadas) delante
de la máquina en corredores y rutas de salida es necesario para cumplir los requisitos
de las normas sobre incendios.

February 2010 Introduction

Xerox WorkCentre 5790 Family xiii Translation of Warnings
Introduction February 2010
Translation of Warnings xiv Xerox WorkCentre 5790 Family
 1 Service Call Procedures
SCP 1 Initial Actions........................................................................................................ 1-3
SCP 2 First Call Actions .................................................................................................. 1-4
SCP 3 Normal Call Actions ............................................................................................. 1-4
SCP 4 Fault Analysis ...................................................................................................... 1-5
SCP 5 Subsystem Maintenance ..................................................................................... 1-7
SCP 6 Final Actions ........................................................................................................ 1-9
SCP 7 Machine Features ................................................................................................ 1-9

February 2010 Service Call Procedures

Xerox WorkCentre 5790 Family 1-1
Service Call Procedures February 2010
1-2 Xerox WorkCentre 5790 Family
SCP 1 Initial Actions 3. Touch the enter tab on the UI.

Use the Service Call Procedures to find a problem with the machine. NOTE: There will be a short delay of approximately 10 second before the fault history
report is printed.
Use the Initial Actions to collect the information on the machine performance.
To display the event log on the UI, perform the steps that follow:
Also refer to SCP 7 Machine Features. 1. Press the Machine Status key on the UI.
2. Touch the Fault tab on the UI.
Initial Actions 3. Touch the Event Log button on the UI.
• Switch off the machine, then switch on the machine, GP 14. To display the active messages on the UI, perform the steps that follow:
• If the machine cannot be switched off, go to 03-374 Power Off Failure RAP. 1. Press the Machine Status key on the UI.
2. Touch the Fault tab on the UI
Procedure 3. Touch the Active Messages button on the UI.
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power lead from
the customer supply while preforming tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
WARNING
Do not work in a confined space. 1m (39 inches) space is needed for safe working.
1. Take note of problems, error messages or error codes. If necessary, refer to Machine Sta-
tus.
2. Ask the operator to describe or demonstrate the problem.
3. If the problem is the result of an incorrect action by the operator, refer the operator to the
user documentation.
4. Check the steps that follow:
a. The power lead is connected to the wall outlet and to the machine.
b. The documents are not loaded in the DADH or on the document glass.
c. The paper is loaded correctly.
d. All paper trays are closed.
e. All covers are closed or installed.
f. If a telephone line cable is installed, make sure that the cable is connected between
the line socket and the wall jack.
g. If a telephone line cable is installed, make sure that the customer telephone line is
functioning.
5. Check the machine service log book for previous actions that are related to this call.
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 the last 6 fault codes on the UI, perform the steps that follow:
1. Press the Machine Status key on the UI.
2. Touch the Fault tab on the UI.
3. Touch the All Faults button on the UI.
To print a fault history report of the last 40 fault codes, perform the steps that follow:
1. Simultaneously press the * and Log in/out key on the UI.
2. Use the numerical keypad to input the code 734040.

February 2010 Service Call Procedures

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

Initial Actions Initial Actions

• Switch off the machine, then switch on the machine, GP 14. • Switch off the machine, then switch on the machine, GP 14.
• If the machine cannot be switched off, go to 03-374 Power Off Failure RAP. • If the machine cannot be switched off, go to 03-374 Power Off Failure RAP.

Procedure Procedure
1. Check the machine configuration with the customer. Check that all the required hardware NOTE: If an error message appears, go to the RAP for the error message. If necessary refer to
and software is installed. Check that all the required hardware and software is enabled.
OF4 Status Codes and Messages RAP.
2. Check that all the machine settings are entered correctly.
3. Mark off the hardware options, software options or Tags installed on the Tag matrix cards Perform the steps that follow:
and dC111. 1. Review the copy, print and Fax samples.
4. 35-55 ppm Only. If the machine has a OCT, install the OCT fingers. Go to REP 12.1. 2. Make sure the user access settings are correct. If necessary refer to the user documenta-
tion.
NOTE: The OCT fingers are supplied with the OCT but must be installed by a CSE at the 3. To prevent the deletion of the customer information and soft machine settings, perform
first service call. They are located in a plastic wallet on the rear of the machine. The OCT
NVM Save and Restore. Refer to GP 5.
fingers improve feeding to the OCT.
4. Perform GP 19 Network Clone Procedure.
5. If a fault is found, go to SCP 3 Normal Call Actions. If a fault is not found, go to SCP 6
Final Actions. NOTE: The clone file must be taken whenever the customer changes the network control-
ler setting or after the system software is changed.
6. Check the machine for waste toner contamination. Refer to the OF11 Waste Toner Con-
tamination RAP. 5. Before pressing the on/off switch or clear the memory, check for a customer job in the
7. Save the NVM. Refer to GP 5 Portable Workstation and Tools. memory.
8. Perform GP 19 Network Clone Procedure. 6. Check and record the total print counter.
7. Check the machine for waste toner contamination. Refer to the OF11 Waste Toner Con-
NOTE: The clone file must be taken whenever the customer changes the network control- tamination RAP.
ler setting or after the system software is changed.
8. Clean the optical sensors that follow:
9. Enter the machine information and the customer information in the service logbook. • (40-90 ppm) DADH feed sensor, PL 5.17 Item 2.
10. If the machine has a tray 5 installed, check the top edge registration, ADJ 7.4. • (40-90 ppm) DADH document present sensor, PL 5.35 Item 19.
• DADH length sensors, PL 5.35 Item 8.
• Tray 1 feed sensor, PL 7.30 Item 24.
• Tray 2 feed sensor, PL 7.30 Item 24.
• Tray 4 feed sensor, PL 8.31 Item 10.
• Tray 5 feed sensor, PL 8.45 Item 6.
• Wait sensor, (35-55 ppm) PL 8.15 Item 3, (65-90 ppm) PL 7.30 Item 25.
• Duplex sensor, PL 8.20 Item 4.
• Registration sensor, PL 8.17 Item 3.
• HVF Bin 1 rear wall sensor, PL 11.140 Item 17.
9. Go to SCP 4 Fault Analysis.

Service Call Procedures February 2010

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

February 2010 Service Call Procedures

Xerox WorkCentre 5790 Family 1-5 SCP 4
 – 11A-120 Bin 1 Overload RAP. – 11F-171 Mis-Registration in Stapled and Unstapled Sets RAP.
– 11B-120 Initialization Failure RAP. – 11G-171 HVF BM Poor Stacking RAP.
– 11C-120 1K LCSS Power Distribution RAP. – 11H-171 Pause To Unload (PTU) RAP.
– 11D-120 1K LCSS to Machine Communication Interface RAP. – 11J-171 Inserter Paper Sensing and +5V Supply RAP.
– 11E-120 1K LCSS PWB DIP Switch Settings RAP. – 11K-171 HVF Initialization Failure RAP.
– 11F-120 1K LCSS PWB Damage RAP. – 11L-171 Tri-Folder Not Detected RAP.
– 11G-120 Copy Damage in the 1K LCSS RAP. – 11M-171 Curl Suppressor RAP
– 11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. – 11N-171 Chad Bin Present and Bin Full RAP.
– 11J-120 1K LCSS Poor Stacking RAP. – 11P-171 Buffer Clamp RAP
• If the machine has the problems that follow, go to the 11E-120 1K LCSS PWB DIP Switch • If the staples of a booklet are not correct, perform the correct procedure that follows:
Settings RAP: – 11-063-171, 11-411-171 HVF BM Staple Unit 1 Failure RAP,
– False jam clearance messages. – 11-403-171, 11-413-171, 11-414-171 HVF BM Stapler head 2 and Staple Module
– Communication errors between the LCSS and the machine. RAP.
• If the staples of a stapled set are not correct, go to the 11-364-120 Stapling Failure RAP. • If the tri-folder paper fold is not in the correct position, perform ADJ 11.2-171 Tri-Folder
• If the prints bond together in the LCSS trays, go to OF6 Ozone and Air Systems RAP. Paper Settings.
2K LCSS Problems Fax Problems
• If the machine has an 2K LCSS fault, but not a fault code, perform the procedures that fol- • For Fax problems with no fault code, perform the procedures that follow, as appropriate:
low, as appropriate: – 20A Fax Entry RAP.
– 11A-110 Offline Stapling Faults RAP. – 20B Unable To Send A Fax RAP.
– 11B-110 Bin 1 Overload RAP. – 20C Unable To Send A Fax To Some Machines RAP.
– 11C-110 Initialization Failure RAP. – 20D Unable To Receive A Fax RAP.
– 11D-110 2K LCSS Power Distribution RAP. – 20E Fax Will Not Print RAP.
– 11E-110 2K LCSS to Machine Communications Interface RAP. – 20F Fax Tab Not Available RAP.
– 11F-110 2K LCSS PWB DIP Switch Settings RAP. – 20G Embedded Fax Checkout RAP.
– 11G-110 2K LCSS PWB Damage RAP. – (W/O TAG X-001 machines only) 20H Embedded Fax PWB Voltage Checkout.
– 11H-110 Copy Damage in the 2K LCSS RAP. Other Problems
– 11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. • Hot machine. Go to the OF6 Ozone and Air Systems RAP.
– 11K-110 2K LCSS Poor Stacking RAP. • Convenience stapler faults. Go to the OF13 Convenience Stapler RAP.
• If the punched holes are out of position, perform ADJ 11.3-110 Hole Punch Position. • If the customer has lost the System Administration password. Go to dC001 Reset
• If the machine has the problems that follow, go to the 11F-110 2K LCSS PWB DIP Switch Auditron Master PIN.
Settings RAP: • Image quality fault. Go to the IQ1 Image Quality Entry RAP.
– False jam clearance messages. • Machine noise. Go to the OF1 Audible Noise RAP.
– Communication errors between the LCSS and the machine. • Machine odour. Go to the OF6 Ozone and Air Systems RAP.
• If the staples of a stapled set are not correct, go to the 11-364-110 Stapling Failure RAP. • If the UI displays ‘system not available’ or the machine continues to boot up, go to OF5
• If the prints bond together in the LCSS trays, go to OF6 Ozone and Air Systems RAP. Boot Up Failure RAP.
HVF, HVF BM, Inserter and Tri-Folder Problems • The machine will not turn off. Go to 03-374 Power Off Failure RAP.
• If the machine has a fault in the HVF or HVF BM, but with no fault code, perform the pro- • Check the fault history. GP 1 Diagnostic Entry, Facilities and Exit.
cedures that follow, as appropriate: • Foreign device. Go to ACC 1 Foreign Device Checkout.
– 11-300-171, 11-302-171, 11-303-171 HVF Docking and Interlocks RAP • Xerox extensible interface platform faults. Go to the OF14 Xerox Extensible Interface
– 11A-171 HVF BM Power Distribution RAP. Platform RAP.
– 11B-171 HVF BM to Machine Communication Interface RAP. • Xerox secure access faults. Go to the OF15 Xerox Secure Access RAP.
– 11C-171 HVF BM Bin 2 Failure RAP. • Scan to file failure when using the FTP or SMB protocols. Go to 03D FTP/SMB Scan to
File Failure RAP.
– 11D-171 Booklet Quality RAP.
– 11E-171 Copy Damage in the HVF BM RAP.

Service Call Procedures February 2010

SCP 4 1-6 Xerox WorkCentre 5790 Family
Xerographic Module (XRU) Handling SCP 5 Subsystem Maintenance
• The Xerographic Module (XRU) must be protected from light shock and mechanical dam-
Use the Subsystem Maintenance to maintain the machine.
age.
• Do not expose the photoreceptor drum to bright lights for extended periods. Procedure
• When ever the XRU is removed from the IOT, place the XRU in the black plastic bag sup-
plied with the IOT. Store the XRU in a safe place on a clean flat surface, to avoid damage
WARNING
to the photoreceptor drum surface. Switch off the electricity to the machine, GP 14. Disconnect the power lead from the
• Place the XRU in the black bag if the covers are removed or left open for long periods. customer supply while performing tasks that do not need electricity. Electricity can
cause the death or injury. Moving components can cause the injury.
Go to the correct procedure:
• Installation of New Parts
• HFSI
• Lubrication
• How to Clean the Machine
Installation of New Parts
The design life of the major components are shown in Table 1.

Table 1 Component design life

Part Life Parts list reference
Fuser module
35-55 ppm 400k prints PL 10.8 Item 1
65-90 ppm 400k prints PL 10.10 Item 1
Ozone filter 400k prints PL 9.25 Item 3
Xerographic module
35 ppm 200k prints PL 9.22 Item 2
40-90 ppm 400k prints PL 9.20 Item 2
Toner cartridge
35-55 ppm 36.5k prints at 6% area coverage PL 9.17 Item 4
65-90 ppm 50k prints at 6% area coverage PL 9.15 Item 4
Waste toner bottle 100k PL 9.10 Item 1
DADH feed roll assembly
35 ppm 170k feeds PL 5.15 Item 1
40-90 ppm 170k feeds PL 5.17 Item 1
1K LCSS staple cartridge 3k staples PL 26.10 Item 26
2K LCSS staple cartridge 5k staples PL 26.10 Item 11
HVF staple cartridge 5k staples PL 26.10
BM staple cartridge 2k staples PL 26.10 Item 24

February 2010 Service Call Procedures

Xerox WorkCentre 5790 Family 1-7 SCP 4, SCP 5
NOTE: If a range of machine speeds are specified within Table 1, the life expectancy for the Table 2 High frequency service items
part will be specific for that machine.
The
If the speed has not been specified, the life expectancy for the part applies to all machines recommended
within the product family. life for new
component Parts list
HFSI Item Component Description installation reference
The High Frequency Service Items are shown in Table 2. To change HFSI settings, refer to GP
17 High Frequency Service Items. Duplex sen- Duplex sen- The total count of the 1,000k actuator (35-55 ppm) PL
sor sor actuator duplex sensor actuator counts 8.22 Item 4
after the last HFSI reset
Table 2 High frequency service items
Bias foam Bias contact The total sides of copies 500k impres- PL 8.15 Item 23
The
and prints after the last sions
recommended HFSI reset
life for new
Developer Developer The total sides of copies 2,500k impres- (35-55 ppm) PL
component Parts list
drive gear / and prints after the last sions 9.17 Item 2 or
Item Component Description installation reference
pulley and the HFSI reset (65-90 ppm) PL
DADH feeds Feed roll The total DADH feeds in 180k feeds (35 ppm) PL 5.15 main drive 9.15 Item 2
assembly all modes after the last Item 1 or (40-90 gear
HFSI reset ppm) PL 5.17
Post Fuser Tri-roll shaft The total sides of copies 1,200k impres- PL 10.12 Item 8,
Item 1
assembly and and prints after the last sions PL 10.12 Item 9.
Tray 1 feed Feed rolls All sheets fed from tray 1 750k feeds PL 8.25 Post fuser exit HFSI reset
after last HFSI reset roll.
Tray 2 feed Feed rolls All sheets fed from tray 2 750k feeds PL 8.25 HVF Paddle Paddle wheel All sheets fed through the 200k feeds PL 11.145 Item
after last HFSI reset HVF after last HFSI reset 28
Tray 3 feed Feed rolls All sheets fed from tray 3 1,500k feeds PL 8.30 Item 2
after last HFSI reset Lubrication
Tray 4 feed Feed rolls All sheets fed from tray 4 1,500k feeds PL 8.31 Item 2
To lubricate the machine, refer to ADJ 4.1 Machine Lubrication.
after last HFSI reset
Tray 1 trans Transport roll The total feeds from tray 2,500k feeds PL 8.25 Item 8 How to Clean the Machine
1, 2, 3, 4 after last HFSI
• Perform ADJ 9.4 Xerographic’s Cleaning.
reset
• Clean the takeaway roll idlers, PL 5.20 Item 3. Refer to ADJ 5.4 DADH Cleaning Proce-
Tray 2 trans Transport roll The total feeds from tray 2,500k feeds PL 8.25 Item 8
dures.
2, 3, 4 after the last HFSI
reset • Clean the upper surfaces of the CVT glass and document glass. Refer to ADJ 14.1 Optics
Tray 3/4 trans Tray 3 and 4 The total feeds from tray 2,500k feeds PL 8.30 Item 18 cleaning procedures.
transport roll 3, 4 after the last HFSI • (40-90 ppm) Clean the DADH feed sensor and the area around the sensor, PL 5.17 Item
reset 2.
Bypass feeds Bypass tray The total bypass tray 100k feeds PL 7.30 Item 21 • Clean the tray 1 and tray 2 feed sensors and the area around the sensors, PL 8.25.
feed roll and feeds after the last HFSI • Clean the tray 4 feed sensor and the area around the sensor, PL 8.31 Item 10.
retard pad reset • Clean the duplex sensor and the area around the sensor, (65-90 ppm) PL 8.20 Item 4.
assembly • Clean the registration sensor and the surrounding area, (35-55 ppm) PL 8.15 Item 3, (65-
Tray 5 feeds Tray 5 feed All sheets fed from tray 5 1,000k feeds PL 8.45 Item 2 90 ppm) PL 8.17 Item 3.
rolls after last HFSI reset
• For special tools and consumables, refer to GP 8 Special Tools and Consumables.
Inserter Inserter feed Total Inserter feeds 100k feeds PL 11.179
• Go to SCP 6 Final Actions.
rolls Part of inserter
pickup unit
Inverter feeds Nip split shaft The total turned and 2,500k feeds PL 10.11 Item 4
assembly duplex feeds after the last
HFSI reset

Service Call Procedures February 2010

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

February 2010 Service Call Procedures

Xerox WorkCentre 5790 Family 1-9 SCP 6, SCP 7
• Server fax scanning kit.
• Color scanning enablement kit (an option on 65-90 ppm machines, standard on 35-55
ppm machines W/TAG 150).
• FreeFlow SMART send 3.0.
• FreeFlow SMART send 3.0 Professional.
• Nationalization kits.
• Foreign device interface kit.
• Tray 2/4 lock kit.
• Unicode international printing kit.
• Secure access kit.
• Common access card.

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

Development History
The WC5790F machines have been developed from the WC5687F and offer the following new
features:
• New model speeds of 35 and 90 ppm.
• Color user interface.
• Color scanner fitted to all 65-90 ppm machines but an option on 35-55 ppm machines. Figure 1 WC5735 with stand, document cover and OCT
The installation of the color scanner on 35-55 ppm machines is identifiable by the striking
of TAG 150.
Machine Identification
The diagrams that follow illustrate some of the various machine configurations:
• Figure 1 WC5735 with stand, document cover and OCT.
• Figure 2 WC5740 with DADH, work shelf and OCT.
• Figure 3 WC5745 with DADH, work shelf and 1K LCSS.
• Figure 4 WC5755 with DADH, work shelf and 2K LCSS.
• Figure 5 WC5775 with DADH, work shelf and HVF.
• Figure 6 WC5790 with DADH, work shelf and HVF BM.

Figure 2 WC5740 with DADH, work shelf and OCT

Service Call Procedures February 2010

SCP 7 1-10 Xerox WorkCentre 5790 Family
 Figure 3 WC5745 with DADH, work shelf and 1K LCSS Figure 5 WC5775 with DADH, work shelf and HVF

Figure 4 WC5755 with DADH, work shelf and 2K LCSS Figure 6 WC5790 with DADH, work shelf and HVF BM

February 2010 Service Call Procedures

Xerox WorkCentre 5790 Family 1-11 SCP 7
Service Call Procedures February 2010
SCP 7 1-12 Xerox WorkCentre 5790 Family
 2 Status Indicator RAPs
Chain 1 - Standby Power 03-480 IOT +24V Supply Failure RAP ............................................................................ 2-98
01-300 Front Door Open RAP......................................................................................... 2-5 03-700, 03-780, 03-785, 03-790 Power On / Power Off Event Fault RAP ...................... 2-99
01-305 Left Hand Door Open RAP ................................................................................. 2-7 03-720 ODIO Timeout Error RAP.................................................................................... 2-99
01A Ground Distribution RAP ......................................................................................... 2-8 03-770 IOT PWB Software Reset RAP ........................................................................... 2-100
01B 0V Distribution RAP ................................................................................................. 2-18 03-777 Power Loss Detected RAP.................................................................................. 2-100
01C AC Power RAP ........................................................................................................ 2-30 03A Single Board Controller PWB Module Cooling Fan Failure RAP ............................. 2-101
01D +3.3V Distribution RAP............................................................................................ 2-33 03B Mark Service Unavailable RAP................................................................................ 2-101
01E +5V Distribution RAP ............................................................................................... 2-36 03C Hard Disk Failure RAP............................................................................................. 2-102
01F +12V Distribution RAP ............................................................................................. 2-39 03D FTP/SMB Scan to File Failure RAP......................................................................... 2-102
01G +24V Distribution RAP............................................................................................. 2-42
01H Short Circuit and Overload RAP .............................................................................. 2-48
Chain 4 - Main Drives
04A Main Drive Motor and Photoreceptor Motor RAP .................................................... 2-103
01J Power On and LVPS Control Signal RAP ................................................................ 2-53
01K Sleep Mode RAP ..................................................................................................... 2-55 Chain 5 - DADH
Chain 2 - User Interface 05-300 DADH Open RAP................................................................................................ 2-105
02-309 UI Control Panel Button or Touch Screen RAP .................................................. 2-61 05-305 DADH Top Cover Open RAP .............................................................................. 2-106
05-310 Document too Short RAP.................................................................................... 2-108
02-320, 02-380 UI Communication Test RAP ................................................................. 2-61
05-330, 05-331 DADH Feed Sensor Failure Entry RAP ................................................. 2-108
02-390, 02-391, 02-704, 02-706 UI Software Error RAP ................................................ 2-62
02-392 Custom Services Access RAP ............................................................................ 2-62 05-330A, 05-331A DADH Feed Sensor Failure RAP (35 ppm)....................................... 2-109
05-330B, 05-331B DADH Feed Sensor Failure RAP (40-90 ppm) ................................. 2-111
02-705, 02-707, 02-709, 02-712, 02-715 UI Failure RAP ............................................... 2-63
05-335 DADH Takeaway Sensor Failure RAP................................................................ 2-114
Chain 3 - Machine Run Control 05-340 DADH Registration Sensor Failure RAP ............................................................. 2-116
03-300, 306, 461, 482, 805, 870 Single Board Controller PWB to IOT PWB Error RAP 2-65 05-345, 05-346 DADH Exit Sensor Failure RAP ............................................................. 2-118
03-310 Single Board Controller PWB to UI Error RAP.................................................... 2-67 05-350, 05-352 DADH CVT Sensor Failure RAP............................................................ 2-121
03-315, 325, 347, 348, 349, 355, 400 Single Board Controller PWB Failure RAP ......... 2-68 05A DADH Other Faults RAP.......................................................................................... 2-124
03-320 to 03-324 Single Board Controller PWB to DADH Error RAP ............................. 2-68 05B DADH Document Present Sensor Failure Entry RAP.............................................. 2-124
03-330, 03-462 Single Board Controller PWB to Scanner Fault Entry RAP ................... 2-70 05C Document Size Sensor Failure Entry RAP .............................................................. 2-125
03-330A, 03-462A Single Board Controller PWB to Scanner Fault RAP (W/O TAG 150) 2-70 05D DADH Motor Failure RAP ........................................................................................ 2-125
03-330B, 03-462B Single Board Controller PWB to Scanner Fault RAP (W/TAG 150).. 2-73 05E DADH Feed Clutch Failure RAP .............................................................................. 2-127
03-336 FAX Card Self Test Failure RAP......................................................................... 2-75 05F Damaged Documents RAP ...................................................................................... 2-128
03-338 FAX Communication Error RAP.......................................................................... 2-76 05G DADH Document Present Sensor Failure RAP (35 ppm) ....................................... 2-129
03-340, 03-416 Single Board Controller PWB to Network Controller Fault RAP ............ 2-76 05H DADH Document Present Sensor Failure RAP (40-90 ppm) .................................. 2-130
03-350, 03-351, 03-354 IOT to Tray 1 and Tray 2 PWB Error RAP................................ 2-77 05J Document Size Sensor Failure RAP (35 ppm) ......................................................... 2-131
03-359, 03-407 HCF Communications and Detection Error RAP ................................... 2-78 05K Document Size Sensor Failure RAP (40-90 ppm) ................................................... 2-134
03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error RAP .............................. 2-79
03-365 IOT Bus Failure RAP .......................................................................................... 2-81
Chain 6 - ROS
06-020 ROS Motor Failure RAP...................................................................................... 2-137
03-366 IOT to Tray 5 Module Communication Failure RAP............................................ 2-82
03-367 S2X Data Transmission Failure RAP.................................................................. 2-84 06-340 ROS Laser Failure RAP ...................................................................................... 2-139
06-350 ROS Laser Not Under Control RAP .................................................................... 2-141
03-371, 03-372 Fuser and Xerographic CRUM Communication Error RAP ................... 2-84
03-374 Power Off Failure RAP........................................................................................ 2-87 Chain 7 - Paper Supply
03-395, 396, 852, 853 IOT PWB Fault RAP ................................................................... 2-89 07-301 Tray 1 Open During Run RAP............................................................................. 2-143
03-397 Main Motor Not Controlled RAP.......................................................................... 2-90 07-302 Tray 2 Open During Run RAP............................................................................. 2-145
03-401, 03-403 Fax Not Detected RAP .......................................................................... 2-92 07-303 Tray 3 Open During Run RAP............................................................................. 2-147
03-412 Foreign Device PWB Fault RAP ......................................................................... 2-92 07-304 Tray 4 Open During Run RAP............................................................................. 2-148
03-415 Tray 5 Module Not Detected / Confirmed RAP ................................................... 2-95 07-306 Tray 5 Door Open During Run RAP.................................................................... 2-150
03-417 Incompatible Fax Software RAP ......................................................................... 2-97 07-353 Tray 1 Elevator Lift Failure RAP.......................................................................... 2-151
03-419, 03-420 Incompatible Software RAP................................................................... 2-97 07-354 Tray 2 Elevator Lift Failure RAP.......................................................................... 2-153
03-423, 424, 433, 434, 821, 822, 831, 832 Print Command Late RAP........................... 2-98

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-1
07-355 Tray 3 Elevator Lift Failure RAP ......................................................................... 2-154 09-380 Waste Toner Door Switch Failure RAP............................................................... 2-241
07-360 Tray 4 Elevator Lift Failure RAP ......................................................................... 2-156 09-399 Incompatible Xerographic Module RAP .............................................................. 2-243
07-372 Tray 5 Undocked During Run RAP ..................................................................... 2-158 09A Photoreceptor Motor RAP........................................................................................ 2-244
07-373 Tray 5 Elevator Lift Failure RAP ......................................................................... 2-160 09B Waste Toner Full Sensor RAP................................................................................. 2-244
07-374 Tray 5 Elevator Lower Failure RAP .................................................................... 2-164 09C Photoreceptor Fan RAP........................................................................................... 2-246
07A Tray 1 and Tray 2 Empty RAP................................................................................. 2-167
07B Tray 3 and Tray 4 False Low Paper Level RAP ...................................................... 2-169 Chain 10 - Fusing and Copy/Print transportation
07C Bypass Tray RAP .................................................................................................... 2-170 10-101, 10-102, 10-103 Lead Edge Late to Fuser Exit Switch Entry RAP...................... 2-247
07D Tray 1 and 2 Wrong Size Paper RAP ...................................................................... 2-172 10-101A, 10-102A, 10-103A Lead Edge Late to Fuser Exit Switch RAP (35-55 ppm) ... 2-247
07E Tray 3 or Tray 4 Out of Paper RAP ......................................................................... 2-175 10-101B, 10-102B, 10-103B Lead Edge Late to Fuser Exit Switch RAP (65- 90 ppm) .. 2-251
07F Tray Out of Service RAP.......................................................................................... 2-177 10-107, 10-108, 10-109, 10-110 Trail Edge Late from Fuser Exit Switch RAP............... 2-254
07G Tray 5 Empty RAP................................................................................................... 2-177 10-120, 10-121, 10-126 IOT Exit Sensor RAP ................................................................ 2-258
10-132, 10-133, 10-134 Lead Edge Late to Inverter Sensor RAP (65-90 ppm).............. 2-262
Chain 8 - Paper Transport 10-135, 10-136, 10-137, 10-138 Trail edge Late from Inverter Sensor RAP .................. 2-264
08-100 Wait Sensor Jam Entry RAP............................................................................... 2-179 10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 10-365, 10-380
08-100A Wait Sensor Jam RAP (35-55 ppm) ................................................................. 2-179 Fuser Over Temperature RAP ........................................................................................ 2-269
08-100B Wait Sensor Jam RAP (65-90 ppm) ................................................................. 2-181 10-322, 10-324, 10-325, 10-330, 10-370 Fuser Under Temperature RAP ..................... 2-273
08-101 Tray 1 Misfeed RAP............................................................................................ 2-183 10-399 Fuser Authorization Failure RAP......................................................................... 2-277
08-102 Tray 2 Misfeed RAP............................................................................................ 2-185 10A Fuser Web Motor RAP............................................................................................. 2-277
08-103, 08-113 Tray 3 Misfeed RAP............................................................................... 2-187
08-104, 08-114 Tray 4 Misfeed RAP............................................................................... 2-189 Chain 11-110 - 2K LCSS
08-106 Late to Tray 1 Feed Sensor RAP ........................................................................ 2-191 11-005-110, 11-006-110, 11-310-110, 11-311-110 Front Tamper Move Failure RAP.... 2-279
08-107 Tray 3 Paper Feed Jam RAP .............................................................................. 2-193 11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-319-110
08-108 Tray 3 or Tray 4 Paper Feed Jam RAP .............................................................. 2-195 Rear Tamper Move Failure RAP ..................................................................................... 2-281
08-115, 08-117 Tray 5 Misfeed RAP............................................................................... 2-197 11-024-110, 11-025-110 Paddle Roll Failure RAP.......................................................... 2-284
08-115A, 08-117A Tray 5 Misfeed RAP (35-55 ppm) ..................................................... 2-198 11-030-110, 11-334-110, 11-335-110, 11-336-110 Bin 1 Movement Failure RAP ......... 2-286
08-115B, 08-117B Tray 5 Misfeed RAP (65-90 ppm) ..................................................... 2-201 11-043-110, 11-350-110 Hole Punch Operation Failure RAP......................................... 2-290
08-150, 08-151 Registration Jam Entry RAP .................................................................. 2-205 11-050-110, 11-360-110 Staple Head Operation Failure RAP........................................ 2-293
08-150A, 08-151A Registration Jam RAP (35-55 ppm) .................................................. 2-205 11-053-110, 11-370-110 Staple Head Unit Movement Failure RAP ............................... 2-296
08-150B, 08-151B Registration Jam RAP (65-90 ppm) .................................................. 2-207 11-100-110 2K LCSS Paper Entry RAP.......................................................................... 2-299
08-155, 08-156 Bypass Tray Registration Jam Entry RAP ............................................. 2-209 11-110-110 Sheet Late to Hole Punch RAP.................................................................... 2-300
08-155A, 08-156A Bypass Tray Registration Jam RAP (35-55 ppm) ............................. 2-210 11-130-110, 11-132-110 Paper Exiting to Bin 0 RAP...................................................... 2-302
08-155B, 08-156B Bypass Tray Registration Jam RAP (65-90 ppm) ............................. 2-212 11-140-110, 11-142-110 Sheet Late to Bin 1 RAP.......................................................... 2-305
08-160, 08-161 Duplex Paper Path Jam Entry RAP ....................................................... 2-215 11-300-110, 11-302-110, 11-303-110 Interlocks RAP .................................................... 2-308
08-160A, 08-161A Duplex Paper Path Jam RAP (35-55 ppm) ....................................... 2-215 11-320-110, 11-322-110 Ejector Movement Failure RAP ............................................... 2-310
08-160B, 08-161B Duplex Paper Path Jam RAP (65-90 ppm) ....................................... 2-218 11-364-110 Stapling Failure RAP.................................................................................... 2-313
08-171 Unexpected Time Out RAP................................................................................. 2-221 11A-110 Offline Stapling Fault RAP ................................................................................ 2-316
08-174 Missing Pre-release Sheet RAP ......................................................................... 2-222 11B-110 Bin 1 Overload RAP.......................................................................................... 2-319
08-180 Unable to Feed Next Sheet RAP ........................................................................ 2-222 11C-110 2K LCSS Initialization Failure RAP................................................................... 2-320
08-181 Unexpected Time Out in Simplex Inverted Mode RAP ....................................... 2-223 11D-110 2K LCSS Power Distribution RAP .................................................................... 2-321
08-182 Unexpected Time Out in Duplex Mode RAP....................................................... 2-223 11E-110 2K LCSS to Machine Communications Interface RAP ..................................... 2-324
08-190 Post Jam Clearance Initialization RAP ............................................................... 2-224 11F-110 2K LCSS PWB DIP Switch Settings RAP ......................................................... 2-324
11G-110 2K LCSS PWB Damage RAP .......................................................................... 2-325
Chain 9 - Xerographics 11H-110 Copy Damage in the 2K LCSS RAP................................................................. 2-326
09-060 HVPS Fault RAP ................................................................................................. 2-225 11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP........................... 2-327
09-310, 09-390 Low Toner Sensor Failure RAP ............................................................. 2-229 11K-110 2K LCSS Poor Stacking RAP ........................................................................... 2-328
09-341, 09-342 Scorotron Cleaning Failure RAP............................................................ 2-231
09-350 Erase Lamp Failure RAP .................................................................................... 2-232 Chain 11-120 - 1K LCSS
09-360, 09-361, 09-362, 09-363 Toner Concentration Sensor Failure RAP ................... 2-234 11-005-120, 11-006-120, 11-310-120, 11-311-120 Front Tamper Move Failure RAP.... 2-329
09-365 Relative Humidity Sensor Failure RAP ............................................................... 2-237 11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-319-120
09-370 Developer Temperature Sensor Failure RAP ..................................................... 2-238 Rear Tamper Move Failure RAP ..................................................................................... 2-331
09-375 Ambient Temperature Sensor Failure RAP ........................................................ 2-240 11-024-120, 11-025-120 Paddle Roll Failure RAP.......................................................... 2-334

Status Indicator RAPs February 2010

2-2 Xerox WorkCentre 5790 Family
11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Movement Failure RAP ......... 2-336 11-450-171, 11-456-171 to 11-459-171 HVF Ejector Module RAP................................. 2-450
11-050-120, 11-360-120 Staple Head Operation Failure RAP ....................................... 2-340 11-451-171 to 11-455-171 HVF Ejector Roll & Lower Paddle RAP ................................ 2-453
11-100-120 1K LCSS Paper Entry RAP.......................................................................... 2-342 11-460-171 to 11-462-171 HVF Bin 1 Position RAP ....................................................... 2-457
11-130-120, 11-132-120 Paper Exiting to Bin 0 RAP ..................................................... 2-343 11-463-171, 11-464-171 HVF BM +24V Failure RAP ..................................................... 2-461
11-140-120, 11-142-120 Sheet Late to Bin 1 RAP ......................................................... 2-346 11-465-171 to 11-468-171 Paddle Unit Position RAP..................................................... 2-464
11-300-120, 11-302-120, 11-303-120 Interlocks RAP .................................................... 2-349 11-473-171 to 11-478-171 Support Finger Position RAP................................................ 2-466
11-320-120, 11-322-120 Ejector Movement Failure RAP ............................................... 2-352 11-479-171 Inserter Paper Length Fault RAP................................................................. 2-470
11-364-120 Stapling Failure RAP ................................................................................... 2-355 11A-171 HVF Power Distribution RAP ............................................................................ 2-474
11A-120 Bin 1 Overload RAP ......................................................................................... 2-358 11B-171 HVF BM to Machine Communications Interface and BM Present RAP............ 2-478
11B-120 Initialization Failure RAP .................................................................................. 2-359 11C-171 HVF BM Bin 2 Failure RAP .............................................................................. 2-479
11C-120 1K LCSS Power Distribution RAP .................................................................... 2-360 11D-171 Booklet Quality RAP ......................................................................................... 2-481
11D-120 1K LCSS to Machine Communications Interface RAP ..................................... 2-363 11E-171 Copy Damage in the HVF BM RAP .................................................................. 2-485
11E-120 1K LCSS PWB DIP Switch Settings RAP......................................................... 2-363 11F-171 Mis-Registration in Stapled and Unstapled Sets RAP ...................................... 2-485
11F-120 1K LCSS PWB Damage RAP ........................................................................... 2-364 11G-171 HVF BM Poor Stacking RAP ............................................................................ 2-486
11G-120 Copy Damage in the 1K LCSS RAP ................................................................ 2-365 11H-171 Pause to Unload (PTU) RAP ............................................................................ 2-486
11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.......................... 2-366 11J-171 Inserter Paper Sensing and +5V Supply RAP................................................... 2-487
11J-120 1K LCSS Poor Stacking RAP............................................................................ 2-366 11K-171 HVF Initialization Failure RAP .......................................................................... 2-492
11L-171 Tri-Folder Not Detected RAP ............................................................................ 2-493
Chain 11-171 - HVF 11M-171 Curl Suppressor RAP....................................................................................... 2-493
11-024-171, 11-026-171 Paddle Roller Position RAP..................................................... 2-367 11N-171 Chad Bin Present and Bin Full RAP ................................................................. 2-495
11-044-171 to 11-047-171 Punch Unit Head and Position RAP ..................................... 2-369 11P-171 Buffer Clamp RAP ............................................................................................ 2-497
11-056-171, 11-057-171 Inserter Bottom Plate RAP ...................................................... 2-372
11-061-171, 11-416-171 HVF BM Creasing RAP ........................................................... 2-374 Chain 12 - Offset Catch Tray
11-062-171 HVF BM Crease Roll Failure RAP ............................................................... 2-377 12-301 Offset Catch Tray Failure RAP............................................................................ 2-499
11-063-171, 11-411-171 HVF BM Staple Unit 1 Failure RAP......................................... 2-379
11-065-171, 11-383-171 HVF BM Backstop Failure RAP............................................... 2-381 Chain 14 - Scanner
11-066-171, 11-384-171 HVF BM Tamper Failure RAP ................................................. 2-383 14-110 Scan Carriage Home Sensor Entry RAP ............................................................ 2-501
11-083-171, 11-440-171 to 11-443-171 Paper Pusher RAP........................................... 2-385 14-110A Scan Carriage Home Sensor RAP (W/O TAG 150) ......................................... 2-501
11-100-171, 11-101-171 HVF Entry Sensor RAP ........................................................... 2-387 14-110B Scan Carriage Home Sensor RAP (W/TAG 150) ............................................. 2-505
11-130-171, 11-132-171 HVF Top Exit Sensor RAP ...................................................... 2-389 14-310 CCD PWB Not Detected RAP (W/O TAG 150)................................................... 2-508
11-140-171, 11-142-171 HVF 2nd to Top Exit Sensor RAP ........................................... 2-391 14-320 CVT Active Hot Line in Wrong State RAP........................................................... 2-510
11-157-171, 11-161-171 HVF Buffer Position Sensor RAP ............................................ 2-393 14-322 Platen Active Hot Line in Wrong State RAP (W/O TAG 150).............................. 2-510
11-158-171, 11-160-171, 162-171, 163-171 HVF BM Entry RAP................................... 2-395 14-340 Scanner AGC Failure RAP.................................................................................. 2-511
11-164-171, 11-165-171 HVF Buffer Path RAP.............................................................. 2-398 14-703 to 14-706, 712, 714, 716, 718 Failure To Calibrate Entry RAP........................... 2-511
11-172-171 HVF BM Compiler Exit Jam RAP................................................................. 2-400 14-703A to 14-706A, 712A, 714A, 716A, 718A Failure To Calibrate RAP
11-173-171 to 11-177-171 HVF Offset Unit RAP............................................................ 2-403 (W/O TAG 150) ............................................................................................................... 2-512
11-180-171, 11-182-171 HVF BM Exit Jam RAP............................................................ 2-405 14-703B to 14-706B, 712B, 714B, 718B Failure To Calibrate RAP
11-183-171, 11-184-171 HVF BM Paper Jam RAP ........................................................ 2-408 W/TAG 150) .................................................................................................................... 2-514
11-185-171 to 11-187-171 Tri-Folder Exit Sensor and Assist Sensor RAP .................... 2-412 14-710 NVM Value Out Of Range RAP .......................................................................... 2-517
11-188-171, 11-189-171 HVF Nip Split RAP .................................................................. 2-417 14-720 Scan Length Out Of Range RAP ........................................................................ 2-517
11-191-171, 11-193-171, 11-194-171, 11-196-171 Inserter Paper Jam RAP................. 2-419 14-730 Scanner Application Card Failure RAP ............................................................... 2-518
11-198-171, 11-199-171 HVF Paper Jam RAP .............................................................. 2-423 14A Scanning Document Size Entry RAP....................................................................... 2-518
11-300-171, 11-302-171, 11-303-171 HVF Docking and Interlock RAP ......................... 2-426 14B Scanning Document Size RAP (W/O TAG 150) ...................................................... 2-519
11-306-171, 11-309-171 HVF Inserter Interlock RAP ..................................................... 2-429 14C Scanning Document Size RAP (W/TAG 150).......................................................... 2-522
11-307-171, 11-308-171 Tri-folder Interlock RAP ........................................................... 2-431 14D Exposure Lamp Failure RAP ................................................................................... 2-524
11-371-171 to 11-377-171 HVF Stapler Position and Priming RAP ............................... 2-433 Chain 19 - Image Processing
11-380-171 HVF Punch Unit Paper Edge Detect RAP ................................................... 2-438
19-401, 19-402, 19-403 Out of Memory Resources RAP ............................................... 2-527
11-392-171 to 11-395-171 HVF Front Tamper Tray RAP............................................... 2-440
19-404 Compressor Time-out RAP ................................................................................. 2-527
11-396-171 to 11-399-171 HVF Rear Tamper Tray RAP ............................................... 2-442 19-406 Loopback DVMA Time-out RAP.......................................................................... 2-528
11-403-171, 11-413-171, 11-414-171 HVF BM Staple Head 2 and Stapler Module RAP 2-444
19-407, 19-408 Middle Function DVMA Time-out RAP................................................... 2-528
11-415-171 HVF BM Crease Roll Gate Home RAP........................................................ 2-446
19-409 Video Job Integrity Fault RAP ............................................................................. 2-529
11-417-171, 11-418-171 HVF BM Flapper RAP ............................................................. 2-448

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-3
Chain 20 - Fax OF4a Status Codes in Numerical Order.......................................................................... 2-565
20-302, 20-303 Fax Reset Failure RAP .......................................................................... 2-531 OF4b Status Messages in Alphabetical Order ................................................................ 2-591
20-305 Fax System Low Memory Unrecoverable RAP................................................... 2-531 OF5 Boot Up Failure RAP ............................................................................................... 2-614
20-320 Fax Fault Not Cleared RAP ................................................................................ 2-532 OF6 Ozone and Air Systems RAP .................................................................................. 2-615
20-322 Fax Non-Volatile Device not Present RAP.......................................................... 2-532 OF7 IOT PWB Diagnostics RAP ..................................................................................... 2-615
20-323, 20-324 Fax System Memory Low RAP .............................................................. 2-533 OF8 Multi-feed RAP ........................................................................................................ 2-616
20-327 Extended Fax PWB Failure RAP ........................................................................ 2-533 OF9 False Fuser End of Life RAP................................................................................... 2-618
20-331, 20-339, 20-341 Fax Network Line 1 Fault RAP ................................................. 2-534 OF10 Intermittent Failure RAP ........................................................................................ 2-619
20-332, 20-340 Fax Network Line 2 Fault RAP .............................................................. 2-534 OF11 Waste Toner Contamination RAP ......................................................................... 2-622
20-342 Fax File Integrity Fault RAP ................................................................................ 2-535 OF12 False Xerographic Module End of Life RAP.......................................................... 2-623
20-701 Fax Phone Book Download Failed RAP ............................................................. 2-535 OF13 Convenience Stapler RAP..................................................................................... 2-624
20-701A Fax Phone Book Download Failed RAP (W/O TAG X-001) ............................. 2-536 OF14 Extensible Interface Platform RAP ........................................................................ 2-624
20-701B Fax Phone Book Download Failed RAP (W/TAG X-001) ................................. 2-536 OF15 Xerox Secure Access RAP.................................................................................... 2-625
20-710, 20-711 Image Overwrite Error RAP ................................................................... 2-537
20-710A, 20-711A Image Overwrite Error RAP (W/O TAG X-001)................................. 2-537
20-710B, 20-711B Image Overwrite Error RAP (W/TAG X-001) .................................... 2-538
20A Fax Entry RAP ......................................................................................................... 2-538
20B Unable To Send A Fax RAP .................................................................................... 2-539
20C Unable To Send A Fax To Some Machines RAP .................................................... 2-541
20D Unable To Receive A Fax RAP ............................................................................... 2-542
20E Fax Will Not Print RAP............................................................................................. 2-543
20F Fax Tab Not Available RAP ..................................................................................... 2-543
20G Embedded Fax Checkout........................................................................................ 2-544
20H Embedded Fax PWB Voltage Checkout (W/O TAG X-001) .................................... 2-545
20J Fax Problems on Digital Networks RAP ................................................................... 2-546

Chain 22 - System Errors

22-300 AHA End of Record Error RAP ........................................................................... 2-547
22-306 to 22-315, 22-801, 22-814 System Error RAP .................................................... 2-548
22-316, 22-810, 22-820 Capability That Does Not Exist RAP ........................................ 2-548
22-370 Cannot Communicate to the XSA Database RAP .............................................. 2-549
22-400 to 22-403, 22-423, 22-426, 22-427, 22-775 Option Install Failure RAP.............. 2-549
22-404 to 22-406 Option Install Failure RAP .................................................................. 2-550
22-407 Embedded Fax Install Failure RAP ..................................................................... 2-550
22-410 to 22-416, 22-423, 22-425, 22-428, 22-777 Option Remove Failure RAP.......... 2-551
22-417 Embedded Fax Remove Failure RAP ................................................................. 2-551
22-419 Embedded Fax Enable Failure RAP ................................................................... 2-552
22-421 Embedded Fax Disable Failure RAP .................................................................. 2-552
22-450 Test Pattern Standard Grey Level Too High RAP .............................................. 2-553
22-451 Test Pattern Average Grey Level Too Low RAP ................................................ 2-553
22-452 Test Pattern Average Grey Level Too High RAP................................................ 2-554
22-760 IQA Factor Set to Maximum RAP ....................................................................... 2-554
22-761 IQA Factor Set to Minimum RAP ........................................................................ 2-555
22-774 CPSR File Cabinet Enable Failure RAP ............................................................. 2-555
22-776 CPSR File Cabinet Disabled Failure RAP .......................................................... 2-556
22-819, 22-831 to 22-837 Time Out Error RAP .............................................................. 2-556

OF - Other Faults
OF1 Audible Noise RAP.................................................................................................. 2-557
OF2 Touch Screen Failure RAP ..................................................................................... 2-562
OF3 Dead Machine RAP................................................................................................. 2-564
OF4 Status Codes and Messages RAP.......................................................................... 2-564

Status Indicator RAPs February 2010

2-4 Xerox WorkCentre 5790 Family
01-300 Front Door Open RAP • (40-90 ppm) the xerographic module latch, PL 9.20 Item 7.
• (35-55 ppm) the fuser latch, PL 10.8 Item 5.
01-300 The front door has opened during machine operation.
• (65-90 ppm) the fuser latch, PL 10.10 Item 5.
Procedure • The post fuser jam clearance latch, PL 10.15 Item 11.
WARNING • The latch cam handle, PL 10.15 Item 14.

Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Enter dC330, code 01-300 front door interlock, Figure 1. Press start, open and close the front
door. The display changes.
Y N
Go to Flag 2. +12V is available at P/J147 pin 4 on the main drive PWB.
Y N
Go to Flag 2. +12V is available at P/J147 pin 3 on the main drive PWB.
Y N
Go to Flag 2. +12V is available at P/J16 pin 3 on the LVPS.
Y N
Go to the 01F +12V Distribution RAP.

Repair the wiring or the connector pins between P/J16 and P/J147. Door interlock switch S01-300.

Remove the main drive module, (35-55 ppm) REP 4.1 or (65-90 ppm) REP 4.5, Flag
2, check the continuity to the xerographic module CRUM at P/J147, between pins 3
and 4. If necessary check and repair the wiring between the main drive module and
the xerographic CRUM, REP 1.2.

Go to Flag 1. +12V is available at P/J17, pin 5.

Y N
Install a new LVPS and base module, PL 1.10 Item 3.

Go to Flag 1. +12V is available at P/J17, pin 6.

Y N
Check the switch S01-300 and associated wiring. Refer to:
• GP 13 How to Check a Switch.
• P/J17 LVPS and base module.
Figure 1 Component Location
• REP 1.2 Wiring Harness Repairs.
If necessary, install a new door interlock switch, PL 1.10 Item 7.

Go to Flag 3. Open the front of the machine then measure the signal at P/J26 pin 8 on
the IOT PWB. +3.3V is measured.
Y N
Install a new LVPS and base module, PL 1.10 Item 3.

Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
2.

Check that the front door, PL 8.10 Item 10 closes correctly. If not, check the following:
• The jam clearance latch, PL 8.20 Item 5.
• (35 ppm) the xerographic module latch, PL 9.22 Item 7.

February 2010 Status Indicator RAPs

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

Status Indicator RAPs February 2010

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

Procedure
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can Left hand door
cause death or injury. Moving parts can cause injury. interlock, S01-305.
NOTE: To access the left door interlock, remove the interlock cover, PL 7.30 Item 23.

Enter dC330, code 01-305 left door interlock. Press Start, open and close the left hand door,
Figure 1. The display changes.
Y N
Go to Flag 1. Check the left hand door interlock, S01-305. Refer to:
• GP 13, How to Check a Switch.
• P/J7 on the IOT PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP
• Install new components as necessary:
– Left hand door interlock, PL 7.30 Item 3.

Check that the left hand door closes correctly. If not, check the following:
• Hinge pin, PL 7.30 Item 8, is located correctly.
• Left hand door latch, part of the LH door, PL 7.30 Item 2.
• Check that the interlock cover is not loose, PL 7.30 Item 23. If necessary push the cover
towards the front and tighten the screws.

Figure 1 Component Location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-7 01-305
 01A Ground Distribution RAP
Use this RAP to identify ground distribution faults.

Procedure
WARNING
Do not switch on the electricity to the machine while a ground circuit is disconnected.
Ground circuits ensure that the machine remains safe during a fault condition.

NOTE: Ground distribution faults must be isolated by continuity checks and visual inspection.
Check all circuits between each connection and ground.

Ground distribution faults can cause the following:

• Image quality faults
• Paper feed faults.
• Paper path faults.
• Random logic faults
To diagnose a suspected ground distribution fault, the following must be considered:
• Ensure that all the connectors are not damaged. Check crimping for suspect electrical
connections or any mechanical failure that could cause a failed or poor electrical contact.
Refer to REP 1.2 for information concerning wiring harness repairs.
Figure 2 Circuit diagram
• When making a continuity check on a harness, disconnect the harness at both ends, to
ensure that other wiring does not cause continuity readings to be incorrect. Ensure that
any in-line connectors are installed correctly.
• When making a check between connectors and ground, preferably use the main frame
ground connection, Figure 1. Alternatively use any unpainted metal part of the machine
frame.
• Check the ground conductor of the main power cord for continuity or damage, if neces-
sary install a new main power cord, PL 1.10 Item 10.
• Check that the ground connections that follow are secure.
– Figure 1, main frame, main input and auxiliary output ground connections. Check for
continuity of less than 1 ohm between the ground contact of each mains connector
and the main frame ground. Check that the hardware is tight and the harness crimp-
ing is good. To improve continuity, disconnect the terminals, clean the contact faces
and re-assemble.

Status Indicator RAPs February 2010

01-305, 01A 2-8 Xerox WorkCentre 5790 Family
 – Figure 2, corotron shield ground. Check for continuity of less than 10 ohms between
the exposed metal end of the corotron shield and ground. To improve continuity,
remove the duplex transport, REP 8.7, then check the corotron shield ground return,
Main frame ground
connection.

Main input ground

connection.

Figure 2 Corotron shield ground

– Figure 3. Check the connection of the Faston connector and the tightness of the
screw at the rear of the machine frame. If necessary disconnect the terminals, clean
the contact faces and re-assemble, to improve continuity.

Auxiliary output
ground connection.

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-9 01A
 Right hinge ground connection. Motor ground
connections.

Ground connection
to the machine
frame.

Corotron shield ground return

wire (violet) to machine frame.

Figure 3 Corotron shield ground return Auxiliary DADH ground con-

nections.
– Figure 4, DADH ground connection. Remove the DADH rear cover, PL 5.10 Item 1.
Check for continuity of less than 1 ohm between the DADH frame and the main
frame ground connection. To improve continuity, check that the hardware is tight and
the harness crimping is good. If necessary disconnect the terminals, clean the con- Left hinge ground.
tact faces and re-assemble, to improve continuity.
Main DADH ground
connection

Figure 4 DADH ground connection

– Figure 5, paper path ground check points. With the duplex transport in the latched
position, check for continuity of less than 1M ohms between the ends of the three
duplex roll shafts, the steel frame of the duplex path and the main frame ground con-
nection. Also check for continuity of less than 10 ohms between the steel frame of
the duplex path and the ends of the three duplex roll shaft. To improve continuity,
remove the duplex transport, REP 8.7.

Status Indicator RAPs February 2010

01A 2-10 Xerox WorkCentre 5790 Family
 Duplex paper path
ground contact spring.

Duplex roll shafts and the steel frame of duplex path.

Ground wire terminal.

Figure 5 Paper path ground check points Figure 6 Duplex path ground contact spring

NOTE: The (35-55 ppm) duplex transport is shown in Figure 6. The (65-90 ppm) – Figure 7, registration ground check points. Check for continuity of less than 2k ohms
duplex transport has a duplex duct installed, PL 8.20 Item 12. between the ends of the pre-registration drive roll shaft, the registration roll shaft and
the grounding screw. To improve continuity, remove the registration transport, REP
– Figure 6, check the duplex paper path ground contact spring and ground wire termi-
8.4.
nal. If necessary remove and clean the spring, shafts and bearings, then re-assem-
ble to improve continuity.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-11 01A
 – Figure 8, check the registration ground contact spring and ground wire terminal. If
necessary remove and clean the spring, shafts and bearings, then re-assemble to
improve continuity.

NOTE: The two bearings in contact with the registration ground contact spring are
manufactured from conductive plastic. It is not possible to measure the resistance of
these bearings with the standard multi meter.

Registration ground
contact spring.

Ground wire terminal.

Figure 8 Registration ground contact spring

– Figure 9, bypass paper tray guide. Check for continuity of less than 2k ohms
between the ground contact spring and the lift plate (Figure 10). Check for continuity
Pre-registration of less than 1 ohm between the bypass paper guide and the main frame ground con-
drive roll shaft. Grounding screw.
Registration roll nection, when the left hand door is closed. To improve continuity, disconnect the
shaft. ground terminals clean the spring contact faces and re-assemble, to improve conti-
nuity. Also check and clean, if necessary the part of the machine frame where the
ground contact spring makes contact.

Figure 7 Registration ground check points

Status Indicator RAPs February 2010

01A 2-12 Xerox WorkCentre 5790 Family
 Bypass paper guide. Ground connection
spring.

Lift plate.

Feed shaft.
Ground contact spring.

Figure 9 Bypass tray guide Figure 10 Bypass tray paper feed

– Figure 10, bypass tray paper feed. Check for continuity of less than 2k ohms – Figure 11, tray 3 and 4 transport rolls. Remove the tray 3 front cover, REP 7.2. With
between the ground contact spring (Figure 9) and the feed shaft. Check for continu- tray 3 closed, check for continuity of less than 10k ohms between the tray 3 take-
ity of less than 2k ohms between the feed shaft and the main frame ground connec- away roll shaft, the tray 3 transport roll shaft and the main frame ground connection.
tion when the left hand door is closed. To improve continuity, dismantle the ground If necessary, perform the following:
connection spring, clean the spring contact faces and re-assemble, to improve conti- 1. Open the tray. Rotate the shafts. Close the tray and repeat the measurements.
nuity.
2. To improve continuity, remove tray 3, REP 7.2. Figure 13, check the tray 3
ground contact spring.
3. If necessary remove and clean the spring, shafts and bearings, REP 8.31, then
re-assemble to improve continuity.
Figure 12, Also remove and clean the tray 3 and 4 transport drive gear. Clean
the gear on the tray 3 and 4 transport motor, REP 8.11.
4. Clean the area in the back of the tray 3 cavity where the ground spring makes
contact.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-13 01A
 Tray 3 and 4 transport drive
gear.

Tray 3 and 4 transport motor.

Tray 3 transport Tray 3 takeaway
roll shaft. roll shaft. Tray 3 and 4 transport roll
shaft ground contact spring
(35-55 ppm).
Figure 11 HCF transport roll assembly Figure 12 HCF transport drive gear

Status Indicator RAPs February 2010

01A 2-14 Xerox WorkCentre 5790 Family
 Tray 3 ground contact spring.
Tray 3 grounding
spring.

Figure 13 Tray 3 ground contact spring Figure 14 Tray 3 grounding spring

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

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-15 01A
 Tray 1 transport
roll shaft.

Tray 4 grounding
spring. Tray 2 transport
roll shaft. Tray 3 and 4 transport roll shaft.

Figure 15 Tray 4 grounding spring Figure 16 Paper transport rolls

– Figure 16, paper transport rolls. Open the left hand door. Rotate the rolls by hand – Figure 17. Embedded FAX PWB ground connection. Ensure the grounding strip is
and check for continuity of less than 10k ohms between the tray 1 and tray 2 trans- clean and correctly installed.
port roll shaft, tray 3 and 4 transport roll shaft and the main frame ground connection.
To improve continuity for the tray 1 and tray 2 transport roll shaft, remove and clean
and re-install the shaft and bearing.
To improve continuity for the tray 3 and 4 transport roll shaft, perform the following:
Remove, clean and re-install the tray 3 and 4 transport roll shaft ground contact
spring, Figure 11. If necessary, re-form the spring to make good contact with
the end of the shaft.
Remove and clean the tray 3 and 4 transport drive gear. Clean the gear on the
tray 3 and 4 transport motor, REP 8.11.

Status Indicator RAPs February 2010

01A 2-16 Xerox WorkCentre 5790 Family
 Ground connection
under the paper tray.

Grounding strip.

Figure 17 Embedded FAX PWB ground connection

In-line ground
Ground connection. connector.
– Figure 18. Tray 5 ground connections. Check the ground connection on the frame,
the elevator motor and on the base of the paper tray. Ensure that the in-line connec-
tors are connected.
Figure 18 Tray 5 ground connections

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-17 01A
01B 0V Distribution RAP • Tray 1 and 2 control PWB, PL 7.10 Item 2.
– Flag 2, P/J271, P/J9.
Use this RAP to identify 0V distribution faults.
– Flag 4, P/J27.
Procedural Notes • Single board controller PWB, PL 3.24 Item 3.
1. If a voltage is measured between ground and a return 0V line, then the continuity of that – Flag 49, P/J137, P/J106.
0V circuit must be checked. – Flag 48, P/J25, P/J131.
2. To isolate a 0V distribution fault, check the following: • DADH PWB, PL 5.10 Item 5.
• The continuity of a harness while the harness is disconnected at both ends. This is – Flag 50, P/J132, P/J188, P/J152
to ensure that other wiring does not cause false continuity readings. – Flag 48, P/J25, P/J131.
• The continuity and perform a visual inspection of each connection sequentially, back • UI control PWB,PL 2.10 Item 11.
to its source. – Flag 51, P/J133, P/J130.
• Any in-line connectors are installed correctly. – Flag 48, P/J25, P/J131.
• All connectors are mechanically good. Check crimping for suspect electrical connec- • HCF PWB, PL 7.20 Item 2.
tions or any mechanical failure that could cause a failed or poor electrical contact,
– Flag 3, P/J394, P/J272.
GP 7. Refer to REP 1.2 for information concerning wiring harness repairs.
– Flag 2, P/J271, P/J9.
3. The expression “return” is used to identify the 0V line that completes the circuit for a par-
ticular voltage. – Flag 4, P/J27.
Procedure • Scanner PWB, W/TAG 150, PL 14.15 Item 4.
– Flag 9, P/J920, P/J135.
WARNING
– Flag 48, P/J25, P/J131.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
• Scanner PWB, W/O TAG 150, PL 14.25 Item 4.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. – Flag 8, P/J451, P/J452.
Go to the 0V circuit that has the suspect problem. – Flag 52, P/J135, P/J450.
• Refer to 01B +3.3V Return. – Flag 48, P/J25, P/J131.
• Refer to 01B +5V Return. • CCD PWB, W/O TAG 150, PL 14.25 Item 19.
• Refer to 01B +12V Return. – Flag 52, P/J135, P/J450.
• Refer to 01B +24V Return. – Flag 48, P/J25, P/J131.
01B +3.3V Return • Riser PWB, PL 3.22 Item 3.
– Flag 53, P/J138, P/J155.
Go to the appropriate component in the list that follows that has the suspect 0V supply. Check
the wiring GP 7. – Flag 48, P/J25, P/J131.
• ROS, PL 6.10 Item 4. • Embedded fax PWB, PL 20.10 Item 4.
– Flag 1, P/J18, P/J120. – Flag 53, P/J138, P/J155, P/J157,
• Bypass tray width sensor, PL 7.30 Item 1 and bypass tray empty sensor, PL 7.30 Item 7. – Flag 48, P/J25, P/J131.
– Flag 5, IOT PWB, P/J10. • Power distribution PWB, PL 3.24 Item 5.
– Flag 4, IOT PWB, P/J27. – Flag 48, P/J25, P/J131.
• Paper path module components (35-55 ppm); IOT exit sensor, PL 10.11 Item 13, duplex
sensor, PL 8.22 Item 4, wait sensor, PL 8.15 Item 3, registration sensor, PL 8.15 Item 3.
Paper path module components (65-90 ppm); IOT exit sensor, PL 10.11 Item 13, duplex
sensor, PL 8.20 Item 4, wait sensor, PL 7.30 Item 24, registration sensor, PL 8.17 Item 3.
– Flag 7, IOT PWB, P/J5.
– Flag 4, IOT PWB, P/J27.
• IOT PWB PL 1.10 Item 2.
– Flag 4, P/J27.
– Flag 6, P/J27.

Status Indicator RAPs February 2010

01B 2-18 Xerox WorkCentre 5790 Family
 Figure 1 3.3V Return

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-19 01B
 Figure 2 3.3V Return

Status Indicator RAPs February 2010

01B 2-20 Xerox WorkCentre 5790 Family
01B +5V Return
Go to the appropriate component in the list that follow that has the suspect 0V supply. Check
the wiring GP 7.
• Xerographic module, xerographic CRUM, (35 ppm) PL 9.22 Item 2 or (40-90 ppm) PL
9.20 Item 2.
– Flag 17, P/J144, P/J142.
– Flag 16, P/J149, P/J8.
– Flag 15, P/J27.
• Fuser module, fuser CRUM, (35-55 ppm) PL 10.8 Item 1 or (65-90 ppm) PL 10.10 Item 1.
– Flag 18, P/J146, PJ141
– Flag 16, P/J149, P/J8.
– Flag 15, P/J27.
• Main drive PWB (35-55 ppm) PL 4.15 Item 1 or (65-90 ppm) PL 4.10 Item 1.
– Flag 16, P/J149, P/J8.
– Flag 15, P/J27.
• IOT PWB, PL 1.10 Item 2.
– Flag 15, P/J27.
– (65-90 ppm) Flag 47, P/J16.
• HCF control PWB, PL 7.20 Item 2.
– Flag 20, P/J272, P/J394, P/J63.
– Flag 19, P/J9, P/J271.
– Flag 15, P/J27.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.
– Flag 19, P/J271, P/J9.
– Flag 19, P/J270, P/J9.
– Flag 15, P/J27.
– Flag 15, P/J19.
• Output device, PL 12.10, PL 11.26, PL 11.124, PL 11.130.
– Flag 21, PJ151, P/J11.
– Flag 15, P/J27.
• Riser PWB, PL 3.22 Item 3.
– Flag 24, P/J155, P/J138.
– Flag 22, P/J131, P/J25.
• Embedded fax, PL 20.10 Item 4.
– Flag 24, P/J138, P/J155, P/J157.
– Flag 22, P/J25, P/J131.
• Power distribution PWB, PL 3.24 Item 5.
– Flag 22, P/J25, P/J131.
• Paper path module components, waste toner switch, PL 9.10 Item 6, left hand door inter-
lock, PL 7.30 Item 2.
– Flag 45, P/J7, P/J16.
• Tray 5 control PWB, PL 7.68 Item 8
– Flag 25, P/J502.
• Hard disk drive, PL 3.22 Item 2.
– Flag 10, P/J999, P/J139.
• Scanner PWB, W/TAG 150, PL 14.15 Item 4.
– Flag 11, P/J920, P/J136.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-21 01B
 Figure 3 5V Return

Status Indicator RAPs February 2010

01B 2-22 Xerox WorkCentre 5790 Family
 Figure 4 5V Return

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-23 01B
01B +12V Return
Go to the appropriate component in the list that follows that has the suspect 0V supply. Check
the wiring GP 7.
• IOT PWB, PL 1.10 Item 2.
– Flag 26, P/J27.
• UI control PWB, PL 2.10 Item 11.
– Flag 28, P/J133, P/J130.
– Flag 27, P/J25, P/J131.
• Scanner PWB, W/TAG 150, PL 14.15 Item 4.
– Flag 29, P/J135, P/J920.
– Flag 27, P/J25, P/J131.
• Riser PWB, PL 3.22 Item 3.
– Flag 30, P/J138, P/J155.
– Flag 27, P/J25, P/J131.
• Embedded fax PWB, PL 20.10 Item 4.
– Flag 30, P/J138, P/J155, P/J157.
– Flag 27, P/J131, P/J25.
• Power distribution PWB, PL 3.24 Item 5.
– Flag 27, P/J25, P/J131.
• Single board controller PWB, PL 3.24 Item 3.
– Flag 27, P/J25, P/J131.
– Flag 30, P/J138, P/J155, P/J101.
• Hard disk drive, PL 3.22 Item 2.
– Flag 12, P/J139, P/J999.
– Flag 27, P/J25, P/J131.

Status Indicator RAPs February 2010

01B 2-24 Xerox WorkCentre 5790 Family
 Figure 5 12V Return

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-25 01B
01B +24V Return
Go to the appropriate component in the list that follows that has the suspect 0V supply. Check
the wiring GP 7.
• Inverter motor driver PWB, PL 10.11 Item 22.
– Flag 33, PJ45, P/J4.
– Flag 32, P/J27.
• Duplex motor driver PWB, (35-55 ppm) PL 8.22 Item 9 or (65-90 ppm) PL 8.20 Item 9.
– Flag 33, PJ91, PJ40, P/J4.
– Flag 32, P/J27.
• Toner dispense module, (35-55 ppm) PL 9.17 Item 1 or (65-90 ppm) PL 9.15 Item 1.
– Flag 34, PJ93, P/J6.
– Flag 32, P/J27.
• Output device, PL 12.10.
– Flag 35, PJ151, P/J11.
– Flag 32, P/J27.
• HVPS, PL 1.10 Item 5.
– Flag 36, PJ55, P/J14.
– Flag 32, P/J27.
• IOT PWB, PL 1.10 Item 2.
– Flag 32, P/J27.
• DADH PWB, PL 5.10 Item 5.
– Flag 38, P/J132, PJ152, P/J188.
– Flag 37, P/J25, P/J131.
• Power distribution PWB, PL 3.24 Item 5
– Flag 37, P/J25, P/J131.
• Scanner PWB
– (W/O TAG 150) PL 14.25 Item 4.
Flag 39, P/J135, P/J455.
Flag 37, P/J25, P/J131.
– (W/TAG 150) PL 14.15 Item 4.
Flag 39, P/J135, P/J920.
Flag 37, P/J25, P/J131.
• Main drive PWB, part of the main drive module, (35-55 ppm) PL 4.15 Item 1 or (65-90
ppm) PL 4.10 Item 1.
– Flag 40, P/J16, P/J147.
• ROS, PL 6.10 Item 4.
– Flag 41, P/J18, PJ120.
• HCF PWB, PL 7.20 Item 2.
– Flag 43, P/J272, PJ63, P/J394.
– Flag 42, P/J19, P/J270.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.
– Flag 42, P/J19, P/J270.
• Tray 5 control PWB, PL 7.68 Item 8.
– Flag 46, P/J502, P/J12, P/J 501.
– Flag 32, P/J27.

Status Indicator RAPs February 2010

01B 2-26 Xerox WorkCentre 5790 Family
 Figure 6 24V Return

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-27 01B
 Figure 7 24V Return

Status Indicator RAPs February 2010

01B 2-28 Xerox WorkCentre 5790 Family
 Figure 8 24V Return

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-29 01B
 A B C D
01C AC Power RAP Install a new LVPS and base module, PL 1.10 Item 3.

Use this RAP to identify AC power input and output failures.

Install a new LVPS and base module, PL 1.10 Item 3.

Procedure Install a new LVPS and base module, PL 1.10 Item 3.

WARNING
Check the power cords to the output device.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
• 1K LCSS, PL 11.124 Item 8.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. • 2K LCSS, PL 11.26 Item 4.
CAUTION • HVF, PL 11.157 Item 4
Incorrect voltage may damage the machine. The machine must not be connected to the power
outlet if the voltage is incorrect.
WARNING
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury.
Check the AC mains (line) voltage at the customer power outlet. The voltage measured is
within the electrical power requirements, GP 22.
Y N
If the voltage is incorrect or the wiring of the main supply is found to be defective, inform
your technical manager and the customer. Do not attempt to repair or adjust the customer
supply.

Check the main power cord for continuity and damage. The main power cord is good.
Y N
Install a new main power cord, PL 1.10 Item 10. PJ22 power supply for the output device.

Switch on the machine, GP 14. Go to Flag 1. Measure the voltage at the outlet connection,
PJ22, Figure 1. The voltage measured is within the electrical power requirements, GP
22.
Y N
Go to Flag 2. Check for the AC voltage at PJ24 on the LVPS, Figure 2. The AC voltage PJ21
is present.
Y N
Switch off the machine, GP 14. Remove the power cord from PJ21, Figure 1.
Measure the resistance between ACL and ACN at PJ21 on the LVPS, Figure 1. The
resistance reading is greater than 1M Ohms.
Y N
Remove the fuser module. On the fuser module at PJ100 measure the resis-
tance between pin 10 and pins 1, 2, 3 and 4, Figure 3. The reading is infinity,
an open circuit.
Y N Figure 1 Input and output connections
Install a new fuser module, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL
10.10 Item 1 and a new LVPS and base module, PL 1.10 Item 3.

Check the wire harness between PJ24 and PJ100, Figure 2. The harness is
good.
Y N
Install a new fuser connector assembly, (35-55 ppm) PL 4.15 Item 9, (65-
90 ppm) PL 4.10 Item 9 and a new LVPS and base module, PL 1.10 Item
3.

A B C D
Status Indicator RAPs February 2010
01C 2-30 Xerox WorkCentre 5790 Family
 Pin 1
Pin 5
Pin 5
Pin 6

Pin 6

Pin 7
Pin 8
Pin 1
Pin 2 Pin 8

Pin 7
Pin 9
Pin 2 Pin 3

Pin 9 Pin 10
Pin 3
Pin 4

Pin 10 P/J 100

Pin 4
P/J100

CRUM

Figure 3 Fuser module

PJ24

Figure 2 Supply to the fuser module

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-31 01C
 Figure 4 AC circuit diagram

Status Indicator RAPs February 2010

01C 2-32 Xerox WorkCentre 5790 Family
01D +3.3V Distribution RAP • Riser PWB, PL 3.22 Item 3.
– Flag 14, P/J138, P/J155, P/J157.
Use this RAP to identify +3.3V distribution problems.
– Flag 9, P/J25, P/J131.
NOTE: Short circuit or overload of +3.3V or +5V supply will result in all outputs off, except • Embedded fax PWB, PL 20.10 Item 4.
+3.3VSB (standby). – Flag 14, P/J138, P/J157, P/J155.
Procedure – Flag 9, P/J25, P/J131.

WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Refer to Figure 1 and Figure 2. Go to the appropriate component in the list that follows that has
a suspect +3.3V supply. Check the wiring, GP 7.
• ROS, PL 6.10 Item 4.
– Flag 1, P/J18, PJ120.
• Paper path module components, waste toner door switch, PL 9.10 Item 6, left hand door
interlock, PL 7.30 Item 3.
– Flag 8, P/J7.
– Flag 5, P/J27.
• Bypass tray width sensor and bypass empty sensor, PL 7.30.
– Flag 6, P/J10.
– Flag 5, P/J27.
• Paper path module components (35-55 ppm); IOT exit sensor, PL 10.11 Item 13, duplex
sensor, PL 8.22 Item 4, wait sensor, PL 8.15 Item 3, registration sensor, PL 8.15 Item 3.
Paper path module components (65-90 ppm); IOT exit sensor, PL 10.11 Item 13, duplex
sensor, PL 8.20 Item 4, wait sensor, PL 8.15 Item 3, registration sensor, PL 8.17 Item 3.
– Flag 7, P/J5.
– Flag 5, P/J27.
• Power distribution PWB, PL 3.24 Item 5.
– Flag 9, P/J25
• Single board controller PWB, PL 3.24 Item 3.
– Flag 10, P/J137, P/J106.
– Flag 9, P/J25, P/J131.
• DADH PWB, PL 5.10 Item 5.
– Flag 11, P/J132, PJ152, P/J188.
– Flag 9, P/J25, P/J131.
• UI control PWB, PL 2.10 Item 11.
– Flag 12, P/J133, P/J130
• Scanner PWB, W/TAG 150. PL 14.15 Item 4.
– Flag 13, P/J135, P/J920.
– Flag 13, P/J136, P/J920.
– Flag 9, P/J25, P/J131.
• CCD PWB, W/O TAG 150. PL 14.25 Item 19.
– Flag 13, P/J135, P/J450.
– Flag 9, P/J25, P/J131.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-33 01D
 Figure 1 +3.3V distribution circuit diagram

Status Indicator RAPs February 2010

01D 2-34 Xerox WorkCentre 5790 Family
 Figure 2 +3.3V distribution circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-35 01D
01E +5V Distribution RAP – Flag 1, P/J27.
• Single board controller PWB, PL 3.24 Item 3.
Use this RAP to identify +5V distribution problems.
– Flag 17, P/J137, P/J106.
NOTE: Short circuit or overload of +3.3V or +5V supply will result in all outputs off, except – Flag 16, P/J25, P/J131.
+3.3VSB (standby). • Riser PWB, PL 3.22 Item 3.
Procedure – Flag 16, P/J131, P/J25.
– Flag 18, P/J138, P/J155.
WARNING
• Embedded FAX PWB, PL 20.10 Item 4.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
– Flag 18, P/J138, P/J155, P/J157.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. • Power distribution PWB, PL 3.24.
Refer to Figure 1 and Figure 2. Go to the appropriate component in the list that follows that has – Flag 16, P/J131, P/J25.
a suspect +5V supply. Check the wiring, GP 7. • IOT PWB, PL 1.10 Item 2.
• Paper path module components (35-55 ppm); developer temperature sensor, PL 9.22 – Flag 1, P/J27.
Item 5, relative humidity sensor and ambient temperature sensor, PL 9.20 Item 4, waste • Tray 5 control PWB, PL 7.68 Item 8.
toner full sensor, PL 9.10 Item 2, left door interlock, PL 7.30 Item 3, waste toner door – Flag 15, P/J502
switch, PL 9.10 Item 6, registration sensor, PL 8.15 Item 3.
• Hard disk drive, PL 3.22 Item 2.
Paper path module components (65-90 ppm); developer temperature sensor, PL 9.20
– Flag 19, P/J139, P/J999.
Item 5, relative humidity sensor and ambient temperature sensor, PL 9.20 Item 4, waste
toner full sensor, PL 9.10 Item 2, left door interlock, PL 7.30 Item 3, waste toner door – Flag 16, P/J25, P/J131.
switch, PL 9.10 Item 6, registration sensor, PL 8.17 Item 3. • DADH PWB, PL 5.10 Item 5.
– Flag 2, P/J7. The +5V supply on the DADH PWB is generated on board from the +3.3V supply, refer to
– Flag 1, P/J27. Figure 2.
• Xerographic CRUM, part of the xerographic module, (35 ppm) PL 9.22 Item 2 or (40-90 • Wait sensor, (65-90 ppm), PL 7.30 Item 25.
ppm) PL 9.20 Item 2. – Flag 10, P/J16, P/J553.
– Flag 4, P/J142, P/J144.
– Flag 3, P/J149, P/J8.
– Flag 1, P/J27.
• Fuser CRUM, part of the fuser module, PL 10.10 Item 1.
– Flag 5, P/J146, PJ141.
– Flag 3, P/J149, P/J8.
– Flag 1, P/J27.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.
– Flag 6, P/J19, P/J270.
• HCF control PWB, PL 7.20 Item 2.
– Flag 7, P/J394, P/J272.
– Flag 6, P/J19, P/J270.
• OCT Module, PL 12.10.
– Flag 8, P/J11.
– Flag 1, P/J27.
• Inverter motor driver PWB, PL 10.11 Item 22.
– Flag 9, P/J4.
– Flag 1, P/J27.
• Duplex motor driver PWB, (35-55 ppm) PL 8.22 Item 9 or (65-90 ppm) PL 8.20 Item 9.
– Flag 11, P/J4.

Status Indicator RAPs February 2010

01E 2-36 Xerox WorkCentre 5790 Family
 Figure 1 +5V distribution circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-37 01E
 Figure 2 +5V distribution circuit diagram

Status Indicator RAPs February 2010

01E 2-38 Xerox WorkCentre 5790 Family
01F +12V Distribution RAP
Use this RAP to identify +12V distribution problems.

Procedure
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Refer to Figure 1 and Figure 2. Go to the appropriate component in the list that follows that has
a suspect +12V supply. Check wiring, GP 7.
• Power distribution PWB, PL 3.24 Item 5.
– Flag 1, P/J131, P/J25.
• User interface control PWB, PL 2.10 Item 11.
– Flag 2, P/J133, P/J130.
– Flag 1, P/J25, P/J131.
• Scanner PWB, PL 14.15 Item 4.
– Flag 3, P/J920, P/J135.
– Flag 1, P/J131, P/J25.
• CCD PWB, W/O TAG 150.
– Flag 3, P/J450, P/J135.
– Flag 1, P/J131, P/J25.
• Riser PWB PL 3.22 Item 3.
– Flag 4, P/J155, P/J138.
– Flag 1, P/J131, P/J25.
• Embedded FAX PWB, PL 20.10 Item 4.
– Flag 4, P/J157, P/J155, P/J138.
– Flag 1, P/J131, P/J25.
• IOT PWB, PL 1.10 Item 2.
– Flag 6, P/J27.
• Xerographic CRUM, part of the xerographic module, (35 ppm) PL 9.22 Item 2, (40-90
ppm) PL 9.20 Item 2.
– Flag 8, P/J142, PJ144.
– Flag 7, P/J147, P/J16.
• Main drive PWB (35-55 ppm), PL 4.15 Item 6, (65-90 ppm) PL 4.10 Item 6.
– Flag 7, P/J147, P/J16.
• Door interlock switch, PL 1.10 Item 7.
– Flag 9, P/J17.
• Single board controller PWB, PL 3.24 Item 3.
– Flag 10, P/J137, P/J106.
– Flag 1, P/J131, P/J25.
• Hard disk drive, PL 3.22.
– Flag 11, P/J139, P/J999.
– Flag 1, P/J25, P/J131.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-39 01F
 Figure 1 +12V distribution circuit diagram

Status Indicator RAPs February 2010

01F 2-40 Xerox WorkCentre 5790 Family
 Figure 2 +12V distribution circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-41 01F
01G +24V Distribution RAP Duplex motor driver PWB, (35-55 ppm) PL 8.22 Item 9, (65-90 ppm) PL 8.20 Item 9.
Refer to the 01G Fused Distribution Check.
Use this RAP to identify +24V distribution problems.
– Flag 6, P/J4.
Initial Actions – Flag 5, P/J27.
Check the following: • Toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90 ppm) PL 9.15 Item 1. Refer
to the 01G Fused Distribution Check.
• The door interlock switch is closed.
– Flag 7, P/J6.
• The xerographic module is correctly installed.
– Flag 5, P/J27.
Procedure • Bypass tray feed solenoid, PL 7.30 Item 4. Refer to the 01G Fused Distribution Check.
– Flag 8, P/J10.
WARNING
– Flag 5, P/J27.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
• OCT Module, PL 12.10, Refer to the 01G Fused Distribution Check.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. – Flag 9, P/J11.
Refer to Figure 2, Figure 3, Figure 4 and Figure 5. Go to the appropriate component in the list – Flag 5, P/J27.
that follows that has a suspect +24V supply. Check the wiring, GP 7. • HVPS, PL 1.10 Item 5, Refer to the 01G Fused Distribution Check.
• Power distribution PWB, PL 3.24 Item 5. – Flag 10, P/J14, P/J55.
– Flag 1, P/J25, P/J131. – Flag 5, P/J27.
• IOT PWB, PL 1.10 Item 2. • Photoreceptor drive motor, part of the main drive module, (35-55) PL 4.15 Item 17, (65-90
Flag 5, P/J27. ppm) PL 4.10 Item 17. Refer to the 01G Fused Distribution Check.
• Main drive PWB, part of the main drive module, (35-55 ppm) PL 4.15 Item 6, (65-90 ppm) – Flag 12, P/J151.
PL 4.10 Item 6. – Flag 11, P/J147, P/J16.
– Flag 11, P/J147, P/J16. • Ozone fan, PL 9.25 Item 1. Refer to the 01G Fused Distribution Check.
• ROS PL 6.10 Item 4 – Flag 13. P/J153.
– Flag 16, P/J18. – Flag 12, P/J151.
• Tray 1 and 2 control PWB, PL 7.10 Item 2. – Flag 11, P/J147, P/J16.
– Flag 17, P/J270, P/J19. • Fuser web motor, part of the main drive module, (35-55 ppm) PL 4.17 Item 1, (65-90 ppm)
• HCF control PWB, PL 7.20 Item 2. PL 4.12 Item 1. Refer to the 01G Fused Distribution Check.
– Flag 18, P/J394, P/J272. – Flag 14, P/J154.
– Flag 17, P/J270, P/J19. – Flag 11, P/J147, P/J16.
• DADH PWB, PL 5.10 Item 5. Refer to the 01G Fused Distribution Check. WARNING
– Flag 3, P/J188. Do not install a fuse of a different type or rating. Installing the wrong type or rating of
– Flag 2, P/J132. fuse can cause overheating and a risk of fire.
– Flag 1, P/J131, P/J25. • Paper path module containing: in-line fuse and wiring, GP 7, PL 1.10 Item 9, Figure 1.
• Tray 5 control PWB, PL 7.68 Item 8. Refer to the 01G Fused Distribution Check. – Erase lamp, (35 ppm) PL 9.22 Item 1, (45-90 ppm) PL 9.20 Item 1.
– Flag 20, P/J12. – Inverter path solenoid, PL 10.11 Item 14.
– Flag 21, P/J502, P/J501. – Registration clutch, PL 8.15 Item 7.
• Scanner PWB, W/TAG 150, PL 14.15 Item 4. – Inverter nip solenoid, PL 10.11 Item 6.
– Flag 4, P/J920, P/J135. – Vacuum transport fan (part of short paper path assembly), PL 10.25 Item 1.
– Flag 1, P/J131, P/J25. – Refer to the 01G Fused Distribution Check.
• Scanner PWB, W/O TAG 150, PL 14.25 Item 4. – Flag 15, in-line fuse, PL 1.10 Item 9, Figure 1.
– Flag 4, P/J455, P/J135.
– Flag 1, P/J131, P/J25.
• Inverter motor driver PWB, PL 10.11 Item 22.

Status Indicator RAPs February 2010

01G 2-42 Xerox WorkCentre 5790 Family
01G Fused Distribution Check • On the paper path module, Figure 4:
Procedure – Flag 15, P/J17.
WARNING • On the ROS, Figure 5:
– Flag 16, P/J18.
Do not repair or install a new fuse F1 on the IOT PWB. Repairing or installing a new fuse
can cause overheating and a risk of fire. • On the tray 1 and 2 control PWB and HCF control PWB, Figure 5:
WARNING – Flag 17, P/J19
– Flag 18, P/J272.
Do not repair or install a new fuse F1 on the power distribution PWB. Repairing or
installing a new fuse can cause overheating and a risk of fire. c. Connect the circuit or harness.
WARNING d. If the voltage drops lower than +22V, switch off the machine, GP 14. Recheck the
component and harness for overheating or short circuits. Repair or install new com-
Do not repair or install a new fuse F1 on the main drive PWB. Repairing or installing a
ponents as necessary.
new fuse can cause overheating and a risk of fire.
e. Actuate the component using its control code, dC330.
WARNING f. If the voltage drops lower than +22V, switch off the machine, GP 14. Recheck the
Do not install a fuse of a different type or rating. Installing the wrong type or rating of component and harness for overheating or short circuits. Repair or install new com-
fuse can cause overheating and a risk of fire. ponents as necessary.
CAUTION
If the surface mounted fuse on the power distribution PWB, IOT PWB or main drive PWB has
blown, do not install a new PWB until the cause of the fault is repaired.
Use this procedure when checking the +24V fused distribution. Perform the following:
1. Switch off the machine, GP 14.
2. Refer to Figure 2, Figure 3 and Figure 4. Disconnect the relevant circuit or harnesses.
Check each one for evidence of overheating or short circuits, GP 7.
3. Refer to 01H Short Circuits and Overloads RAP.
4. Monitor the +24V test point as the circuit or harnesses are individually reconnected as fol-
lows:
a. Switch on the machine, GP 14.
b. Monitor the voltage at the appropriate test point:
• On the power distribution PWB, Figure 2:
In-line +24 volt fuse
– Flag 2, P/J132.
– Flag 4, P/J135.
• On the Tray 5 Control PWB, Figure 2:
– Flag 20, P/J12.
– Flag 21, P/J501, P/J502.
• On the IOT PWB, Figure 3:
– Flag 6, P/J4. Figure 1 +24 volt in-line fuse
– Flag 7, P/J6.
– Flag 8, P/J10.
– Flag 9, P/J11.
– Flag 10, P/J14.
– Flag 19, P/J61.
• On the main drive module, Figure 4:
– Flag 12, P/J151.
– Flag 13, P/J153.
– Flag 14, P/J154.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-43 01G
 Figure 2 +24V distribution circuit diagram

Status Indicator RAPs February 2010

01G 2-44 Xerox WorkCentre 5790 Family
 Figure 3 +24V distribution circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-45 01G
 Figure 4 +24V distribution circuit diagram

Status Indicator RAPs February 2010

01G 2-46 Xerox WorkCentre 5790 Family
 Figure 5 +24V distribution circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-47 01G
01H Short Circuit and Overload RAP • Figure 1. All the PJ connectors on the IOT PWB, except PJ26 Flag 24, PJ27 Flag 25 and
PJ5 Flag 15.
Procedural Notes Press the on / off switch, PL 1.10 Item 8. The LED CR36 is on.
WARNING Y N
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Check for a short circuit on the AC line. Go to 01C AC Power RAP.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. Press the on/off switch, PL 1.10 Item 8. The LEDs, CR12, CR13 and CR15 are on and stay
on.
• The LEDs, Figure 1, CR12, CR13, CR14, CR15 and CR36 on the IOT PWB are used to
Y N
indicate that a supply voltage is available. Refer to OF7 IOT PWB Diagnostics RAP.
Go to Flag 15. Measure the voltage at PJ5, pin 19. Press the on / off switch, PL 1.10 Item
• Short circuit or overload of +3.3VSB (standby) will result in all outputs off.
8. The voltage changes from +3.5V to 0V.
• Short circuit or overload of +3.3V or +5V will result in all outputs off, except +3.3VSB.
Y N
• Short circuit or overload of +12V or +24V will result in only those outputs being off. Check the wiring to the on / off switch, GP 7. If necessary, install a new on / off
• In all instances, when the short circuit or overload is removed all the outputs will recover switch, PL 1.10 Item 8.
to normal operating voltages after 10 seconds.
• If +3.3VSB is over voltage, all outputs will be off. To restore to normal, switch off the Disconnect PJ26. Measure the voltage at the harness of PJ26, pin 7, Flag 24. +1.16V is
machine, GP 14. Wait three minutes. Switch on the machine. available at pin 7.
• If +3.3V, +5V or +12V are over voltage, all outputs will be off, except +3.3VSB. To restore Y N
to normal, switch off the machine, GP 14. Wait three minutes. Switch on the machine. Install a new LVPS and base module, PL 1.10 Item 3.
• If the +24V is over voltage, only the 24V the output will be off. To restore to normal, switch
off the machine, GP 14. Wait three minutes. Switch on the machine. Reconnect PJ26. Measure the voltage at the harness of PJ26, pin 7, Flag 24. Press the
WARNING on / off switch. The voltage changes from +1.16V to 0V and stays at 0V.
Y N
Do not repair or install a new fuse F1 on the IOT PWB. Repairing or installing a new fuse
Install new components in the order that follows:
can cause overheating and a risk of fire.
1. Install a new LVPS and base module, PL 1.10 Item 3.
WARNING 2. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
Do not repair or install a new fuse F1 on the power distribution PWB. Repairing or PL 1.10 Item 2.
installing a new fuse can cause overheating and a risk of fire.
WARNING Disconnect the power cord. Use a service multi-meter set to DC amps. Ensure the meter
Do not repair or install a new fuse F1 on the main drive PWB. Repairing or installing a leads are connected to the correct meter sockets to measure amps. Connect the black
lead to the machine frame. Reconnect the power cord. Use the probe on the red lead to
new fuse can cause overheating and a risk of fire.
ground PJ26, pin 7 to ground, through the multi-meter. When the LEDs CR27, CR28 and
WARNING CR29 are flashing, press and release the on / off switch and remove the probe. The
Do not install a fuse of a different type or rating. Installing the wrong type or rating of LEDs, CR12, CR13 and CR15 are ON and stay ON.
fuse can cause overheating and a risk of fire. Y N
Procedure Set the service multi-meter to measure volts. Ensure the meter leads are connected
to the correct meter sockets to measure volts. Measure the voltage at the harness of
Switch off the machine, GP 14. Remove the rear cover, PL 8.10 Item 1. Reconnect the power
PJ26, pin 7, Flag 24. 0V is measured.
cord. CR36 is on, Figure 1.
Y N
Y N Check that the F1 fuse on the IOT PWB has not failed. Go to 01H +24 Volt Cir-
Go to 01J Power On and LVPS Control Signals RAP.
cuits before a new IOT PWB is installed, PL 1.10 Item 2.

NOTE: To disconnect the connectors PJ16, PJ17, PJ18, PJ19 and PJ25 on the LVPS, open Install a new LVPS and base module, PL 1.10 Item 3.
tray 1 and tray 2. Remove the screw that secures the power and control assembly, PL 1.10.
Slide the power and control assembly to the left.
Set the service multi-meter set to volts. Ensure the meter leads are connected to the cor-
NOTE: Refer to Figure 3 for the low voltage distribution. This is an overview of all the low volt- rect meter sockets to measure volts. Measure the voltage at PJ25, pins 1 and 2, Flag 5.
age harnesses within the machine. +24V is measured.
Y N
NOTE: Refer to GP 7 at every harness check and if necessary perform, REP 1.2. Measure the voltage at the harness of PJ26, pin 9, Flag 24. 0V is measured.
To check the output voltages of the LVPS, disconnect the following.
• Figure 2. PJ16, PJ17, PJ18, PJ19 and PJ25.
A B
Status Indicator RAPs February 2010
01H 2-48 Xerox WorkCentre 5790 Family
A B
Y N a. Developer temperature sensor, (35 ppm) PL 9.22 Item 5, (40-90 ppm) PL 9.20 Item
Check that the F1 fuse on the IOT PWB has not failed. Go to 01H +24 Volt Cir- 5, WD 10.
cuits before a new IOT PWB is installed, PL 1.10 Item 2. b. Relative humidity sensor, (35 ppm) PL 9.22 Item 4, (40-90 ppm) PL 9.20 Item 4, WD
10.
Install a new LVPS and base module, PL 1.10 Item 3. c. Ambient temperature sensor, (35 ppm) PL 9.22 Item 4, (40-90 ppm) PL 9.20 Item 4,
WD 10.
Disconnect the power cord. Disconnect the in-line fuse in the harness from PJ17. Recon- d. Waste toner full sensor, PL 9.10 Item 2, WD 10.
nect PJ16 and PJ17. Set the service multi-meter to measure amps. Ensure the meter
leads are connected to the correct meter sockets to measure amps. Clip the black lead to
01H +3.3 Volt and +5 Volt Circuits
the machine frame. Reconnect the power cord. Use the probe on the red lead to ground NOTE: After every disconnection, the on / off switch, PL 1.10 Item 8, must be pressed. If CR12
PJ26, pin 7 to ground. When the LEDs CR27, CR28 and CR29 are flashing, press and and CR13 are not on, reconnect and go to the next step.
release the on/off switch and remove the probe. The LEDs, CR12, CR13, CR15 and
CR16 are ON and stay ON 1. Perform the steps that follow:
Y N a. Disconnect PJ137, power distribution PWB. If the LEDs CR12 and CR13 are on,
Check the interlock circuit, Flag 26, Flag 27 and Flag 28. If the circuit is good, check then check the harness, Flag 11, from the power distribution PWB to PJ106 on the
that F1 fuse on the IOT PWB has not failed. Go to 01H +24 Volt Circuits before a single board controller PWB, WD 3.
new IOT PWB is installed, PL 1.10 Item 2. b. Disconnect PJ138 from the power distribution PWB. If the LEDs, CR12 and CR13
are on, then check the harness, Flag 12, to the riser PWB, WD 3
The LVPS is good. Continue at 01H Initial Isolation Check. 2. If no short circuit is found is found in the +3.3V and +5V circuits, go to 01H +3.3 Volt Cir-
cuits.
Disconnect the power cord. Reconnect PJ16 and PJ17. Connect the power cord. Press the on/
off switch. The LED CR16 is ON.
01H +3.3 Volt Circuits
Y N NOTE: After every disconnection, the on / off switch, PL 1.10 Item 8, must be pressed. If CR12
Check the interlock circuit, Flag 1, Flag 2 and Flag 6. If the circuit is good, go to 01H +24 and CR13 are not on, reconnect and go to the next step.
Volt Circuits before a new a new IOT PWB is installed, PL 1.10 Item 2.
1. Disconnect PJ132, power distribution PWB. If the LEDs, CR12 and CR13 are on, then
The LVPS is good. Continue at 01H Initial Isolation Check. check the harness, Flag 8, to the DADH PWB, WD 3.
01H Initial Isolation Check 2. Disconnect PJ133, power distribution PWB. If the LEDs, CR12 and CR13 are on, then
check the harness, Flag 9, to the UI control PWB, WD 3.
NOTE: After every disconnection, the on/off switch, PL 1.10 Item 8, must be pressed. If CR12 3. Disconnect PJ135, power distribution PWB. If the LEDs, CR12 and CR13 are on, then
and CR13 are not on, reconnect and go to the next step. check the harness, Flag 10, to the Scanner PWB W/O TAG 150, CCD PWB W/O TAG
150 or Scanner PWB W/TAG 150.
Disconnect the power cord. Reconnect all the disconnected PJ connections on the IOT PWB,
LVPS and the power distribution PWB. Reconnect the power cord. Switch on the machine, GP 4. If no failure is found in the +3.3V circuits, go to 01H +5 Volt Circuits.
14. If ALL the LEDs, Figure 1, CR12, CR13, CR15 and CR16 are OFF, go to step1. If the CR15 01H +5 Volt Circuits
is OFF, go to 01H +12 Volt Circuits. If the CR16 is OFF, go to 01H +24 Volt Circuits.
1. Disconnect PJ25, Flag 5, Figure 3. If the LEDs CR12 and CR13 are on, check the har- NOTE: After every disconnection, the on / off switch, PL 1.10 Item 8, must be pressed. If CR12
and CR13 are not on, reconnect and go to the next step.
ness from PJ25 to PJ131. If the harness is good, go 01H +3.3 Volt and +5 Volt Circuits.
2. Disconnect PJ18, Flag 3, Figure 3. If the LEDs CR12 and CR13 are on, check the har- 1. Disconnect PJ8, IOT PWB. If the LEDs CR12 and CR13 are on, then check the harness,
ness, Flag 3, from PJ18 to the ROS, PL 6.10 Item 4. WD 1. Flag 14, to the xerographic CRUM, part of the xerographic module, (35 ppm) PL 9.22 Item
3. Disconnect PJ19, Flag 4, Figure 3. If the LEDs CR12 and CR13 are on, check the har- 2 or (40-90 ppm) PL 9.20 Item 2, and to the fuser CRUM, part of the fuser module, (35-55
ness, Flag 4, from PJ19 on the LVPS, to the Tray 1 and 2 Control PWB, PL 7.10, WD 1. ppm) PL 10.8 or (65-90 ppm) PL 10.10 Item 1, WD 6.
a. Check the harness at Flag 7, WD 20. 2. Disconnect PJ9, IOT PWB. If the LEDs CR12 and CR13 are on, then check the harness,
b. Check the harness, Flag 4, from PJ19 on the LVPS, to the Tray 1 and 2 Control Flag 17, to tray 1 and 2 control PWB, PL 7.10 Item 1, WD 10.
PWB, PL 7.10 Item 2, WD 1. 3. Disconnect PJ4, IOT PWB. If the LEDs CR12 and CR13 are on, then check the harness,
4. Disconnect PJ10, Flag 20, Figure 3. If the LEDs CR12 and CR13 are on, check the har- Flag 16, to the inverter motor driver PWB, PL 10.11 Item 22, and to the duplex motor
ness, Flag 20, from PJ10 on the IOT PWB, to the bypass tray, PL 7.30, WD 10. driver PWB, (35-55 ppm) PL 8.22 Item 9, (65-90 ppm) PL 8.20 Item 9, WD 7.
5. Disconnect PJ11, Flag 21, Figure 3. If the LEDs CR12 and CR13 are on, check the har-
ness, Flag 21, from PJ11 on the IOT PWB to the output devices, WD 5.
6. Disconnect PJ7, Flag 19, Figure 3. If the LEDs CR12 and CR13 are on, check the har-
ness, Flag 19, from PJ7 to the components that follow:

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-49 01H
01H +12 Volt Circuits 6. Disconnect PJ135 on the power distribution PWB check the harness, to the CCD PWB W/
O TAG 150 or Scanner PWB W/TAG 150.
NOTE: Before disconnection, switch off the machine, GP 14. Switch on the machine, GP 14, to
check CR15.
CR15 is OFF. Check the harnesses that follow for a short circuit, until CR15 is on, Figure 1.
1. Disconnect PJ25 on the LVPS. CR15 is ON. Check from PJ25, Flag 5, to the power distri-
bution PWB, WD 2. If the harness from PJ25 to PJ131 is good. Reconnect PJ25 and per-
form the steps that follow:
a. Disconnect PJ133 on the power distribution PWB. Check the harness, Flag 9, to
PJ130 on the UI control PWB, PL 2.10.
b. Disconnect PJ135 on the power distribution PWB. Check the harness, Flag 10, to
the Scanner PWB W/O TAG 150, CCD PWB W/O TAG 150 or Scanner PWB W/TAG
150.
c. Disconnect PJ138 on the power distribution PWB. Check the harness, Flag 12, to
PJ155 on the riser PWB, PL 3.22 Item 3.
01H +24 Volt Circuits
NOTE: Before disconnection, switch off the machine, GP 14. Switch on the machine, GP 14, to
check CR16.
CR16 is OFF. Check the harnesses that follow for a short circuit, until CR16 is on, Figure 1.
1. Disconnect PJ18 on the LVPS. CR16 is ON. Check from PJ18 to the ROS, PL 6.10 Item
4, WD 1.
2. Disconnect PJ19 on the LVPS. CR16 is ON. Check from PJ19, Flag 4, to the tray 1 and 2 Figure 1 IOT PWB, LED and PJ location
control PWB, WD 1, WD 20 and WD 21.
3. Switch off the machine, GP 14.
If the F1 fuse on the IOT PWB has failed. Set the meter to measure ohms. Connect the
black lead to PJ27 pin 9 or pin 10 and the red lead to the bottom of the F1 fuse on the IOT
PWB. If the output is shorted the measurement will be less than 1 ohm.
a. Disconnect PJ3 on the IOT PWB. The value is below 1 Ohm. Check from PJ3, Flag
13, to the main drive PWB, WD 6.
b. Disconnect PJ4 on the IOT PWB. The value is below 1 Ohm. Check from PJ4, Flag
16, to the inverter motor, PL 10.11 Item 11, and the duplex motor, (35-55) PL 8.22
Item 8, (65-90 ppm) PL 8.20 Item 8, WD 7.
c. Disconnect PJ6 on the IOT PWB. The value is below 1 Ohm. Check from PJ6, Flag
18, to PJ93 on the developer module, WD 10.
d. Disconnect PJ10 on the IOT PWB. The value is below 1 Ohm. Check from PJ10,
Flag 20, to the paper tray bypass, PL 7.30, WD 10.
e. Disconnect PJ11 on the IOT PWB. The value is below 1 Ohm. Check from PJ11,
Flag 21, to P/J151 and onto the output device, WD 5.
f. Disconnect PJ14 on the IOT PWB. The value is below 1 Ohm. Check from PJ14,
Flag 22, to PJ55 on the HVPS, PL 1.10, WD 11.
g. Install a new IOT PWB, PL 1.10 Item 2.
h. If after completing the checks above, the F1 fuse on the IOT PWB fails. Switch off
the machine, GP 14. Install a new IOT PWB, PL 1.10 Item 2.
Disconnect PJ3, PJ4, PJ6, PJ11 and PJ14. Switch off the machine, GP 14 before a Figure 2 LVPS PJ location
PJ is connected. Install each PJ, one at a time until the PJ is found that causes the
fuse to fail. Check and repair the harness or install new components as necessary.
4. Switch on the machine, GP 14.
5. Disconnect PJ132 on the power distribution PWB, check the harness, to DADH, Flag 8.

Status Indicator RAPs February 2010

01H 2-50 Xerox WorkCentre 5790 Family
 Figure 3 Low voltage distribution

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-51 01H
 Figure 4 +12V interlock circuit diagram

Status Indicator RAPs February 2010

01H 2-52 Xerox WorkCentre 5790 Family
01J Power On and LVPS Control Signal RAP
Use this RAP to check and identify power on and standby signals from the LVPS.

Ensure that the 01C AC Power RAP is performed before starting this RAP.

Procedural Notes
NOTE: Short circuit or overload of +3.3VSB (standby) will result in all the LVPS outputs off.
Short circuit or overload of +3.3V or +5V will result in all the LVPS outputs off, except +3.3VSB.

NOTE: For an explanation of the LEDs on the IOT PWB and their function, go to OF7 IOT
PWB Diagnostics RAP.

NOTE: +3.3VSB (standby) is generated from the LVPS when the machine is connected to the
AC supply. +3.3VSB is required to initialize the machine from standby to power on.

Procedure
Ensure that the machine is switched off, GP 14. Remove the rear cover, PL 8.10 Item 1.
Reconnect the power cord. Check CR36, Figure 1. CR36 is on.
Y N
Go to Flag 3. +3.3VSB is available at P/J27, between pin 6 and pin 14, on the IOT
PWB.
Y N
Figure 1 LED location on IOT PWB
Disconnect P/J27. +3.3VSB is available at the disconnected end of the harness,
P/J27, between pins 6 and 14.
Y N
Go to 01C AC Power RAP.

Check the harness and connector P/J27, if necessary repair the harness/connector
or install a new LVPS and base module, PL 1.10 Item 3.

Check the pin to pin connections of P/J27. If the connections are good, install a new IOT
PWB, PL 1.10 Item 2. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
installed.

Go to Flag 1. Monitor the voltage at P/J5, pin 19. Press the on/off switch, PL 1.10 Item 8.
The voltage changes to 0V.
Y N
Check the wiring to the switch, GP 7. If necessary, repair the wiring or install a new on/off
switch, PL 1.10 Item 8.

Monitor the voltage at P/J26, pin 7. Switch off the machine, then switch on the machine, GP
14. Go to Flag 2. The voltage changes from +2.3V to 0V.
Y N
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
2.

Go to the 01H Short Circuits and Overloads RAP.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-53 01J
 Figure 2 Power ON circuit and dependencies

Status Indicator RAPs February 2010

01J 2-54 Xerox WorkCentre 5790 Family
01K Sleep Mode RAP • An incoming Fax job. To indicate a wake up call has been initiated the Fax PWB will gen-
erate a power management event/wake up (PME/wake up) signal. The PME/wake up sig-
Use this RAP to diagnose problems entering or exiting sleep mode.
nal is sent via the riser PWB through the PCI bus to the single board controller PWB to
the IOT PWB. The IOT on/off control circuit detects the PME/wake up line is active and
Sleep Mode Operation enables the PS ON signal to the LVPS, which in turn switches on the low voltage DC out-
The machine is designed to be energy efficient by reducing the power consumption after peri- puts of the machine, and also asserts the LOW PWR signal to enable AC power to the fin-
ods of inactivity. The machine has three power modes: isher.
• Standby or run mode - full power consumption. In this mode, the energy saver button, Fig- • An incoming print job to the single board controller PWB will generate a power manage-
ure 1, is not illuminated. ment event/wake up (PME/wake up) signal that is passed through single board controller
• Low power mode - the fuser temperature is reduced to save power, yet allow a quick PWB to the IOT PWB. This causes the IOT to generate the PS ON signal to the LVPS,
return to run temperature. In this mode, the energy saver button, Figure 1, is blinking. which in turn switches on the low voltage DC outputs of the machine and also asserts the
LOW PWR signal to enable AC power to the finisher.
• Sleep mode - power consumption for the whole machine is reduced to below 10 watts by
powering down all but the essential parts, see the note below. In this mode, the energy Reading or Setting the Power Save Duration Times
saver button, Figure 1, is illuminated. Access the power save feature by performing the following:
1. Access the customer administration tools screen, GP 24.
NOTE: When the machine is in sleep mode, +12V sleep is supplied from a special power
supply located within the LVPS to the power distribution PWB. The power distribution 2. Touch the More button.
PWB supplies +3.3V sleep and 12V sleep to power the PWBs that follow: 3. Touch the Power Saver Administration button.
– Riser PWB. 4. Set the Standby/Low Power duration times.
– Fax PWB. 5. Touch save.
– Single board controller (SBC) PWB. The default time for standby mode to low power mode is 15 minutes, the minimum value is 1,
– UI control PWB. the maximum value is 120.

Off to Run Mode The default time for low power mode to sleep mode is 45 minutes, the minimum value is 10,
When the On/off button is pressed, the IOT PWB sends the PS ON signal to the LVPS to the maximum value is 120.
power-on the low voltage DC outputs of the machine. The PS ON signal is diode coupled
within the LVPS to the sleep signal, therefore whenever the main power supply is on, the sleep To change either of the timing values, touch the appropriate input area, enter the new value
mode power supply is on. When the machine is in run mode the IOT watchdog signal and the using the keypad. Touch the Save button to confirm the change.
SBC watchdog signal keep the PS ON signal active.
Initial Actions
Run Mode to Sleep Mode Make sure that the cooling fan, PL 3.24 Item 2 is connected to PJ221 on the Single Board Con-
After a period of machine inactivity that equates to the sum of the low power mode duration troller PWB, not PJ134 on the Power distribution PWB.
plus the sleep mode duration, as set in the customer tools options, both the SBC and IOT
watchdogs are stopped. After approximately 4.5 seconds the PS ON signal goes inactive, Procedure
causing the low voltage DC outputs of the machine to switch off. Before the SBC and IOT stop
their watchdogs, the UI watchdog is started, this causes the sleep signal to be active; this in WARNING
turn keeps the sleep mode power supply on when the main power supply switches off. Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
Sleep Mode to Run Mode cause death or injury. Moving parts can cause injury.
Exit from sleep mode requires one of the wake events that follows to occur: Refer to Sleep Mode to Run Mode. The machine remains in sleep mode after a wake
• An operator presses the on/off switch. This causes the IOT to generate the PS ON signal event.
to the LVPS, which in turn switches on the low voltage DC outputs of the machine and Y N
also asserts the LOW PWR signal to enable AC power to the finisher. Refer to Run Mode to Sleep Mode. The machine remains in standby mode or low
power mode after both power save duration times have elapsed.
• An operator touches the UI screen or presses any UI buttons. This causes the UI to acti-
vate the PME wake up signal. The wake signal is passed through the single board con- Y N
The machine switches off when it should enter sleep mode.
troller PWB to the IOT. This causes the IOT to generate the PS ON signal to the LVPS,
Y N
which in turn switches on the low voltage DC outputs of the machine and also asserts the
LOW PWR signal to enable AC power to the finisher. The system is operating correctly, perform SCP 6 Final Actions.

A B C

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-55 01K
A B C A B D E
Perform the following: Install new parts as necessary:
• Refer to Reading or Setting the Power Save Duration Times. Set both the • User interface harness, PL 2.10 Item 3.
standby mode to low power mode and the low power mode to sleep mode val- • User interface control PWB, PL 2.10 Item 11.
ues to 1 minute. • User interface touch screen PWB, PL 2.10 Item 6.
• Disconnect the Fax telephone lines to prevent a power management event. • User interface touch screen, PL 2.10 Item 5.
• Disconnect the ethernet connection P/J114 to prevent a power management • Single board controller PWB, PL 3.24 Item 3.
event.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
Go to Flag 1. Check the voltage at P/J27 pin 8 on the IOT PWB. After 2 minutes
installed, PL 1.10 Item 2.
the voltage changes from +3.3V to 0V.
Y N Install anew LVPS and base module, PL 1.10 Item 3.
Go to Flag 2. Check the wiring and connectors between PJ1 pin 9 and P/J105
pin 7. Refer to the information that follows:
Perform the following:
• P/J1 IOT PWB.
• If the embedded fax option is installed, ensure it has been enabled and set up. If the
• P/J114 Single Board Controller PWB. customer does not use this option, it may be disabled via the tools menu, but the
Go to Flag 3. Check the wiring and connectors between P/J103 pin 3 and PJ81 embedded fax must be set up to allow the operation of the Sleep Mode.
pin 1. Refer to the information that follows: • Refer to Reading or Setting the Power Save Duration Times. Set both the standby
• P/J103 Single Board Controller PWB mode to low power mode and the low power mode to sleep mode values to 1 minute.
• P/J81 User interface PWB. • Disconnect the input Fax line(s) to prevent a power management event.
The wiring and connectors are good. • Disconnect from the network to prevent a power management event.
Y N • Leave the machine untouched and observe the user interface.
Repair the wiring, REP 1.2.
After one minute the energy saver button flashes, then after a further minute the
energy saver button illuminates.
Go to Flag 8. Check for +3.3V at P/J155 between pins 2 and 6, also check for
Y N
+12V between pins 4 and 8. Refer to the information that follows:
Install a new IOT PWB, PL 1.10 Item 2. Perform OF7 IOT PWB Diagnostics RAP
• P/J155 Riser PWB. before the new IOT PWB is installed. Return the power save settings to the previous
The voltages are good. values and reconnect the Fax and network lines. Perform SCP 6 Final Actions.
Y N
Go to Flag 8. Check for +3.3V at the Power distribution PWB P/J138 The system is operating correctly. Return the power save settings to the previous values
between pins 2 and 6, also check for +12V between pins 7 and 8. The and reconnect the Fax and network lines. Perform SCP 6 Final Actions.
voltages are good.
Y N The wake event is from the user interface.
Go to Flag 5 and Flag 7. Check for +12V at the Power distribution Y N
PWB P/J131 between pins 17 and 13, also check for +12V between The wake event is from the network.
pins 14 and 18. The voltages are good. Y N
Y N The wake event is from the Fax PWB.
Go to Flag 5 and Flag 7. Check for +12V at the LVPS and base Y N
module P/J25 between pins 3 and 13, also check for +12V Go to the 01J Power On and LVPS Control Signals RAP, check the operation of
between pins 4 and 14. The voltages are good. the on/off switch.
Y N
Install a new LVPS and base module, PL 1.10 Item 3. Perform the following:
1. Refer to 20A Fax Entry RAP and complete all of the initial actions.
Check the wiring and connectors between P/J25 and P/J131. 2. Remove and re-seat the Fax PWB and riser PWB, REP 3.2.
Repair the wiring as necessary, REP 1.2.
3. Refer to Reading or Setting the Power Save Duration Times. Set both the
standby mode to low power mode and the low power mode to sleep mode val-
Install a new Power distribution PWB, PL 3.24 Item 5.
ues to 1 minute.
Go to Flag 8. Check the wiring and connectors between P/J138 and P/ 4. Go to Flag 2, Measure the voltage at P/J105 pin 11.
J155. Repair the wiring as necessary, REP 1.2. 5. Leave the machine untouched, allow the machine to enter sleep mode.
6. Arrange for a Fax job to be sent from another machine to this machine.
A B D E F G
Status Indicator RAPs February 2010
01K 2-56 Xerox WorkCentre 5790 Family
F G F G
The voltage measured changes from +3.3V to 0V when the Fax arrives at the Arrange for a Fax job to be sent from another machine to this machine. The voltage
machine. measured changes from +3.3V to 0V.
Y N Y N
Go to Flag 8. Check for +3.3V at PJ155 between pins 2 and 6, also check for Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
+12V between pins 4 and 8. Refer to the information that follows: PL 1.10 Item 2.
• P/J155 Riser PWB.
Install a new LVPS and base module, PL 1.10 Item 3.
The voltages are good.
Y N
Go to Flag 8. Check for +3.3V at the Power distribution PWB P/J138 Go to P/J114. Check the network connection. The harness and connectors are good.
Y N
between pins 2 and 6, also check for +12V between pins 7 and 8. The
Install a new ethernet harness.
voltages are good.
Y N
Perform the following:
Go to Flag 5 and Flag 7. Check for +12V at the Power distribution
PWB P/J131 between pins 17 and 13, also check for +12V between 1. Refer to Reading or Setting the Power Save Duration Times. Set both the standby
pins 18 and 14. The voltages are good. mode to low power mode and the low power mode to sleep mode values to 1 minute.
Y N 2. Disconnect the telephone network harness from the Fax PWB to prevent a power
Go to Flag 5 and Flag 7. Check for +12V at the LVPS and base management event.
module P/J25 between pins 3 and 13, also check for +12V 3. Go to Flag 2. Measure the voltage at P/J105 pin 11. Refer to the information that fol-
between pins 4 and 14. The voltages are good. lows:
Y N • P/J114 Single Board Controller PWB.
Install a new LVPS and base module, PL 1.10 Item 3.
4. Leave the machine untouched, allow the machine to enter sleep mode.
Check the wiring and connectors between P/J25 and P/J131. 5. Arrange for a print job to be sent from a PC to this machine.
Repair the wiring as necessary, REP 1.2. The voltage measured changes from +3.3V to 0V, when the print job arrives at the
machine.
Install a new power distribution PWB, PL 3.24 Item 5. Y N
Go to Flag 8. Check for +3.3V at PJ155 between pins 2 and 6, also check for +12V
Check the wiring and connectors between PJ138 and PJ155. Refer to the between pins 4 and 8. Refer to the information that follows:
information that follows • P/J155 Riser PWB.
• P/J138 Power distribution PWB. The voltages are good.
• P/J155 Riser PWB. Y N
Repair the wiring as necessary, REP 1.2. Go to Flag 8. Check for +3.3V at the Power distribution PWB P/J138 between
pins 2 and 6, also check for +12V between pins 7 and 8. The voltages are
Install new parts as necessary: good.
Y N
• Fax PWB, PL 20.10 Item 4.
Go to Flag 5 and Flag 7. Check for +12V at the Power distribution PWB P/
• Riser PWB PL 3.22 Item 3.
J131 between pins 17 and 13, also check for +12V between pins 14 and
• Single board controller PWB PL 3.24 Item 3. 18. The voltages are good.
Y N
Go to Flag 2. Measure the voltage at P/J1 pin 5 on the IOT PWB. Go to Flag 5 and Flag 7. Check for +12V at the LVPS and base mod-
Arrange for a Fax to be sent from another machine to this machine. The voltage ule P/J25 between pins 3 and 13, also check for +12V between pins
measured changes from +3.3V to 0V when the Fax arrives at the machine. 4 and 14. The voltages are good.
Y N Y N
Check the wiring and connectors between PJ1 and PJ105. Refer to the infor- Install a new LVPS and base module, PL 1.10 Item 3.
mation that follows:
• P/J1 IOT PWB. Check the wiring and connectors between P/J25 and P/J131. Repair
• P/J114 Single Board Controller PWB. the wiring as necessary, REP 1.2.
Repair the wiring as necessary, REP 1.2.
Install a new power distribution PWB, PL 3.24 Item 5.
Go to Flag 4. Measure the voltage at P/J26 pin 7 on the IOT PWB.

F G F H I J

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-57 01K
F H I J K L M
Check the wiring and connectors between PJ138 and PJ155. Refer to the infor- Check the wiring and connectors between P/J133 and P/J130. Repair the wiring,
mation that follows REP 1.2, as necessary.
• P/J138 Power distribution PWB.
Install new parts as necessary:
• P/J155 Riser PWB.
• User interface harness, PL 2.10 Item 3.
Repair the wiring as necessary, REP 1.2.
• User interface control PWB, PL 2.10 Item 11.
Install new parts as necessary: • User interface touch screen PWB, PL 2.10 Item 6.
• Riser PWB, PL 3.22 Item 3. • User interface touch screen, PL 2.10 Item 5.
• Single board controller PWB, PL 3.24 Item 3.
Go to Flag 3. Measure the voltage at PJ103 pin 2. Refer to the information that follows:
Go to Flag 2. Measure the voltage at P/J1 pin 5 on the IOT PWB. Arrange for a print job • P/J103 Single Board Controller PWB
to be sent from a PC to this machine. The voltage measured changes from +3.3V to The voltage changes from +3.3V to 0V when the UI screen is touched or a UI button is
0V when the print job arrives at the machine. pressed.
Y N Y N
Check the wiring and connectors between PJ1 and PJ105. Refer to the information Check the wiring and connectors between PJ103 and PJ81.
that follows:
• P/J103 Single Board Controller PWB
• P/J1 IOT PWB.
• P/J81 User interface PWB.
• P/J114 Single Board Controller PWB.
Repair the wiring, REP 1.2, as necessary.
Repair the wiring as necessary, REP 1.2.
Go to Flag 2. Measure the voltage at P/J105 pin 11. Refer to the information that follows:
Go to Flag 4. Measure the voltage at P/J26 pin 7 on the IOT PWB. Arrange for a print job
• P/J114 Single Board Controller PWB
to be sent from a PC to this machine. The voltage measured changes from +3.3V to
0V when the print job arrives at the machine. The voltage changes from +3.3V to 0V when the UI screen is touched or a UI button is
Y N pressed.
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL Y N
1.10 Item 2. Install a new single board controller PWB, PL 3.24 Item 3.

Install a new LVPS and base module, PL 1.10 Item 3. Go to Flag 2. Measure the voltage at P/J1 pin 5 on the IOT PWB. The voltage changes from
+3.3V to 0V when the UI screen is touched or a UI button is pressed.
Go to Flag 3. Measure the voltage at P/J81 pin 2 on the User interface PWB. The voltage Y N
changes from +3.3V to 0V when the UI screen is touched or a UI button is pressed. Check the wiring and connectors between PJ1 and P/J105. Refer to the information that
Y N follows:
Go to Flag 6. +3.3V is available at P/J130 on the User interface PWB between pins 1 • P/J1 IOT PWB.
and 2. • P/J114 Single Board Controller PWB
Y N Repair the wiring, REP 1.2 as necessary.
Go to Flag 6. +3.3V is available at P/J133 on the Power distribution PWB
between pins 3 and 4. Go to Flag 4.Measure the voltage at P/J26 pin 7 on the IOT PWB. The voltage changes
Y N from +3.3V to 0V when the UI screen is touched or a UI button is pressed.
Go to Flag 5 and Flag 7. +12V is available at P/J131 on the Power distribu- Y N
tion PWB between pins 13 and 17 and also between pins 14 and 18. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
Y N 2.
Go to Flag 5 and Flag 7. +12V is available at P/J25 on the LVPS and
base module between pins 13 and 3 and also between pins 4 and 14. Install a new LVPS and base module, PL 1.10 Item 3.
Y N
Install a new LVPS and base module, PL 1.10 Item 3.

Check the wiring and connectors between P/J25 and P/J131. Repair the
wiring, REP 1.2, as necessary.

Install a new power distribution PWB, PL 3.24 Item 5.

K L M
Status Indicator RAPs February 2010
01K 2-58 Xerox WorkCentre 5790 Family
 Energy saver button.

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-59 01K
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

01K 2-60 Xerox WorkCentre 5790 Family
02-309 UI Control Panel Button or Touch Screen RAP 02-320, 02-380 UI Communication Test RAP
02-309 The User Interface Button Test or the Touch Area Test failed during the UI Test. 02-320 The UI does not receive the requested data from the single board controller PWB within
the correct time out period.
Procedure
02-380 UI main controller communications test failed.
CAUTION
Before a new user interface assembly is installed, identify the software level (GP 4). Check the
compatibility of the software on the new user interface assembly. Install the software to meet
Procedure
the customer machine requirements. Perform the next steps:
Perform the next steps: • Switch off the machine, then switch on the machine, GP 14.
• Switch off the machine, then switch on the machine, GP 14. • Enter dC305 UI test. Perform the Communications Self Test.
• Reload the UI software, GP 4. • Go to 03-310 Single Board Controller PWB to UI Errors RAP.
• Check the condition of CR12 and CR15 on the IOT PWB, refer to the OF7 IOT PWB Diag-
nostics RAP.
• Enter dC305 UI test. Perform the Communications Self Test.
• Check the harness connections between the user interface, PL 2.10 and the single board
controller PWB, PL 3.24.
• Install new components as necessary:
– UI control PWB, PL 2.10 Item 11.
– UI touch screen PWB, PL 2.10 Item 6.
– UI touch screen, PL 2.10 Item 5.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-61 02-309, 02-320, 02-380
02-390, 02-391, 02-704, 02-706 UI Software Error RAP 02-392 Custom Services Access RAP
02-390 All of the configured services have not reached a stable state after five minutes from 02-392 User interface/USB communication error.
start.
Procedure
02-391 All the services are not registered when the single board controller PWB/UI synchroni-
Perform the following.
zation has occurred.
• OF14 Extensible Interface Platform RAP.
02-704 Application software checksum has failed.

02-706 UI VRAM failure.

Procedure
CAUTION
Before a new user interface assembly is installed, identify the software level (GP 4). Check the
compatibility of the software on the new user interface assembly. Install the software to meet
the customer machine requirements.
Perform the next steps:
• Switch off the machine, then switch on the machine, GP 14.
• Enter dC305 UI test. Perform the Application Checksum Verification Test.
• Reload the UI software, GP 4.
• Install new components as necessary:
– UI control PWB, PL 2.10 Item 11.
– UI touch screen PWB, PL 2.10 Item 6.
– UI touch screen, PL 2.10 Item 5.

Status Indicator RAPs February 2010

02-390, 02-391, 02-704, 02-706, 02-392 2-62 Xerox WorkCentre 5790 Family
02-705, 02-707, 02-709, 02-712, 02-715 UI Failure RAP
02-705 The UI audio tones failed to operate.

02-707 Indicate a fault with a button on the UI control panel.

02-709 Indicate a fault with the touch screen on the UI.

02-712 UI LCD module test failed.

02-715 The LED control panel indicator test has failed.

Procedure
CAUTION
Before a new user interface assembly is installed, identify the software level (GP 4). Check the
compatibility of the software on the new user interface assembly. Install the software to meet
the customer machine requirements.
Perform the next steps:
• Switch off the machine, then switch on the machine, GP 14.
• Enter dC305 UI test. Perform the relevant test.
• Reload the UI software, GP 4.
• Install new components as necessary:
– UI control PWB, PL 2.10 Item 11.
– UI touch screen PWB, PL 2.10 Item 6.
– UI touch screen, PL 2.10 Item 5.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-63 02-705, 02-707, 02-709, 02-712, 02-715
Status Indicator RAPs February 2010
02-705, 02-707, 02-709, 02-712, 02-715 2-64 Xerox WorkCentre 5790 Family
03-300, 306, 461, 482, 805, 870 Single Board Controller
PWB to IOT PWB Error RAP
03-300 The single board controller PWB to IOT communications have failed.

03-306 The IOT PWB has received an inappropriate print command from the single board con-
troller PWB.

03-461 A speed mismatch has been detected between the single board controller PWB and
the IOT PWB, in the NVM settings.

03-482 The single board controller PWB has failed to receive a +24V on signal from the IOT
PWB.

03-805 The IOT PWB has received an un-recognized message from the single board controller
PWB.

03-870 The IOT PWB cannot be recognized by the single board controller PWB.

Initial Actions
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
• If the fault occurs during a software upgrade, wait 15 minutes for the software program-
ming operation to complete, before the next action.
• Switch off the machine, then switch on the machine, GP 14. If the on/off switch fails to
operate, go to the 03-374 Power Off Failure RAP.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.

Procedure
1. Switch off the machine, GP 14. Ensure all the connectors on the single board controller
PWB, PL 3.24 Item 3 and the IOT PWB, PL 1.10 Item 2 are correctly and securely seated.
Switch on the machine, GP 14.
2. If the fault was detected during a software upgrade, go to Flag 1. Check P/J107 on the
single board controller PWB. Re-load the software set, GP 4 Machine Software.
3. Perform OF7 IOT PWB Diagnostics RAP.
4. Go to Flag 2. Check the wiring, GP 7. If necessary, install a new single board controller
PWB module / LVPS / IOT PWB harness, PL 3.24 Item 14.
5. 03-461 Only: Go to the OF7 IOT PWB Diagnostics RAP. Check CR 27 for an indication of
NVM Test Failure.
6. Install a new IOT PWB, PL 1.10 Item 2. Perform OF7 IOT PWB Diagnostics RAP before a
new IOT PWB is installed.
7. Install a new single board controller PWB, PL 3.24 Item 3.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-65 03-300, 306, 461, 482, 805, 870
 Figure 1 Circuit diagram

Status Indicator RAPs February 2010

03-300, 306, 461, 482, 805, 870 2-66 Xerox WorkCentre 5790 Family
03-310 Single Board Controller PWB to UI Error RAP
03-310 The single board controller PWB cannot communicate with the UI within one minute of
power-on or after three retries.

Initial Actions
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
• Switch off the machine, then switch on the machine, GP 14.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.

Procedure
1. Ensure all the connectors on the single board controller PWB, PL 3.24 Item 3 and UI con-
trol PWB, PL 2.10 Item 11 are correctly and securely seated.
2. Go to Flag 1, Flag 2 and Flag 3. Check the wiring. Repair or install new harnesses as nec-
essary, PL 2.10.
3. Go to Flag 1. Check the voltages. Refer to:
• 01B 0V Distribution RAP.
• 01D +3.3V Distribution RAP.
• 01F +12V Distribution RAP.
4. Install new components as necessary:
• Single board controller PWB, PL 3.24 Item 3.
• UI control PWB, PL 2.10 Item 11.

Figure 1 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-67 03-310
03-315, 325, 347, 348, 349, 355, 400 Single Board Controller 03-320 to 03-324 Single Board Controller PWB to DADH
PWB Failure RAP Error RAP
03-315 The single board controller PWB has performed a crash recovery procedure. 03-320 Communications between the single board controller PWB and the DADH have failed.

03-325 A single board controller PWB clock is not functioning. 03-321 Communications between the single board controller PWB and the DADH are out of
sequence.
03-347 The single board controller PWB POST has failed the EPC test.
03-322 The DADH has detected a read/write error.
03-348 The single board controller PWB POST has failed the ASIC test.
03-323 The DADH has detected a software error.
03-349 The single board controller PWB POST has failed the rotation memory test.
03-324 The DADH has detected a boot check sum error.
03-355 The single board controller PWB POST has failed the NVM integrity test.
Initial Actions
03-400 The single board controller PWB cannot detect additional EPC memory.
WARNING
Initial Actions Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
WARNING cause death or injury. Moving parts can cause injury.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the • Remove originals from the DADH.
customer supply while performing tasks that do not need electricity. Electricity can
• Switch off the machine, then switch on the machine, GP 14.
cause death or injury. Moving parts can cause injury.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
• Switch off the machine, then switch on the machine, GP 14. domly, the cause may be due to electrical noise. Go to the OF10 intermittent Failure RAP.
• Check that the single board controller PWB cooling fan is operating. If necessary, go to
the 03A Single Board Controller PWB Cooling Fan Failure RAP.
Procedure
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
1. Ensure all the connectors on the PWBs that follow are correctly and securely seated:
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.
• Single board controller PWB, PL 3.24 Item 3.
Procedure • Scanner daughter PWB, PL 3.24 Item 20.
• Power distribution PWB, PL 3.24 Item 5.
1. Ensure all the connectors on the PWBs that follow are correctly and securely seated:
• DADH PWB, PL 5.10 Item 5.
• Single board controller PWB, PL 3.24 Item 3.
Check also, the in-line connector in the communications/power cable, PL 5.10 Item 6.
• Software module, PL 3.24 Item 8.
2. Go to Flag 2. Check the voltages. Refer to:
• Memory module, PL 3.24 Item 12.
• 01B 0V Distribution RAP.
• (W/TAG 150) Scanner daughter PWB, PL 3.24 Item 20.
• 01D +3.3V Distribution RAP.
2. Install new parts as necessary:
• 01G +24V Distribution RAP.
• Memory module, PL 3.24 Item 12.
3. Go to Flag 1 and Flag 2. Check the wiring, GP 7. If necessary, install a new communica-
• Software module, PL 3.24 Item 8.
tion/power cable, PL 5.10 Item 6.
• (W/TAG 150) Scanner daughter PWB, PL 3.24 Item 20.
4. If the fault was detected during a software upgrade, go to Flag 3. Check the connection.
• Single board controller PWB, PL 3.24 Item 3.
Reload the software, GP 4, Machine Software.
5. Install new components as necessary:
• Single board controller PWB, PL 3.24 Item 3.
• DADH PWB, PL 5.10 Item 5.

Status Indicator RAPs February 2010

03-315, 325, 347, 348, 349, 355, 400, 03-320 to 03-324 2-68 Xerox WorkCentre 5790 Family
 Figure 1 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-69 03-320 to 03-324
03-330, 03-462 Single Board Controller PWB to Scanner 03-330A, 03-462A Single Board Controller PWB to Scanner
Fault Entry RAP Fault RAP (W/O TAG 150)
03-330 A single board controller PWB to scanner PWB communications error has been Initial Actions
detected.
WARNING
03-462 A speed mismatch between the single board controller PWB and the scanner has been Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
detected in the NVM. customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Procedure • Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 03-
330, 03-462 Single Board Controller PWB to Scanner Faults Entry RAP.
WARNING
• Switch off the machine, then switch on the machine, GP 14.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.
Perform one of the steps that follow:
• For machines W/O TAG 150, go to the 03-330A, 03-462A Single Board Controller PWB to
Procedure
Scanner Faults RAP (W/O TAG 150). 1. Ensure all the connectors on the PWBs that follow are correctly and securely seated:
• For machines W/TAG 150, go to the 03-330B, 03-462B Single Board Controller PWB to • Single board controller PWB, PL 3.24 Item 3.
Scanner Faults RAP (W/TAG 150). • Power distribution PWB, PL 3.24 Item 5.
• Scanner PWB, PL 14.25 Item 4.
• CCD PWB, PL 14.25 Item 19.
NOTE: To gain access to the scanner PWB, remove the document glass, PL 14.20 Item 5
and the scanner PWB cover, PL 14.25 Item 1.

2. Go to Flag 1, Flag 2 and Flag 3. Check the wiring. Repair or install new harnesses as nec-
essary, PL 14.25 Item 5 or PL 14.25 Item 13.

NOTE: Flag 4 indicates the main communication lines.

3. Go to Flag 1 and Flag 2. Check the voltages. Refer to:

• 01B 0V Distribution RAP.
• 01D +3.3V Distribution RAP.
• 01F +12V Distribution RAP.
• 01G +24V Distribution RAP.
4. Re-load the software, GP 4 Machine Software.
5. If necessary, install new components:
• Single board controller PWB, PL 3.24 Item 3.
• Power distribution PWB, PL 3.24 Item 5.
• Scanner PWB, PL 14.25 Item 4.
• Scanner module, PL 14.20 Item 1.

Status Indicator RAPs February 2010

03-330, 03-462, 03-330A, 03-462A 2-70 Xerox WorkCentre 5790 Family
 Figure 1 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-71 03-330A, 03-462A
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

03-330A, 03-462A 2-72 Xerox WorkCentre 5790 Family
03-330B, 03-462B Single Board Controller PWB to Scanner
Fault RAP (W/TAG 150)
Initial Actions
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 03-
330, 03-462 Single Board Controller PWB to Scanner Faults Entry RAP.
• Switch off the machine, then switch on the machine, GP 14.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.

Procedure
1. Ensure all the connectors on the PWBs that follow are correctly and securely seated:
• Single board controller PWB, PL 3.24 Item 3.
• Power distribution PWB, PL 3.24 Item 5.
• Scanner PWB, PL 14.25 Item 4.
• CCD PWB, PL 14.25 Item 19.
• Scanner daughter PWB, PL 3.24 Item 20.
NOTE: To gain access to the scanner PWB, remove the document glass, PL 14.10 Item 5
and the scanner PWB cover, PL 14.15 Item 1.

2. Go to Flag 1, Flag 2 and Flag 3. Check the harnesses, GP 7. Repair or install new har-
nesses as necessary:
• Scanner daughter PWB/scanner PWB video harness, PL 14.15 Item 13.
• Single board controller/DADH comms/scanner PWB harness, PL 3.24 Item 7.
3. Go to Flag 3. Check the voltages. Refer to:
• 01B 0V Distribution RAP.
• 01D +3.3V Distribution RAP.
• 01E +5V Distribution RAP.
• 01F +12V Distribution RAP.
• 01G +24V Distribution RAP.
4. Re-load the software, GP 4, Machine Software.
5. If necessary, install new components:
• Scanner daughter PWB, PL 3.24 Item 20.
• Scanner PWB, PL 14.15 Item 4.
• Power distribution PWB, PL 3.24 Item 5.
• Single board controller PWB, PL 3.24 Item 3.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-73 03-330B, 03-462B
 Figure 1 Circuit diagram

Status Indicator RAPs February 2010

03-330B, 03-462B 2-74 Xerox WorkCentre 5790 Family
 03-336 FAX Card Self Test Failure RAP
03-336 Power on self test failure detected on the embedded fax PWB.

Initial Actions
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Switch off the machine, then switch on the machine, GP 14.

Procedure
Perform the following:
1. Go to 20G Embedded FAX Checkout.
2. Clear the fax card NVM. Go to dC132, select Embedded Fax NVM initialization and per-
form the routine, Reformat.
3. Install a new embedded fax PWB, PL 20.10 Item 4.

Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-75 03-330B, 03-462B, 03-336
03-338 FAX Communication Error RAP 03-340, 03-416 Single Board Controller PWB to Network
03-338 No response detected to commands from the single board controller PWB to the Controller Fault RAP
embedded fax PWB. 03-340 The network communications with the single board controller PWB have failed.

Initial Actions 03-416 The network controller software version supplied at power on is not compatible with the
WARNING single board controller PWB software.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can Initial Actions
cause death or injury. Moving parts can cause injury. WARNING
Switch off the machine, then switch on the machine, GP 14. Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
Procedure cause death or injury. Moving parts can cause injury.
Perform the following: • Switch off the machine, then switch on the machine, GP 14.
1. Remove, then re-install the embedded fax PWB, PL 20.10 Item 4. • Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.
2. Go to 20G Embedded Fax Checkout.
3. (W/O TAG X-001) Install a new compact flash memory, PL 20.10 Item 3.
4. Install new embedded fax PWB, PL 20.10 Item 4.
Procedure
1. Ensure that the ethernet connector P/J114 on the Single Board Controller PWB is
securely connected.
2. Perform RAP 03C Hard Disk Failure.
3. Reload the software, GP 4 Machine Software.
4. Install new components as necessary:
• Software module, PL 3.24 Item 8.
• Hard disk drive, PL 3.22 Item 2.
• Single board controller PWB, PL 3.24 Item 3.

Status Indicator RAPs February 2010

03-338, 03-340, 03-416 2-76 Xerox WorkCentre 5790 Family
03-350, 03-351, 03-354 IOT to Tray 1 and Tray 2 PWB Error • Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.
RAP
03-350 The IOT has detected no response from the tray 1 and 2 control PWB to the ping Procedure
request.
1. Switch off the machine, GP 14. Ensure P/J9 and P/J271 are correctly and securely con-
03-351 Tray 1 and 2 control PWB has detected a feed buffer overflow. nected.
2. Go to Flag 1. Check the harness. Repair as necessary, GP 7.
03-354 Communications failure. Tray 1 and 2 control PWB has detected a communications 3. Go to Flag 2. Check the +3.3V and 0V lines. Refer to:
failure. • P/J271
• 01D +3.3V Distribution RAP.
Initial Actions • 01B 0V Distribution RAP.
WARNING 4. Switch on the machine, GP 14. Perform OF7 IOT PWB Diagnostics RAP.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the 5. Re-load the software, GP 4 Machine Software.
customer supply while performing tasks that do not need electricity. Electricity can
6. Install new components as necessary:
cause death or injury. Moving parts can cause injury.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
• Switch off the machine, then switch on the machine, GP 14. 1.10 Item 2.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Figure 1 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-77 03-350, 03-351, 03-354
03-359, 03-407 HCF Communications and Detection Error Procedure
RAP 1. Ensure the P/Js on the tray 1 and 2 control PWB, PL 7.10 Item 2 and the HCF PWB, PL
7.20 Item 2 are correctly and securely connected.
03-359 The HCF has failed to respond to tray 1 and 2 control PWB ping requests.
2. Go to Flag 1. Check the harness. Repair as necessary, GP 7.
03-407 The system has failed to detect the HCF module at power on. 3. Go to Flag 1. Check the power supply lines. Refer to:
• 01G +24V Distribution RAP.
Initial Actions • 01E +5V Distribution RAP.
WARNING • 01B 0V Distribution RAP.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the 4. Go to Flag 2. Check for the presence of pulses on the two data lines, using the AC volts
customer supply while performing tasks that do not need electricity. Electricity can range of the meter.
cause death or injury. Moving parts can cause injury.
NOTE: Pulses should be measured approximately every 20 seconds. Between pulses,
• Switch off the machine, then switch on the machine, GP 14. the voltage should be approximately 1.5VAC.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
5. As necessary, install new components:
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.
• HCF control PWB, PL 7.20 Item 2.
6. Reload the software, GP 4, Machine Software.

Figure 1 Circuit diagram

Status Indicator RAPs February 2010

03-359, 03-407 2-78 Xerox WorkCentre 5790 Family
03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error 4. OCT Only. If the problem persists install a new OCT, PL 12.10 Item 2.
5. 1K LCSS Only. Perform the following:
RAP
• Go to the 11C-120 1K LCSS Power Distribution RAP. Check the +5V and +24V sup-
03-360 The IOT to output device communications have failed.
ply from the power supply module to the 1K LCSS PWB. Ensure that the voltages
are steady.
03-408 The IOT has failed to detect the OCT at power on.
• Ensure that there is a good ground continuity between the power supply module, PL
11.124 Item 2 and the 1K LCSS frame.
03-410 The system failed to detect the output device at power on.
• Install new components as necessary:
03-418 The system has detected that the output device software is not compatible with the – Power supply module, PL 11.124 Item 2.
image processing software. – 1K LCSS PWB, PL 11.124 Item 1.
6. 2K LCSS Only. Perform the following:
Initial Actions • Remove fuse F1 from the 2K LCSS PWB. Check the fuse. If the fuse is good, re-
WARNING install the fuse. If fuse F1 is blown, install a new 2K LCSS PWB, PL 11.26 Item 1.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the • Go to the 11D-110 2K LCSS Power Distribution RAP. Check the +5V and +24V sup-
customer supply while performing tasks that do not need electricity. Electricity can ply from the power supply module to the 2K LCSS PWB. Ensure that the voltages
cause death or injury. Moving parts can cause injury. are steady.
• 1K LCSS Only. Un-dock the 1K LCSS from the machine, refer to REP 11.11-120 1K • Ensure that there is a good ground continuity between the power supply module, PL
LCSS Removal. Check that the docking actuator, PL 11.102 Item 7 is correctly installed. 11.26 Item 2 and the 2K LCSS frame.
• 2K LCSS Only. Perform REP 11.13-110 LCSS Un-docking. Check that the docking actu- • Install new components as necessary:
ator, PL 11.4 Item 7 is correctly installed. – Power supply module, PL 11.26 Item 2.
• HVF and HVF BM Only. Perform 11-300-171, 11-302-171, 11-303-171, HVF Un-docking – 2K LCSS PWB, PL 11.26 Item 1
RAP. Check that the docking actuator, PL 11.130 Item 17, is correctly installed.
7. HVF and HVF BM Only. Perform the following:
• Switch off the machine, then switch on the machine, GP 14.
• Go to the 11A-171 HVF Power Distribution RAP. Check the +5V and +24V supply
• Ensure the output device power cord is connected to PJ22 on the Power and Control from the power supply module to the HVF PWB. Ensure that the voltages are steady.
Module.
• Ensure that there is a good ground continuity between the power supply module, PL
• Check the fault history file for other 03-XXX fault codes. If the 03-XXX fault codes occur 11.157 Item 1 and the HVF frame.
randomly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP. • Install new components as necessary:
– Communications cable, PL 11.157.
Procedure – Power supply module, PL 11.157 Item 1.
CAUTION 8. If the correct output device is not detected, go to Flag 3. Check that the voltages on the
Do not connect the output device power cord directly to the AC wall outlet. The output device device ID lines are correct according to the table in Figure 1. Install new components as
cannot operate without the machine. The machine controls the distribution of electricity to the necessary:
output device for correct power on and power off sequencing.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
NOTE: No parts of the OCT are spared. Where necessary, install a new OCT, PL 12.10 Item 2. 1.10 Item 2.
• 1K LCSS PWB, PL 11.124 Item 1.
NOTE: Figure 1 and Figure 2 show the external connections to the output devices.
• 2K LCSS PWB, PL 11.26 Item 1.
1. As necessary, ensure that the connectors that follow are correctly and securely con- • HVF PWB, PL 11.157 Item 2.
nected: • OCT, PL 12.10 Item 2.
• OCT Only. P/J495 on the OCT PWB, P/J151 on the Power and Control Module and
P/J11 on the IOT PWB.
• 1K LCSS Only. P/J3 on the 1K LCSS PWB, P/J151 on the Power and Control Mod-
ule and P/J11 on the IOT PWB.
• 2K LCSS Only. P/J301 on the 2K LCSS PWB, P/J151 on the Power and Control
Module and P/J11 on the IOT PWB.
2. Go to Flag 1 and Flag 2. Check the harnesses. Repair as necessary, GP 7.
3. Perform the OF7 IOT PWB Diagnostics RAP.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-79 03-360, 03-408 to 03-410, 03-418
 Figure 1 Circuit diagram

Status Indicator RAPs February 2010

03-360, 03-408 to 03-410, 03-418 2-80 Xerox WorkCentre 5790 Family
 03-365 IOT Bus Failure RAP
03-365 The communications driver has failed.

NOTE: This fault code can occur when the driver fails because of system electrical noise.

Initial Actions
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
• Switch off the machine, then switch on the machine, GP 14.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.

Procedure
NOTE: The IOT controller should clear an I2C bus fault indication after five seconds.

1. Ensure the P/Js on the IOT PWB, PL 1.10 Item 2 are correctly seated.
2. Check that there is continuity between the upper and lower registration guide. Ensure that
the screw that secures the upper and lower registration guides is tight, Figure 1.
3. Check that there is continuity between the halo guide and the registration guide. Raise
and lower the short paper path assembly, PL 10.15, several times to ensure that the con-
tinuity is consistent. If the continuity is inconsistent, perform the following:
• Examine the registration and halo guide bias contact for deformation or damage, PL
8.15 Item 23.
• Ensure the transfer / detack harness is routed correctly at the rear of the short paper
path, refer to REP 10.1.
4. This fault may be caused by a ground fault, perform 01A Ground Distribution RAP.
5. Reload the software, GP 4 Machine Software.
6. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
2.

Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-81 03-360, 03-408 to 03-410, 03-418, 03-365
 03-366 IOT to Tray 5 Module Communication Failure RAP
03-300 The IOT PWB has detected a communications failure with the tray 5 module.
Upper registration
guide
Initial Actions
WARNING
Lower registration
guide Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Halo guide • Check the condition of P/J501 on the sleeved harness from the tray 5 module, paying
attention to the condition of the pins.
• Check that P/J501 is correctly and securely connected at the rear of the machine.

Registration and halo Procedure

guide bias contact 1. Go to Flag 1 and check the wiring. Repair the wiring as necessary, GP 7.
2. As necessary, perform the following:.
• Perform OF7 IOT Diagnostics RAP.
• Install a new tray 5 control PWB, PL 7.68 Item 8.
• Install a new IOT PWB, PL 1.10 Item 2.

Registration guides
securing screw.

Figure 1 Component Location

Status Indicator RAPs February 2010

03-365, 03-366 2-82 Xerox WorkCentre 5790 Family
 Figure 1 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-83 03-366
03-367 S2X Data Transmission Failure RAP 03-371, 03-372 Fuser and Xerographic CRUM
03-367: The single board controller PWB does not receive the S2X ready line signal within 10 Communication Error RAP
seconds of scan start. 03-371: The fuser CRUM communications have failed.

Procedure 03-372: The xerographics CRUM communications have failed.

WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Initial Actions
customer supply while performing tasks that do not need electricity. Electricity can WARNING
cause death or injury. Moving parts can cause injury.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
1. Install a new single board controller PWB, PL 3.24 Item 3. customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
• Switch off the machine, then switch on the machine, GP 14.
• Ensure the fuser module, (35-55 ppm), PL 10.8 Item 1 or (65-90 ppm), PL 10.10 Item 1 is
correctly installed.
• Ensure the xerographic module, PL 9.20 Item 2 is correctly installed.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.

Procedure
CAUTION
Remove the fuser and xerographic modules to prevent damage to the CRUMs when checking
for continuity.
1. Ensure the P/Js on the IOT PWB, PL 1.10 Item 2 and the main drive motor and PWB
assembly, (35-55 ppm) PL 4.15 Item 6 or (65-90 ppm) PL 4.10 Item 6 are correctly and
securely connected.
2. Perform OF7 IOT PWB Diagnostics RAP.
3. Switch off the machine, GP 14. Go to Flag 1. Disconnect P/J8 on the IOT PWB. Switch
on the machine, GP 14. Make a copy. Check the fault history for new occurrences of 03-
371 and 03-372 faults. If new occurrences are not listed, install a new IOT PWB, PL 1.10
Item 2.
4. Go to Flag 1. Check the harness, GP 7 and measure the voltages. As necessary, refer to:
• 01B 0V Distribution RAP.
• 01E +5V Distribution RAP.

NOTE: PJ141 and PJ144 are in-line connectors on the rear panel, (refer to Flag 2 and
Flag 3). They are connected when the module is installed and are susceptible to damage.
Remove any torn paper / debris from the contacts.

5. 03-371 Only: Go to Flag 2. Check the harness. Remove any torn paper / debris from the
fuser CRUM connector, (35-55ppm) PL 4.17 Item 12 or (65-90ppm) PL 4.12 Item 12.
Repair as necessary, REP 1.2.
6. 03-372 Only: Go to Flag 3. Check the harness. Remove any torn paper / debris from the
xerographic CRUM connector, (35-55ppm) PL 4.17 Item 4 or (65-90) PL 4.12 Item 4.
Repair as necessary, REP 1.2.
7. Install new components as necessary:
• 03-371 Only: Fuser connector assembly, (35-55 ppm) PL 4.15 Item 9 or (65-90
ppm) PL 4.10 Item 9.

Status Indicator RAPs February 2010

03-367, 03-371, 03-372 2-84 Xerox WorkCentre 5790 Family
 • 03-371 Only: Fuser Module, (35-55 ppm) PL 10.8 Item 1 or (65-90 ppm) PL 10.10
Item 1.
• 03-372 Only: Xerographic module, PL 9.20 Item 2.
• Main drive motor PWB assembly, (35-55 ppm) PL 4.15 Item 6 or (65-90 ppm) PL
4.10 Item 6.
• Main Drive Module, (35-55 ppm) PL 4.15 Item 1 or (65-90 ppm) PL 4.10 Item 1.
8. Reload the software, GP 4 Machine Software.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-85 03-371, 03-372
 Figure 1 Circuit diagram

Status Indicator RAPs February 2010

03-371, 03-372 2-86 Xerox WorkCentre 5790 Family
 A
03-374 Power Off Failure RAP Go to Flag 2. Measure the voltage at P/J1 pin 15 on the IOT PWB. Operate the on / off switch.
A single low pulse is detected.
03-374 The single board controller PWB has detected that the LVPS is still on, 30 seconds
Y N
after a power off request. Go to Flag 2. Check the wiring. Repair as necessary, GP 7. Install new components as
necessary:
Initial Actions • Single board controller PWB, PL 3.24 Item 3.
WARNING • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the 1.10 Item 2.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. Go to Flag 2. Set the meter to measure frequency. Check the pulses at P/J1 pin 13, on the IOT
PWB. These are approximately 1Hz pulses. The pulses have stopped.
• If possible, switch off the machine, then switch on the machine GP 14. If the UI fails to
Y N
respond, perform the 03-310 Single Board Controller PWB to UI Errors RAP.
Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran- 2.
domly, the cause may be due to electrical noise. Go to OF10 intermittent Failure RAP.
• If the drives module has recently been removed, then check the pins and connections at Perform the following:
P/J1 on the IOT PWB.
• Check that all associated wiring is in good condition, GP 7.
• Reload the software, GP 4, Machine Software.
Procedure • Install a new single board controller PWB, PL 3.24 Item 3.
Ensure the P/Js on the IOT PWB, PL 1.10 Item 2 and the single board controller PWB, PL 3.24
Item 3 are correctly and securely connected. The fault is still present.
Y N
Perform SCP 6 Final Actions.

Remove the left hand cover, PL 8.10 Item 3. Go to Flag 1. Measure the voltages at the on/off
switch terminals. The voltages are +3.3V and 0V.
Y N
Go to:
• GP 13 How to check a switch.
• P/J5.
• 01B, 0V Distribution RAP.
• 01J Power On and LVPS Control Signals RAP.
• If necessary, install a new on/off switch, PL 1.10 Item 8.

NOTE: The LVPS is software controlled. When the voltage on PJ26 is low, the LVPS should be
on. When the voltage on PJ26 pin 7 is high, the LVPS should be off.

Go to Flag 3. Measure the voltage at P/J26 pin 7 on the IOT PWB. Operate the on / off switch.
Select power down then confirm from the UI. The voltage changes from low to high within
30 seconds.
Y N
Install new components as required:
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
• Single board controller PWB, PL 3.24 Item 3.

Check the state of the LVPS by observing the power indication LEDs on the IOT PWB, (refer to
the OF7 IOT PWB Diagnostics RAP). The LVPS has switched off.
Y N
Install a LVPS and base module, PL 1.10 Item 3.

A
February 2010 Status Indicator RAPs
Xerox WorkCentre 5790 Family 2-87 03-374
 Figure 1 Circuit diagram

Status Indicator RAPs February 2010

03-374 2-88 Xerox WorkCentre 5790 Family
03-395, 396, 852, 853 IOT PWB Fault RAP • LVPS and base module, PL 1.10 Item 3.

03-395 The IOT has cycled without printing.

03-396 The photoreceptor is detected not turning while the laser is on.

03-852 IOT has detected that it is out of timers.

03-853 IOT has detected that it is nearly out of timers.

Also use this RAP for fault code 06-350 ROS Laser Not Under Control.

Initial Actions
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
• Switch off the machine, then switch on the machine, GP 14.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to the OF10 intermittent Failure RAP.

Procedure
1. Ensure all the P/Js on the IOT PWB, PL 1.10 Item 2 are correctly and securely con-
nected.
2. 03-395 Only: This fault can be caused by a poor ground on the duplex tray or a paper
path problem. Check the active fault list for an 08-XXX or 09-XXX. Go to the indicated
RAP.
3. 03-395 Only: This fault can also be caused by a paper guide in a paper tray being set to
the wrong paper size. Check the paper guide settings in the paper trays.
4. Perform the OF7 IOT PWB Diagnostics RAP.
5. Reload the software set, GP 4, Machine Software.

NOTE: The supply harness is a flying lead that is a part of the LVPS and is not spared
separately.

6. Go to Flag 1. Check the voltages. As necessary, refer to:

• 01G +24V Distribution RAP.
• 01F +12V Distribution RAP.
• 01E +5V Distribution RAP.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP. Figure 1 Circuit diagram
7. 03-853 Only: Print off a fault history report then troubleshoot any codes that coincide with
the 03-853 fault, refer to SCP 1.
8. 03-396 Only: If necessary, go to the 04A Main Drive Motor and Photoreceptor Motor RAP.
Perform the photoreceptor motor checkout.
9. As necessary, install new components:
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-89 03-395, 396, 852, 853
03-397 Main Motor Not Controlled RAP
03-397 The IOT software has detected that the main motor is not being controlled. The soft-
ware that monitors the main motor and the photoreceptor motor was not reset within the
expected time.

Initial Actions
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
• Switch off the machine, then switch on the machine, GP 14.
• Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to the OF10 intermittent Failure RAP.

Procedure
Ensure that the connectors that follow are securely connected:
• IOT PWB, PL 1.10 Item 2.
• LVPS and base module, PL 1.10 Item 3.
• Main drive motor and PWB, (35-55 ppm) PL 4.15 Item 6 or (65-90 ppm) PL 4.10 Item 6.
The fault is still present.
Y N
Perform SCP 6 Final Actions.

Go to Flag 1 and Flag 2. Check the wiring, GP 7. The wiring is good.

Y N
Repair the wiring, GP 7.

Go to Flag 1. Check the voltages at P/J16, pins 1 and 2 on the LVPS. The voltages are cor-
rect.
Y N
As necessary, refer to:
• 01B 0V Distribution RAP.
• 01G +24V Distribution RAP.

Go to Flag 2. Measure the voltage at P/J3 pin 3, on the IOT PWB. Enter dC330 code 04-010,
Main Motor On. Stack the photoreceptor motor code, 09-010. The voltage changes from
high to low and the main motor runs.
Y N
Perform the OF7 IOT PWB Diagnostics RAP. If necessary, install new components:
• IOT PWB, PL 1.10 Item 2.
• Main drive motor and PWB, (35-55 ppm) PL 4.15 Item 6 or (65-90 ppm) PL 4.10 Item
6.

Reload the software, GP 4, Machine Software. If necessary, install new components:

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

Status Indicator RAPs February 2010

03-397 2-90 Xerox WorkCentre 5790 Family
 Figure 1 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-91 03-397
03-401, 03-403 Fax Not Detected RAP 03-412 Foreign Device PWB Fault RAP
03-401 The embedded fax PWB has not been detected or confirmed. 03-412 The foreign interface device was not detected at power on.

03-403 The extended fax PWB has not been confirmed or detected. Initial Actions
WARNING
Procedure
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
WARNING customer supply while performing tasks that do not need electricity. Electricity can
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the cause death or injury. Moving parts can cause injury.
customer supply while performing tasks that do not need electricity. Electricity can CAUTION
cause death or injury. Moving parts can cause injury. Do not show the customer how to install a temporary shorting link. Do not leave a shorting link
Switch off the machine, then switch on the machine, GP 14. installed.
• Switch off the machine, then switch on the machine, GP 14.
Perform the following:
• Ensure the foreign interface PWB, PL 3.22 Item 4 is securely connected to the single
1. Check that the embedded fax PWB has been installed, PL 20.10 Item 4.
board controller PWB, PL 3.24 Item 3.
2. (W/O TAG X-001) Check that the compact flash is inserted correctly, PL 20.10 Item 3.
NOTE: Do not attach a foreign interface vend adaptor with this configuration of foreign inter-
3. Go to 20G Embedded Fax Checkout.
face PWB.
4. Install a new embedded fax PWB, PL 20.10 Item 4.
Repeat the above checks for the extended fax PWB, and if necessary, install a new extended Procedure
fax PWB, PL 20.10 Item 2. USSG/XCL only, check the operation of the foreign interface device using a foreign interface
test tool (PL 26.10 Item 22) in conjunction with the 7655/65/75 indicator/instruction chart. If a
foreign interface test tool is not available/suitable, perform the procedure that follows:
Go to Flag 1. Check the harness. The harness is good.
Y N
Perform the following as necessary:
• Repair the harness. Refer to GP 7.
• Install a new foreign interface harness, PL 3.22 Item 5.

NOTE: Do not attempt to repair the harness from PJ124 to the foreign device.

Check the +3.3V supply to P/J201at pins 1, 5, 9, 16 and 22 on the single board controller
PWB, The +3.3V supply is good.
Y N
Go to:
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP.

Disconnect the foreign device. Install a temporary shorting link between pins 2 and 3 on P/
J124. Check the voltage at PJ124 pin 2. 0V is measured.
Y N
Install a new foreign interface PWB, PL 3.22 Item 4.
If the fault remains, the foreign device is faulty.

Disconnect the foreign device. Install a temporary shorting link between pins 1 and 3 on P/
J124. Check the display. Ensure the machine is now enabled to scan or print. The machine
is enabled.
Y N
Install new components as necessary:
• Install a new foreign interface PWB, PL 3.22 Item 4.
• Single board controller PWB, PL 3.24 Item 3.
A
Status Indicator RAPs February 2010
03-401, 03-403, 03-412 2-92 Xerox WorkCentre 5790 Family
A
The enable circuits are working correctly.

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

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-93 03-412
 Figure 1 Circuit diagram

Status Indicator RAPs February 2010

03-412 2-94 Xerox WorkCentre 5790 Family
03-415 Tray 5 Module Not Detected / Confirmed RAP
03-415 The IOT PWB has not detected the tray 5 module at startup, or has failed to detect the
tray 5 module during printing.

Initial Actions
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
• Check that the sleeved harness from the tray 5 module is correctly and securely con-
nected to PJ501 at the rear of the machine.

Procedure
Switch off the machine, GP 14. Go to Flag 1. Check that there is continuity between P/J12,
pins 3 and 4. There is continuity.
Y N
Perform the following:
• Check the wiring between P/J12 and P/J501. Repair the wiring as necessary, GP 7.
• Check the wiring between P/J501and P/J512 on the Tray 5 control PWB. Repair
the wiring as necessary, GP 7.
• Check the condition of P/J501, paying attention to the condition of the pins. Repair
the wiring as necessary, GP 7.
• Check the loop between pins 19 and 20 on P/J501. Repair the wiring as necessary,
GP 7.

Switch on the machine, GP 14. With P/J501 disconnected, check for +3.3V at P/J12, pin 3.
Check for 0V at P/J12, pin 4.
As necessary, perform the following:
• Go to 01D +3.3V Distribution RAP.
• Go to 01B 0V Distribution RAP.
• Perform OF7 IOT PWB Diagnostics RAP before installing a new IOT PWB, PL 1.10 Item
2.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-95 03-415
 Figure 1 Circuit diagram

Status Indicator RAPs February 2010

03-415 2-96 Xerox WorkCentre 5790 Family
03-417 Incompatible Fax Software RAP 03-419, 03-420 Incompatible Software RAP
03-417 The Fax software version supplied at power up is not compatible with the image pro- 03-419 The IOT, DADH or user interface software version supplied at power on is not compati-
cessing software. ble with the image processing software.

Procedure 03-420 The tray 5 module software version supplied at power on is not compatible with the
image processing software.
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Procedure
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. WARNING
1. Switch off the machine, then switch on the machine, GP 14. Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
2. Reload the software, GP 4.
cause death or injury. Moving parts can cause injury.
3. Install a new embedded fax PWB, PL 20.10 Item 4.
1. Switch off the machine, then switch on the machine, GP 14.
2. Reload the software, GP 4 Machine Software.
3. Install new parts as necessary:
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
• DADH PWB, PL 5.10 Item 5.
• UI control PWB, PL 2.10 Item 11.
• Single board controller PWB, PL 3.24 Item 3.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-97 03-417, 03-419, 03-420
03-423, 424, 433, 434, 821, 822, 831, 832 Print Command 03-480 IOT +24V Supply Failure RAP
Late RAP 03-480 The IOT has detected a +24V supply fault.
03-423 The IOT detected print command late with respect to page sync in simplex 3 mode.
Initial Actions
03-424The IOT detected print command late with respect to page sync in simplex 4 mode. Measure the voltage from F1 fuse on the IOT PWB to the machine frame. The F1 is a small
white fuse under PJ27 on the IOT PWB. Refer to 01G +24V Distribution RAP, Figure 4. If the
03-433 The IOT detected print command late with respect to page sync in duplex 3 mode. voltage is less than +24V, install a new LVPS, PL 1.10 Item 3.

03-434 The IOT detected print command late with respect to page sync in duplex 4 mode. Procedure
1. Perform the OF7 IOT PWB Diagnostics RAP.
03-821 The IOT detected print command late with respect to page sync in simplex 1 mode.

03-822 The IOT detected print command late with respect to page sync in simplex 2 mode.

03-831 The IOT detected print command late with respect to page sync in duplex 1 mode.

03-832 The IOT detected print command late with respect to page sync in duplex 2 mode.

Procedure
These codes record events in the fault history file, but do not prevent the machine operating
normally. These faults will also result in a blank sheet being delivered to the output tray.

Delete the job and switch off the machine, then switch on the machine, GP 14. If the fault is still
present, go to the 06-340 ROS Laser Failure RAP.

Status Indicator RAPs February 2010

03-423, 424, 433, 434, 821, 822, 831, 832, 03-480 2-98 Xerox WorkCentre 5790 Family
03-700, 03-780, 03-785, 03-790 Power On / Power Off Event 03-720 ODIO Timeout Error RAP
Fault RAP 03-720 The image processing software has not detected on ODIO (On Demand Image Over-
03-700 This fault code in the fault history file indicates that the single board controller PWB write) completion response within 45 minutes. This indicates that a memory module may be
hung up, or may have crashed while overwriting an image.
module has performed the power on sequence.

03-780 This fault code in the fault history file indicates that quick restart has been selected Initial Actions
from the power down options pop up window. WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
03-785 This fault code in the fault history file indicates that power off has been selected from
customer supply while performing tasks that do not need electricity. Electricity can
the power down options pop up window.
cause death or injury. Moving parts can cause injury.

03-790 This fault code in the fault history file indicates that power off has been selected from • Switch off the machine, then switch on the machine, GP 14.
the machine fault pop up window.
Procedure
Procedure When the response time has been exceeded, the system records the event with this fault code
These codes record events in the fault history file, but do not prevent the machine operating and then returns the machine to normal operation. If the machine is not operating normally,
normally. They will be visible in the fault history file adjacent to the fault that caused the user to perform the following:
switch off the machine, then switch on the machine. They can therefore be used as an aid to 1. Check the Fax confirmation report and the ODIO confirmation report to establish which
identifying the root cause of faults. memory module is not overwriting.
2. Install new parts as necessary:
• (W/O TAG X-001) Fax compact flash memory, PL 20.10 Item 3.
• (W/TAG X-001) Embedded fax PWB, PL 20.10 Item 4.
• Hard disk drive, PL 3.22 Item 2.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-99 03-700, 03-780, 03-785, 03-790, 03-720
03-770 IOT PWB Software Reset RAP 03-777 Power Loss Detected RAP
03-770 This fault code in the fault history file indicates that the IOT PWB has been reset due to 03-777 This fault code in the fault history file indicates that the system has previously detected
a software fault. a power input loss.

Procedure Procedure
This code records an event in the fault history file, but does not prevent the machine operating 1. Check with the customer that the AC mains (line) input power supply is not experiencing
normally. interruptions.
2. Check with the customer that the machine does not share a power supply with any other
equipment. Sharing a power supply may cause the safety over current device to switch off
the electricity to the machine. This would cause a 03-777 fault. If possible, ensure the
machine is connected to a dedicated power supply.
3. Go to the 01C AC Power RAP and check the power input circuit and its connectors.
4. Check the fault history file for other 03-xxx fault codes. If the 03-xxx fault codes occur ran-
domly, the cause may be due to electrical noise. Go to the OF10 intermittent Failure RAP.

Status Indicator RAPs February 2010

03-770, 03-777 2-100 Xerox WorkCentre 5790 Family
03A Single Board Controller PWB Module Cooling Fan 03B Mark Service Unavailable RAP
Failure RAP Before performing this RAP, any relevant status code RAP must have been performed.
Use this RAP if the single board controller PWB module cooling fan is suspected of failure.
Initial Actions
Procedure WARNING
WARNING Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. • Switch off the machine, then switch on the machine, GP 14.
CAUTION
Note the orientation of the cooling fan, PL 3.24 Item 2 before installing a new component. Procedure
1. Go to Flag 1. Check the cooling fan in the single board controller PWB module. Refer to: 1. Switch off the power, disconnect the power cord and ensure the P/Js are properly
installed on the IOT PWB, PL 1.10 Item 2 and single board controller PWB, PL 3.24 Item
• GP 10, How to Check a Motor.
3.
• P/J221 on the Single Board Controller PWB.
2. Reload the software, GP 4, Machine Software.
• 01F, +12V Distribution RAP.
3. Ensure that the output device communications cord is connected and secure, at PJ151 on
• 01B, 0V Distribution RAP. the Power and Control Module at the rear of the machine.
2. If necessary, install new components: 4. Install new components:
• Cooling fan, PL 3.24 Item 2. • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
• Single board controller PWB, PL 3.24 Item 3. 1.10 Item 2.
• Single board controller PWB, PL 3.24 Item 3.

Figure 1 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-101 03A, 03B
03C Hard Disk Failure RAP 03D FTP/SMB Scan to File Failure RAP
Use this RAP to determine failure of the hard dIsk drive. Use this RAP when the customer reports failure to connect to the scan server when using the
FTP or SMB protocols, or when a folder on the scan server cannot be opened.
Initial Actions
Perform the Boot Up Failure RAP OF5. Procedure
Consult your manager before troubleshooting the customer’s network, as the policy varies
Procedure according to region.

WARNING [Go to Troubleshooting the FTP & SMB Protocols to Scan to File]. The CD must be in the CD
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord drive for this link to start.
from the customer supply while performing tasks that do not need electricity. Electricity
can cause death or injury. Moving parts can cause injury.
1. Switch off the machine GP 14.
2. Go to Wiring Diagram 4, check the wiring between the hard disk drive, power distribution
PWB and single board controller PWB, GP 7.
3. Repair the wiring or install a new harness where necessary.
4. Check for +5V distribution, RAP 01E.
5. Check for +12V distribution, RAP 01F.
6. If necessary, install new components:
• Hard disk drive, PL 3.22 Item 2.
• Power distribution PWB, PL 3.24 Item 5.
• Single board controller PWB, PL 3.24 Item 3.

Status Indicator RAPs February 2010

03C, 03D 2-102 Xerox WorkCentre 5790 Family
04A Main Drive Motor and Photoreceptor Motor RAP • Main drive motor and PWB assembly (40- 55 ppm), PL 4.15 Item 6.
• Main drive motor and PWB assembly (65 - 90 ppm), PL 4.10 Item 6.
Use this RAP to determine failures of the main drive motor and the photoreceptor motor.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
Procedure 2.

WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Go to Flag 1. Check for +24V between P/J147 pin 1 and pin 2 on the Main Drive PWB. +24V
is measured.
Y N
Ensure that the drum cartridge is correctly installed and that the CRUM connector is not
damaged.
Check the wiring, GP 7, to the LVPS. Refer to:
• 01H Short Circuits and Overloads RAP.
• 01B 0V Distribution RAP.

Enter dC330, code 04-010 main drive motor and code 09-010 photoreceptor motor, Figure 1.
Press Start. The main drive motor and the photoreceptor motor turn.
Y N
If the photoreceptor motor does not turn, go to the 04A Photoreceptor Motor Checkout. If Photoreceptor
the main drive motor does not turn, go to the 04A Main Drive Motor Checkout. motor

Check all the wiring and connections between the IOT PWB and the main drive module for
damage and loose connections.

04A Photoreceptor Motor Checkout

Go to Flag 3 and Flag 4. Check the wiring, GP 7. Refer to:
• P/J3, IOT PWB.
• P/J148, Main Drive PWB.
• P/J151, Main Drive PWB.
Install new components as necessary:
• Main drive motor and PWB assembly (35 ppm), PL 4.15 Item 6.
• Main drive motor and PWB assembly (40-55 ppm), PL 4.15 Item 6.
• Main drive motor and PWB assembly (65-90 ppm), PL 4.10 Item 6.
• Main drive module (35 ppm), PL 4.15 Item 1.
• Main drive module (40-55 ppm), PL 4.15 Item 1.
• Main drive module (65-90 ppm), PL 4.10 Item 1. Main drive motor
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
2.
04A Main Drive Motor Checkout
Go to Flag 2. Check the wiring, GP 7. Refer to: Figure 1 Component location
• P/J3, IOT PWB
• P/J148, Main Drive PWB.
Install new components as necessary:
• Main drive motor and PWB assembly (35 ppm), PL 4.15 Item 6.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-103 04A
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

04A 2-104 Xerox WorkCentre 5790 Family
05-300 DADH Open RAP
05-300 The DADH closed switch detects that the DADH is open during run.

Initial Actions
Check that the DADH magnet is installed and aligned correctly. Refer to Figure 1.

Procedure
DADH closed
WARNING switch
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Magnet S05-300
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.

NOTE: (W/O TAG 150) To get access to the bulkhead connector, remove the user interface
assembly, PL 2.10 Item 1. To get access to the DADH closed switch, remove the top cover, PL
14.20 Item 3, from the scanner module. To get access to the scanner PWB, remove the docu- Bulkhead
ment glass, PL 14.20 Item 5 and the scanner PWB cover, PL 14.25 Item 1. connector

NOTE: (W/TAG 150) To get access to the bulkhead connector, remove the user interface
assembly, PL 2.10 Item 1. To get access to the DADH closed switch, remove the top cover, PL
14.10 Item 3, from the scanner module. To get access to the scanner PWB, remove the docu-
ment glass, PL 14.10 Item 5 and the scanner PWB cover PL 14.15 Item 1.
Figure 1 Component location
Enter dC330 code 05-300 to check the DADH closed switch, S05-300. Open and close the
DADH. The display changes.
Y N
Go to Flag 1. Check S05-300.
References:
• GP 13 How to Check a Switch.
• (W/O TAG 150) P/J453 and the bulkhead connector.
• (W/TAG 150) P/J927 and the bulkhead connector.
• 01D +3.3V Distribution RAP.
• The 3.3V return in the 01B 0V Distribution RAP.
Install new components as necessary:
• DADH closed switch (W/O TAG 150), PL 14.25 Item 6.
• DADH closed switch (W/TAG 150), PL 14.15 Item 6.
• Scanner PWB (W/O TAG 150), PL 14.25 Item 4.
• Scanner PWB (W/TAG 150), PL 14.15 Item 4.

Perform the steps that follow. Install new components as necessary:

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

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-105 05-300
 05-305 DADH Top Cover Open RAP
05-305 The DADH top cover interlock switch detects that the top cover is open.

Initial Actions
• Remove all documents from the DADH.
• Check the top cover interlock actuator, Figure 1. If the actuator is damaged, install a new
DADH top cover, PL 5.20 Item 15.
• Make sure the latch springs, PL 5.20 Item 7 are installed correctly. Make sure that the top
cover closes correctly. If necessary, install a new top access cover assembly, PL 5.20
Item 17.

Procedure
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Enter dC330 code 05-305 to check the DADH top cover interlock switch, S05-305. Activate
S05-305. The display changes.
Y N
Go to Flag 1. Check S05-305.
References:
• GP 13 How to Check a Switch.
• P/J187, DADH PWB.
• 01G +24V Distribution RAP.
• The 24V return in the 01B 0V Distribution RAP.
Install new components as necessary:
• DADH top cover interlock switch (35 ppm), PL 5.15 Item 11.
Figure 2 Circuit diagram
• DADH top cover interlock switch (40-90 ppm), PL 5.17 Item 11.
• DADH PWB, PL 5.10 Item 5.

Check that S05-305 is installed correctly. Install new components as necessary.

Status Indicator RAPs February 2010

05-300, 05-305 2-106 Xerox WorkCentre 5790 Family
 Actuator

Figure 2 Circuit diagram

DADH top cover interlock switch

S05-305

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-107 05-305
05-310 Document too Short RAP 05-330, 05-331 DADH Feed Sensor Failure Entry RAP
05-310 The DADH detects a document that is shorter than 110mm. 05-330 The DADH feed sensor does not detect the lead edge of the document within the cor-
rect time after the feed motor runs.
Initial Actions
05-331 The DADH feed sensor does not detect the trail edge of the document within the cor-
• Remove all documents from the DADH.
rect time.
• Make sure that the documents are longer than 110 mm (4.3 inches).
• Check for toner contamination on and in the locality of the feed sensor Q05-330, PL 5.17 Procedure
Item 2.
WARNING
Procedure Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
If the documents are longer than 110mm, go to the procedures that follow:
cause death or injury. Moving parts can cause injury.
• 05-330, 05-331 DADH Feed Sensor Failure Entry RAP.
Identify the speed of the machine, refer to SCP 7 Machine Features. Perform one of the steps
• 05-335 DADH Takeaway Sensor Failure RAP. that follow:
• 05-350, 05-352 DADH CVT Sensor Failure RAP. • If the speed of the machine is 35 ppm, go to the 05-330A, 05-331A DADH Feed Sensor
• 05-340 DADH Registration Sensor Failure RAP. Failure RAP (35 ppm).
• If the speed of the machine is 40-90 ppm, go to the 05-330B, 05-331B DADH Feed Sen-
sor Failure RAP (40-90 ppm).

Status Indicator RAPs February 2010

05-310, 05-330, 05-331 2-108 Xerox WorkCentre 5790 Family
 A
05-330A, 05-331A DADH Feed Sensor Failure RAP (35 Enter dC330 code 05-020 to run the DADH feed motor, MOT05-020. MOT05-020 runs.
Y N
ppm) Go to the 05D DADH Motor Failure RAP.
Initial Actions
While MOT 05-020 runs, stack the code 05-025 to energize the DADH feed clutch, CL05-025.
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 05-
330, 05-331 DADH Feed Sensor Failure Entry RAP. NOTE: The feed clutch disengages after 30 seconds. The feed motor stops after 3 minutes.
• Remove all documents from the DADH.
CL05-025 energizes, the nudger rolls and the feed rolls rotate.
• Make sure that the customer is not using damaged documents. If the DADH damages the
Y N
documents, go to the 05F Damaged Documents RAP.
Perform the steps that follow:
• Figure 1. Make sure that the feed sensor actuator is not damaged. If necessary, install a
• Go to the 05E DADH Feed Clutch Failure RAP and check CL05-025.
new feed sensor, PL 5.15 Item 2.
• ADJ 5.1, DADH Drive Belt Adjustment.
• Figure 1. Check that the feed roll assembly is installed correctly, go to REP 5.14.
• Figure 1. Make sure that the feed rolls are clean and rotate freely, refer to ADJ 5.4. If nec- Enter dC330 code 05-010 to energize the DADH feed solenoid, SOL05-010. The feed roll
essary, install a new feed roll assembly, PL 5.15 Item 1 or feed roll assembly cover, PL assembly lowers, then raises after 10 seconds.
5.15 Item 21. Y N
• Figure 2. Check the operation of the feed yoke. Make sure that the feed yoke shaft is Go to Flag 2. Check SOL05-010.
under the clip. Make sure that the feed yoke spring is connected to the feed assembly and References:
to the feed yoke. • GP 12 How to Check a Solenoid or Clutch.
• While the DADH feed solenoid is de-energized, make sure that the feed gates are locked • P/J183, DADH PWB and P/J201.
in the down position. Manually activate the DADH feed solenoid then make sure that the
• 01G +24V Distribution RAP.
feed gates move freely. Manually de-activate the DADH feed solenoid, PL 5.15 Item 5.
• The 24V return in the 01B 0V Distribution RAP.
NOTE: The feed solenoid remains activated (after being energized) until the last docu- Install new components as necessary:
ment has been fed. Then a reverse pulse de-actuates the armature to lift the nudger roll.
• DADH feed solenoid, PL 5.15 Item 5.
• Check the location of the feed solenoid spring. Make sure the spring is correctly located • DADH feed assembly, PL 5.15 Item 18.
on the solenoid armature. • DADH PWB, PL 5.10 Item 5.
• Clean the DADH feed sensor and the area around the sensor, PL 5.15 Item 2.
• Clean the takeaway rolls, PL 5.35 Item 6. Refer to ADJ 5.4. Perform the steps that follow:
• Check that the DADH feed sensor, Q05-330 is installed correctly. If necessary, install a
Procedure new feed roll assembly, PL 5.15 Item 1.
• Ensure the feed motor drive belt and CVT motor drive belt are tensioned correctly, ADJ
WARNING 5.1.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the • When large documents are fed (A3 or 11x17 inch), check the following:
customer supply while performing tasks that do not need electricity. Electricity can
– The CVT motor rotates freely, refer to 05D DADH Motor Failure RAP
cause death or injury. Moving parts can cause injury.
– The CVT drive belt, refer to ADJ 5.1 DADH Drive Belt Adjustment.
Open the DADH top cover. Remove the DADH rear cover, PL 5.10 Item 1. Hold the top cover
interlock switch closed. Enter dC330 code 05-330 to check the DADH feed sensor, Q05-330. – That the CVT roll is clean and rotates freely, refer to ADJ 5.4.
Activate Q05-330. The display changes.
NOTE: If necessary install a new CVT motor, PL 5.25 Item 9.
Y N
Go to Flag 1. Check Q05-330. • Go to the 05E DADH Feed Clutch Failure RAP and check CL05-025.
References: • Make sure that the size of the documents are sensed correctly. Refer to the 05C Docu-
• GP 11 How to Check a Sensor. ment Size Sensor Failure RAP.
• P/J184 DADH PWB.
• 01D +3.3V Distribution RAP.
• The 3.3V return in the 01B 0V Distribution RAP.
Install new components as necessary:
• DADH feed sensor, PL 5.15 Item 2.
• DADH PWB, PL 5.10 Item 5.
A

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-109 05-330A, 05-331A
 CVT motor MOT 05-030 Clip

Top cover interlock switch

Feed yoke and
spring
Feed motor
MOT05-020

Feed clutch
CL05-025
Feed yoke shaft

Feed gates

P/J201
Feed solenoid DADH feed sensor Feed roll assembly
SOL 05-010 Q05-330

Figure 1 Component location

Feed gates

Figure 2 Component location

Status Indicator RAPs February 2010

05-330A, 05-331A 2-110 Xerox WorkCentre 5790 Family
 05-330B, 05-331B DADH Feed Sensor Failure RAP (40-90
ppm)
Initial Actions
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 05-
330, 05-331 DADH Feed Sensor Failure Entry RAP.
• Remove all documents from the DADH.
• Make sure that the customer is not using damaged documents. If the DADH damages the
documents, go to the 05F Damaged Documents RAP.
• Figure 1. Check that the feed roll assembly is installed correctly, go to REP 5.14.
• Figure 1. Make sure that the feed rolls are clean and rotate freely, refer to ADJ 5.4. If nec-
essary, install a new feed roll assembly, PL 5.17 Item 1 or feed roll assembly cover, PL
5.17 Item 21.
• Figure 2. Check the operation of the feed yoke. Make sure that the feed yoke shaft is
under the clip. Make sure that the feed yoke spring is connected to the feed assembly and
to the feed yoke.
• Figure 2. Check that the feed yoke actuates and locks the feed gates in the down posi-
tion. If necessary install a new feed yoke, PL 5.17 Item 6.
• Clean the DADH feed sensor and the area around the sensor, PL 5.17 Item 2.
• Clean the takeaway rolls, PL 5.35 Item 6. Refer to ADJ 5.4.

Procedure
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Open the DADH top cover. Remove the DADH rear cover, PL 5.10 Item 1. Hold the top cover
Figure 3 Circuit diagram interlock switch closed. Enter dC330 code 05-330 to check the DADH feed sensor, Q05-330.
Activate Q05-330. The display changes.
Y N
Go to Flag 1. Check Q05-330.
References:
• GP 11 How to Check a Sensor.
• P/J184,DADH PWB
• 01E +5V Distribution RAP.
• The 5V return in the 01B 0V Distribution RAP.
Install new components as necessary:
• DADH feed sensor, PL 5.17 Item 2.
• DADH PWB, PL 5.10 Item 5.

Enter dC330 code 05-020 to run the DADH feed motor, MOT05-020. MOT05-020 runs.
Y N
Go to the 05D DADH Motor Failure RAP.

While MOT 05-020 runs, stack the code 05-025 to energize the DADH feed clutch, CL05-025.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-111 05-330A, 05-331A, 05-330B, 05-331B
NOTE: The feed clutch disengages after 30 seconds. The feed motor stops after 3 minutes.

CL05-025 energizes, the nudger rolls and the feed rolls rotate. CVT motor MOT 05-030
Y N
Perform the steps that follow:
Top cover interlock switch
• Go to the 05E DADH Feed Clutch Failure RAP and check CL05-025.
• ADJ 5.1 DADH Drive Belt Adjustment.
Feed motor
Enter dC330 code 05-010 to energize the DADH nudger motor, MOT05-010. MOT05-020

NOTE: 40-90 ppm machines are fitted with a nudger motor, PL 5.17 Item 5, not a feed solenoid
SOL 05-010, PL 5.15 Item 5 as installed on 35 ppm machines. The component control code Feed clutch
05-010 is used to energize both the nudger motor and feed solenoid. However, the UI displays CL05-025
the message ‘doc handler feed solenoid’ on both configurations.

The feed roll assembly lowers, then raises after 10 seconds.

Y N
Go to Flag 2. Check nudger motor, MOT05-010.
References:
• GP 10 How to Check a Motor
• P/J183, DADH PWB and P/J201.
• 01G +24V Distribution RAP.
• The 24V return in the 01B 0V Distribution RAP.
Install new components as necessary:
• DADH feed assembly, PL 5.17 Item 8.
• DADH PWB, PL 5.10 Item 5.
• If TAG D-003 has not been struck, install a shim kit, PL 5.17 Item 29.

Perform the steps that follow:

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

• Go to the 05E DADH Feed Clutch Failure RAP and check CL05-025.
Figure 1 Component location
• Make sure that the size of the documents are sensed correctly. Refer to the 05C Docu-
ment Size Sensor Failure RAP.

Status Indicator RAPs February 2010

05-330B, 05-331B 2-112 Xerox WorkCentre 5790 Family
 Clip

Feed yoke
and spring

Feed yoke shaft

Feed gates Figure 3 Circuit diagram

Feed gates

Figure 2 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-113 05-330B, 05-331B
05-335 DADH Takeaway Sensor Failure RAP • Go to the 05E DADH Feed Clutch Failure RAP and check the DADH feed clutch.
• Make sure that the takeaway roll is clean and rotates freely, refer to ADJ 5.4.
05-335 The DADH takeaway sensor does not detect the lead edge of the document within the
correct time. • Make sure that the takeaway roll idlers are clean and rotate freely, refer to ADJ 5.4.
• Check the takeaway roll static eliminator and ground harness, PL 5.35 Item 7.
Initial Actions • Make sure that the DADH ground harness is connected correctly, PL 5.10 Item 11.
• Remove all documents from the DADH. • ADJ 5.1 Feed Motor Drive Belt Adjustment.
• Figure 1. Make sure that the takeaway sensor actuator is not damaged. If necessary, Install new components as necessary:
install a new takeaway sensor, PL 5.20 Item 11. • DADH takeaway roll, PL 5.35 Item 6.
• Clean the feed rolls, refer to ADJ 5.4. If necessary, install a new feed roll assembly, (35 • DADH input tray assembly, PL 5.35 Item 1.
ppm) PL 5.15 Item 1 or (40-90 ppm) PL 5.17 Item 1. • DADH top access cover assembly, PL 5.20 Item 17.
• DADH feed assembly (35 ppm), PL 5.15 Item 18.
Procedure • DADH feed assembly (40-90 ppm), PL 5.17 Item 18.
WARNING If the fault continues, make sure that documents correctly continue past the previous sensor in
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the the document path. Refer to the 05-330, 05-331 DADH Feed Sensor Failure Entry RAP.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.

NOTE: To get access to the DADH takeaway sensor, remove the DADH top cover, PL 5.20
Item 15.

Open the DADH top cover. Enter dC330 code 05-335 to check the DADH takeaway sensor,
Q05-335, Figure 1. Activate Q05-335. The display changes.
Y N
Go to Flag 1. Check Q05-335.
References:
• GP 11 How to Check a Sensor.
• P/J186, DADH PWB and P/J191.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP. Refer to the 3.3V return.
Install new components as necessary:
• DADH takeaway sensor, PL 5.20 Item 11.
• DADH PWB, PL 5.10 Item 5.

Remove the DADH rear cover, PL 5.10 Item 1. Hold the top cover interlock switch closed.
Enter dC330 code 05-020 to run the DADH feed motor, MOT05-020. MOT05-020 runs.
Y N
Go to the 05D DADH Motor Failure RAP.

The takeaway roll rotates.

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

Perform the steps that follow:

• Check that the DADH feed sensor, Q05-335 is installed correctly.

Status Indicator RAPs February 2010

05-335 2-114 Xerox WorkCentre 5790 Family
 Takeaway roll
idlers

Feed motor tension

spring
P/J191
Top cover interlock switch

Feed motor
MOT05-020

Figure 2 Circuit diagram

Feed motor
drive belt

Feed roll assembly

DADH takeaway sensor Feed assembly

Q05-335 Takeaway roll

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-115 05-335
05-340 DADH Registration Sensor Failure RAP Y N
Go to Final Actions.
05-340 The DADH registration sensor does not detect the lead edge of the document within
the correct time. This fault can be caused by the DADH feed motor running too slowly in reverse. Refer to the
05D DADH Motor Failure RAP. If the fault continues, go to Final Actions.
Initial Actions Final Actions
• Remove all documents from the DADH.
Perform the steps that follow:
• Figure 1. Make sure that the registration sensor actuator is not damaged. If necessary,
• Check that Q05-340 is installed correctly.
install a new registration sensor, PL 5.25 Item 1.
• Make sure that the CVT idler rolls are clean and rotate freely, refer to ADJ 5.4.
• Remove the DADH top cover assembly, PL 5.20 Item 16. Make sure the harnesses are
• Make sure that the CVT roll is clean, refer to ADJ 5.4.
routed correctly and away from the document path, Figure 1.
• Make sure the feed motor drive belt and the CVT motor drive belt are tensioned correctly,
• Clean the takeaway rolls, PL 5.35 Item 6. Refer to ADJ 5.4.
ADJ 5.1.
Install new components as necessary:
Procedure
• DADH CVT roll, PL 5.25 Item 5.
WARNING • DADH top access cover assembly, PL 5.20 Item 17.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
If the fault continues, make sure that documents correctly exit the previous sensor in the docu-
customer supply while performing tasks that do not need electricity. Electricity can ment path. Refer to the 05-350, 05-352 DADH CVT Sensor Failure RAP.
cause death or injury. Moving parts can cause injury.

NOTE: To access the DADH registration sensor, remove the DADH top cover, PL 5.20 Item 15.

Open the top access cover assembly. Enter dC330 code 05-340 to check the DADH registra- Ground harness
tion sensor, Q05-340, Figure 2. Activate Q05-340. The display changes.
Y N
Go to Flag 1. Check Q05-340.
References:
• GP 11 How to Check a Sensor.
• P/J186, DADH PWB
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 3.3V return.
Install new components as necessary:
• DADH registration sensor, PL 5.25 Item 1.
• DADH PWB, PL 5.10 Item 5.

Remove the DADH rear cover, PL 5.10 Item 1. Hold the top cover interlock switch closed.
Enter dC330 code 05-030 to check the DADH CVT motor, MOT05-030. MOT05-030 runs.
Y N
Go to the 05D DADH Motor Failure RAP.
DADH registration sensor
Q05-340
The CVT roll rotates.
Y N
Perform the steps that follow:
• Check the CVT motor drive belt, PL 5.25 Item 11. Sensor harnesses
• Check the CVT motor tension spring. Make sure that the CVT motor drive belt ten-
sion is correct, ADJ 5.1.
• Check the CVT roll pulley, refer to GP 7.
If necessary, install a new DADH CVT roll, PL 5.25 Item 5.
Figure 1 Component location
The fault only occurs in duplex mode.

Status Indicator RAPs February 2010

05-340 2-116 Xerox WorkCentre 5790 Family
 DADH registration
sensor Q05-340
CVT motor tension spring

CVT motor MOT05-030

CVT motor drive belt

Top cover interlock

switch

Feed motor
MOT05-020

Figure 3 Circuit diagram

CVT roll

Figure 2 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-117 05-340
 A
05-345, 05-346 DADH Exit Sensor Failure RAP • Check the CVT motor tension spring. Check the CVT motor drive belt tension, ADJ
5.1.
05-345 The DADH exit sensor does not detect the lead edge of the document within the correct
• Check the CVT roll pulley, refer to GP 7.
time in the forward mode.
If necessary, install a new DADH CVT roll, PL 5.25 Item 5.
05-346 The DADH exit sensor does not detect the trail edge of the document within the correct
time in the forward mode. NOTE: The exit roll idlers remain lowered for 30 seconds.

Enter dC330 code 05-050 to energize the DADH duplex solenoid, SOL05-050, to lower the exit
Initial Actions roll idlers Figure 3. The exit roll idlers lower.
• Remove all documents from the DADH exit tray. Raise the DADH, remove all documents Y N
that are wound around the CVT roll. Perform the steps that follow:
• Figure 1. Make sure that the exit sensor actuator is not damaged. If necessary, install a • Go to Flag 2. Check SOL050-050.
new exit sensor, PL 5.30 Item 2. References:
• Make sure that the customer has set the document width guides correctly. – GP 12 How to Check a Solenoid or Clutch.
– P/J181, DADH PWB and P/J205.
Procedure – 01D +3.3V Distribution RAP.
WARNING – 01B 0V Distribution RAP, refer to the 3.3V return.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the • Check the baffle assembly link arm, PL 5.30 Item 13. Make sure that the link arm is
customer supply while performing tasks that do not need electricity. Electricity can connected correctly to the DADH duplex solenoid, refer to REP 5.5.
cause death or injury. Moving parts can cause injury. Install new components as necessary:
NOTE: On 35 ppm machines, the DADH exit sensor is actuated by a flag. On 40-90 ppm • DADH duplex solenoid, PL 5.30 Item 4.
machines, the DADH exit sensor is a reflective type sensor. • DADH PWB, PL 5.10 Item 5.
Enter dC330 code 05-345 to check the DADH exit sensor, Q05-345, Figure 1. Raise the • Baffle assembly, PL 5.30 Item 5.
DADH. Activate Q05-345. The display changes.
Enter dC330 code 05-020 to run the DADH feed motor, MOT05-020. MOT05-020 runs.
Y N
Go to Flag 1. Check Q05-345. Y N
Go to the 05D DADH Motor Failure RAP.
References:
• GP 11 How to Check a Sensor.
The exit roll rotates.
• P/J189, DADH PWB. Y N
• (35 ppm) 01D +3.3 Distribution RAP. Perform the steps that follow:
• (35 ppm) 01B 0V Distribution RAP, refer to the 3.3V return. • Check the feed motor drive belt, PL 5.35 Item 5.
• (40-90 ppm) 01E +5V Distribution RAP. • Check the feed motor tension spring. Check the feed motor drive belt tension, ADJ
• (40-90 ppm) 01B 0V Distribution RAP, refer to the 5V return. 5.1.
Install new components as necessary: • Check the exit roll and pulley, PL 5.35 Item 6 and PL 5.35 Item 15, refer to GP 7.
• DADH exit sensor, PL 5.30 Item 2. If necessary, install a new DADH input tray assembly, PL 5.35 Item 1.
• DADH PWB, PL 5.10 Item 5.
The fault only occurs in duplex mode.
Close the DADH. Open the DADH top cover. Remove the DADH rear cover, PL 5.10 Item 1. Y N
Go to Final Actions.
Hold the top cover interlock switch closed. Enter dC330 code 05-030 to run the DADH CVT
motor, MOT05-030, Figure 2. MOT05-030 runs.
Y N NOTE: During normal operation, the exit roll idlers remain raised (closed) in simplex mode. In
duplex mode, the exit roll idlers remain raised unless the document is longer than 280mm (11
Go to the 05D DADH Motor Failure RAP.
inches). The exit roll idlers raise and lower while feeding longer documents in duplex mode.
The CVT roll rotates. Exit the diagnostics mode. Close the DADH top cover. Make two copies in duplex mode.
Y N Check that the second document is held in the feed rolls until the first document is fed into the
Perform the steps that follow: output tray. The feed rolls held the second document.
• Check the CVT motor drive belt, PL 5.25 Item 11.
A
Status Indicator RAPs February 2010
05-345, 05-346 2-118 Xerox WorkCentre 5790 Family
Y N
Go to the 05E DADH Feed Clutch Failure RAP.

Go to Final Actions. Baffle assembly

Final Actions
Perform the steps that follow:
• For 05-345 and 05-346 faults:
– Check that the pre-scan idlers are clean and rotate freely, refer to ADJ 5.4.
Duplex gate
– Check that the post-scan idlers are clean and rotate freely, refer to ADJ 5.4.
– Check the CVT ramp assembly for damage and rough edges, (W/O TAG 150) PL
14.20 Item 13 or (W/TAG 150) PL 14.10 Item 13.
DADH exit sensor
– Check the duplex gate for damage and rough edges, PL 5.25 Item 12. Q05-345
– Check that Q05-345 is installed correctly.
– Make sure that the DADH ground harness is connected correctly, PL 5.10 Item 11.
– Make sure the feed motor drive belt and CVT motor drive belt are tensioned cor-
rectly, ADJ 5.1.
Install new components as necessary:
– Top access cover assembly, PL 5.20 Item 17.
– Baffle assembly, PL 5.30 Item 5.
• For 05-346 faults:
– Make sure that the exit rolls are clean and rotate freely, refer to ADJ 5.4. Post scan idlers
– Make sure that the exit roll idlers are clean and rotate freely, refer to ADJ 5.4.
– Make sure the tension springs on the exit roll shaft are in the correct position, refer to
REP 5.5
– Check the exit roll static eliminator and ground harness, PL 5.35 Item 7. Pre-scan idlers
– Check the restack arm for damage or rough edges, PL 5.35 Item 3.
Install new components as necessary:
Figure 1 Component location
– DADH exit roll, PL 5.35 Item 6.
– DADH input tray assembly, PL 5.35 Item 1.
If the fault continues, make sure that documents correctly exit the previous sensor in the docu-
ment path. Refer to the 05-340 DADH Registration Sensor Failure RAP.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-119 05-345, 05-346
 CVT motor
tension spring Feed motor tension
CVT motor spring
MOT05-030
Feed motor
MOT05-020
Top cover interlock
switch Feed motor drive belt

Duplex solenoid
SOL05-050 Exit roll pulley

Exit roll

CVT roll Feed clutch

CVT roll pulley and drive belt Feed Rolls

Exit roll idlers

Figure 2 Component location

Figure 3 Component location

Status Indicator RAPs February 2010

05-345, 05-346 2-120 Xerox WorkCentre 5790 Family
 05-350, 05-352 DADH CVT Sensor Failure RAP
05-350 The DADH CVT sensor does not detect the lead edge of the document within the cor-
rect time in the forward mode.

05-352 The DADH CVT sensor does not detect the lead edge of the document within the cor-
rect time in the reverse mode.

Initial Actions
• Remove all documents from the DADH.
• Figure 1. Make sure that the CVT sensor actuator is not damaged. If necessary, install a
new CVT sensor, PL 5.20 Item 12.

Procedure
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.

NOTE: To get access to the DADH CVT sensor, remove the DADH top cover, PL 5.20 Item 15.

Enter dC330 code 05-350 to check the DADH CVT sensor, Q05-350, Figure 1. Activate Q05-
350. The display changes.
Y N
Go to Flag 1. Check Q05-350.
References:
• GP 11 How to Check a Sensor.
• P/J186 and P/J191, DADH PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 3.3V return.
Install new components as necessary:
• DADH CVT sensor, PL 5.20 Item 12.
• DADH PWB, PL 5.10 Item 5.

Remove the DADH rear cover, PL 5.10 Item 1. Hold the top cover interlock switch closed.
Enter dC330 code 05-030 to check the DADH CVT motor, MOT05-030. MOT05-030 runs.
Y N
Go to the 05D DADH Motor Failure RAP.

The CVT roll rotates.

Y N
Perform the steps that follow:
• Check the CVT motor drive belt, PL 5.25 Item 11.
• Check the CVT motor tension spring. Make sure that the CVT motor drive belt ten-
sion is correct, ADJ 5.1.
• Check the CVT roll pulley, refer to GP 7.
Figure 4 Circuit diagram If necessary, install a new DADH CVT roll, PL 5.25 Item 5.

The fault only occurs in duplex mode (fault code 05-352).

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-121 05-345, 05-346, 05-350, 05-352
Y N
Go to Final Actions.
CVT motor tension spring
NOTE: The exit roll idlers remain lowered for 30 seconds.
CVT motor
Enter dC330 code 05-050 to check the DADH duplex solenoid, SOL05-050, to lower the exit MOT05-030
roll idlers, Figure 2. The exit roll idlers lower.
Y N CVT motor drive
Go to Flag 2. Check SOL050-050. belt
References:
• GP 12 How to Check a Solenoid or Clutch. Top cover interlock
• P/J181, DADH PWB. switch
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 3.3V return. P/J191 Feed motor
Install new components as necessary: MOT05-020
• DADH duplex solenoid, PL 5.30 Item 4.
• DADH PWB, PL 5.10 Item 5. Feed clutch CL05-
• Baffle assembly, PL 5.30 Item 5. 025

NOTE: During normal operation, the exit roll idlers remain raised (closed) in simplex mode. In
duplex mode, the exit roll idlers remain raised unless the document is longer than 280mm (11
inches). The exit roll idlers raise and lower while feeding longer documents in duplex mode.

Exit the diagnostics mode. Close the DADH top cover. Make two copies in duplex mode.
Check that the second document is held in the feed rolls until the first document is fed into the
output tray. The feed rolls held the second document.
Y N
Go to the 05E DADH Feed Clutch Failure RAP.

The fault is caused if the DADH feed motor runs too slowly in reverse, refer to the 05D DADH
Motor Failure RAP. If the fault continues, go to Final Actions.
Final Actions
Perform the steps that follow. Install new components as necessary:
• Check that the CVT roll is clean and rotates freely, refer to ADJ 5.4.
• Check that the takeaway roll, PL 5.35 Item 6 is clean, refer to ADJ 5.4. If necessary, install
a new takeaway roll.
• Check that the CVT sensor, Q05-350 is installed correctly, PL 5.20 Item 12.
• Check the takeaway roll static eliminator and ground harness, PL 5.35 Item 7.
• Make sure that the DADH ground harness is connected correctly, PL 5.10 Item 11.
• Make sure the feed motor drive belt tension is correct, ADJ 5.1. Duplex solenoid
• DADH feed assembly, PL 5.15 Item 18. SOL05-050
If the fault continues, make sure that documents correctly exit the previous sensor in the docu- DADH CVT sensor Feed rolls
CVT roll
ment path. Refer to the 05-335 DADH Takeaway Sensor Failure RAP. Q05-350

Figure 1 Component location

Status Indicator RAPs February 2010

05-350, 05-352 2-122 Xerox WorkCentre 5790 Family
 Exit roll idlers

Figure 2 Component location Figure 3 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-123 05-350, 05-352
05A DADH Other Faults RAP 05B DADH Document Present Sensor Failure Entry RAP
This RAP gives the additional information on common DADH problems. Perform the RAP for Use this RAP when the DADH document present sensor performs as follows:
all current fault codes before this RAP is performed. • The sensor detects a document when a document is not present in the input tray during
the startup procedure.
Procedure • The sensor detects a document when a document is not present in the input tray after a
Go to the correct RAP: jam.
• 05B DADH Document Present Sensor Failure Entry RAP. • The sensor does not detect a document when a document is present in the input tray.
• 05C Document Size Sensor Failure Entry RAP. Procedure
• 05D DADH Motor Failure RAP. WARNING
• 05E DADH Feed Clutch Failure RAP.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
• 05F Damaged Documents RAP. customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Identify the speed of the machine, refer to SCP 7 Machine Features. Perform one of the steps
that follow, as appropriate:
• If the speed of the machine is 35 ppm, go to the 05G DADH Document Present Sensor
Failure RAP (35 ppm).
• If the speed of the machine is 40-90 ppm, go to the 05H DADH Document Present Sensor
Failure RAP (40-90 ppm).

Status Indicator RAPs February 2010

05A, 05B 2-124 Xerox WorkCentre 5790 Family
05C Document Size Sensor Failure Entry RAP 05D DADH Motor Failure RAP
Use this RAP when the DADH is in the Auto Paper Select mode and does not detect the cor- Procedure
rect size of paper.
WARNING
Also use this RAP when the DADH detects a document in the input tray when the document Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
tray is empty. customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Initial Actions Go to the correct procedure:
• Make sure that strong lighting is not above the DADH. • DADH Feed Motor Failure
• Remove all documents from the DADH and input tray. • DADH CVT Motor Failure
• Make sure that the sensors and the area around the sensors are clean. NOTE: The component location is shown in Figure 1.

Procedure DADH Feed Motor Failure

WARNING NOTE: In duplex mode, the DADH feed motor runs in the forward and reverse direction. The
duplex mode component control code is provided to reverse the drive of the feed motor.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can Go to Flag 1. Check the DADH feed motor, MOT05-020.
cause death or injury. Moving parts can cause injury.
Identify the speed of the machine, refer to SCP 7 Machine Features. Perform one of the steps References:
that follow, as appropriate: • GP 10 How to Check a Motor.
• If the speed of the machine is 35 ppm, go to the 05J DADH Document Size Sensor Fail- • P/J181, DADH PWB and P/J204.
ure RAP (35 ppm).
• 01G +24V Distribution RAP.
• If the speed of the machine is 40-90 ppm, go to the 05K DADH Document Size Sensor
• 01B 0V Distribution RAP, refer to the 24V return.
Failure RAP (40-90 ppm).
Install new components as necessary:
• DADH feed motor, PL 5.15 Item 16.
• DADH PWB, PL 5.10 Item 5.
DADH CVT Motor Failure
Go to Flag 2. Check the DADH CVT motor, MOT05-030.

References:
• GP 10 How to Check a Motor.
• P/J181, DADH PWB and P/J203.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 24V return.
Install new components as necessary:
• DADH CVT motor, PL 5.25 Item 9.
• DADH PWB, PL 5.10 Item 5.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-125 05C, 05D
 Feed motor CVT motor
MOT05-020 MOT05-030

Figure 1 Component location

Figure 2 Circuit diagram

Status Indicator RAPs February 2010

05D 2-126 Xerox WorkCentre 5790 Family
05E DADH Feed Clutch Failure RAP
Use this RAP when the DADH feed clutch does not operate correctly.
Also use this RAP if the feed clutch energizes at the wrong time in duplex mode, which causes:
• Mis-feeds.
• The feed rolls to reverse and eject the original documents into the DADH input tray.
Procedure
Go to Flag 1. Check the DADH feed clutch, CL05-025, Figure 1.

References:
• GP 12 How to Check a Solenoid or Clutch.
• P/J183,DADH PWB and P/J202.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 24V return.
Install new components as necessary:
• DADH feed clutch, PL 5.15 Item 9.
• DADH PWB, PL 5.10 Item 5.
• DADH feed assembly, PL 5.15 Item 18.
Figure 2 Circuit Diagram

PJ202 Feed clutch

CL05-025

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-127 05E
05F Damaged Documents RAP
Use this RAP if the documents get damaged by the DADH.
Baffle assembly
Procedure
Perform the steps that follow:
1. If the DADH damages the bottom of the documents mid-way along the lead edge, install a
new feed roll assembly, (35 ppm) PL 5.15 Item 1 or (40-90 ppm) PL 5.17 Item 1.
2. ADJ 5.2 DADH height adjustment. Duplex gate
3. Check the input tray for damage, PL 5.35 Item 1.
• Make sure that the document width guides move freely.
• Check that the takeaway roll assembly and exit roll assembly, PL 5.35 Item 6 for
damage and contamination, refer to ADJ 5.4. CVT roll
• Check the restack arm for damage, PL 5.35 Item 3.
4. Open the DADH top access cover assembly, PL 5.20 Item 17.
• Check the document path for damage.
• Check the takeaway roll idlers and CVT roll idlers, PL 5.20 Item 3 for damage. Make
sure the idlers are clean and rotate freely, refer to ADJ 5.4.
5. Raise the DADH. Lower the baffle assembly, Figure 1.
• Remove any pieces of paper.
• Check the duplex gate, PL 5.25 Item 12 for damage. Make sure the duplex gate
moves freely. Post scan idlers
• Check the CVT roll, PL 5.25 Item 5 for damage. If necessary, clean the CVT roll,
ADJ 5.4.
• Check the pre-scan idlers, PL 5.25 Item 6 and post scan idlers, PL 5.30 Item 6 for
damage. Make sure the idlers are clean and rotate freely, refer to ADJ 5.4. Pre-scan idlers
• Check the document path for damage.
• Check the baffle assembly, PL 5.30 Item 5 for damage. Figure 1 Component location
• Check the exit roll idlers for damage, PL 5.30 Item 8. Make sure the idlers are clean
and rotate freely, ADJ 5.4.
6. Check the CVT ramp assembly, (W/O TAG 150) PL 14.20 Item 13 or (W/TAG 150) PL
14.10 Item 13 for damage.
7. Make sure that the customers documents are within the specification, refer to GP 20.

Status Indicator RAPs February 2010

05F 2-128 Xerox WorkCentre 5790 Family
05G DADH Document Present Sensor Failure RAP (35
DADH document present sensor
ppm) Q05-310
Initial Actions
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 05B
DADH Document Present Sensor Failure Entry RAP.
• Remove all documents from the DADH.
• Check the actuator for the document present sensor, PL 5.15 Item 12.
• The DADH document present sensor can fail to detect the last document in a document
set if static electricity is on the input tray. If necessary, clean the input tray with the anti-
static fluid, refer to ADJ 5.4.

Procedure
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Enter dC330 code 05-310 to check the DADH document present sensor, Q05-310, Figure 1.
The display changes.
Y N
Go to Flag 1. Check Q05-310. Figure 1 Component location
References:
• GP 11 How to Check a Sensor.
• P/J184, DADH PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 3.3V return.
Install new components as necessary:
• DADH document present sensor, PL 5.15 Item 13.
• DADH PWB, PL 5.10 Item 5.

Make sure that the area around the sensor is clean. If the problem continues, install new com-
ponents as necessary:
• DADH document present sensor, PL 5.15 Item 13.
• DADH PWB, PL 5.10 Item 5.
• DADH document present sensor actuator, PL 5.15 Item 12.

Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-129 05G
05H DADH Document Present Sensor Failure RAP (40-90
DADH document
ppm) present sensor
Initial Actions Q05-310
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 05B
DADH Document Present Sensor Failure Entry RAP.
• Remove all documents from the DADH.
• Clean the DADH document present sensor and the area around the sensor, PL 5.35 Item
19.
• The DADH document present sensor can fail to detect the last document in a document
set if static electricity is on the input tray. If necessary, clean the input tray with the anti-
static fluid, refer to ADJ 5.4.

Procedure
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Enter dC330 code 05-310 to check the DADH document present sensor, Q05-310, Figure 1.
The display changes.
Y N Figure 1 Component location
Go to Flag 1. Check Q05-310.
References:
• GP 11 How to Check a Sensor.
• P/J184, DADH PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 5V return.
Install new components as necessary:
• DADH document present sensor, PL 5.35 Item 19.
• DADH PWB, PL 5.10 Item 5.

Make sure that the area around the sensor is clean. If the problem continues, install new com-
ponents as necessary:
• DADH document present sensor, PL 5.35 Item 19.
• DADH PWB, PL 5.10 Item 5.

Figure 2 Circuit diagram

Status Indicator RAPs February 2010

05H 2-130 Xerox WorkCentre 5790 Family
 A
05J Document Size Sensor Failure RAP (35 ppm) • 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 3.3V return.
Initial Actions
Install new components as necessary:
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 05B
• DADH feed sensor, PL 5.15 Item 2.
DADH Document Present Sensor Failure Entry RAP.
• DADH PWB, PL 5.10 Item 5.
• Make sure that a spot light or any direct light source is not above the DADH.
• Remove all documents from the DADH and input tray.
Enter dC330 code 05-340 to check the DADH registration sensor, Q05-340. Activate Q05-340.
• Make sure that the sensors and the area around the sensors are clean. The display changes.
Y N
Procedure Go to Flag 4. Check Q05-340.
References:
WARNING
• GP 11 How to Check a Sensor.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
• P/J186, DADH PWB.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. • 01D +3.3V Distribution RAP.
Enter dC330 code 05-315 to check the DADH length sensor 1, Q05-315, Figure 1. Activate • 01B 0V Distribution RAP, refer to the 3.3V return.
Q05-315. The display changes. Install new components as necessary:
Y N • DADH registration sensor, PL 5.25 Item 1.
Go to Flag 1. Check Q05-315. • DADH PWB, PL 5.10 Item 5.
References:
• GP 11 How to Check a Sensor. Completely open the DADH width guides. Go to Flag 5. Measure the voltage at P/J190 pin 8.
• P/J190, DADH PWB. Completely close the DADH width guides. The voltage changes from 3.3V to 0V.
• 01D +3.3 Distribution RAP. Y N
• 01B 0V Distribution RAP, refer to the 3.3V return. Remove the DADH input tray assembly, PL 5.35 Item 1. Make sure the arm of the DADH
width guide sensor is installed correctly, Figure 2. Check the mechanical operation of the
Install new components as necessary:
width guides. Install new components as necessary:
• DADH length sensor 1, PL 5.35 Item 8. • DADH width sensor, PL 5.35 Item 11.
• DADH PWB, PL 5.10 Item 5. • DADH input tray assembly, PL 5.35 Item 1.

Enter dC330 code 05-320 to check the DADH length sensor 2, Q05-320. Activate Q05-320. Make sure that the chain 5 NVM parameters for the detection of the size of paper are correct.
The display changes. Refer to dC131.
Y N Install new components as necessary:
Go to Flag 2. Check Q05-320. • DADH PWB, PL 5.10 Item 5.
References:
• DADH input tray assembly, PL 5.35 Item 1.
• GP 11 How to Check a Sensor.
• P/J190, DADH PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 3.3V return.
Install new components as necessary:
• DADH length sensor 2, PL 5.35 Item 8.
• DADH PWB, PL 5.10 Item 5.

Open the DADH top cover. Enter dC330 code 05-330 to check the DADH feed sensor, Q05-
330. Activate Q05-330. The display changes.
Y N
Go to Flag 3. Check Q05-330.
References:
• GP 11 How to Check a Sensor.
• P/J184, DADH PWB.
A

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-131 05J
 DADH registration sensor
Q05-340 DADH width sensor
Q05-325

Arm
DADH width guides

DADH feed sensor DADH length sensor 1 DADH length sensor 2

Q05-330 Q05-315 Q05-320
Figure 2 Component location
Figure 1 Component location

Status Indicator RAPs February 2010

05J 2-132 Xerox WorkCentre 5790 Family
 Figure 3 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-133 05J
 A
05K Document Size Sensor Failure RAP (40-90 ppm) • P/J184, DADH PWB.
• 01D +3.3V Distribution RAP.
Initial Actions
• 01B 0V Distribution RAP, refer to the 3.3V return.
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 05B
Install new components as necessary:
DADH Document Present Sensor Failure Entry RAP.
• DADH feed sensor, PL 5.17 Item 2.
• Make sure that a bright light is not above the DADH. If necessary, adjust the position of
the machine. • DADH PWB, PL 5.10 Item 5.
• Remove all documents from the DADH and input tray.
Enter dC330 code 05-340 to check the DADH registration sensor, Q05-340. Activate Q05-340.
• Make sure that the sensors and the area around the sensors are clean. The display changes.
Y N
Procedure Go to Flag 4. Check Q05-340.
WARNING References:
• GP 11 How to Check a Sensor.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can • P/J184, DADH PWB.
cause death or injury. Moving parts can cause injury. • 01D +3.3V Distribution RAP.
Enter dC330 code 05-315 to check the DADH length sensor 1, Q05-315, Figure 1. Activate • 01B 0V Distribution RAP, refer to the 3.3V return.
Q05-315. The display changes. Install new components as necessary:
Y N • DADH registration sensor, PL 5.25 Item 1.
Go to Flag 1. Check Q05-315.
• DADH PWB, PL 5.10 Item 5.
References:
• GP 11 How to Check a Sensor.
Completely open the DADH width guides. Go to Flag 5. Measure the voltage at P/J190 pin 8.
• P/J190, DADH PWB. Completely close the DADH width guides. The voltage changes from 3.3V to 0V.
• 01D +3.3 Distribution RAP. Y N
• 01B 0V Distribution RAP, refer to the 3.3V return. Remove the DADH input tray assembly, PL 5.35 Item 1. Make sure the arm of the DADH
width guide sensor is installed correctly, Figure 2. Check the mechanical operation of the
Install new components as necessary:
width guides. Install new components as necessary:
• DADH length sensor 1, PL 5.35 Item 8.
• DADH width sensor, PL 5.35 Item 11.
• DADH PWB, PL 5.10 Item 5.
• DADH input tray assembly, PL 5.35 Item 1.
Enter dC330 code 05-320 to check the DADH length sensor 2, Q05-320. Activate Q05-320.
Make sure that the chain 5 NVM parameters for the detection of the size of paper are correct.
The display changes.
Refer to dC131.
Y N Install new components as necessary:
Go to Flag 2. Check Q05-320.
• DADH PWB, PL 5.10 Item 5.
References:
• DADH input tray assembly, PL 5.35 Item 1.
• GP 11 How to Check a Sensor.
• P/J190, DADH PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP, refer to the 3.3V return.
Install new components as necessary:
• DADH length sensor 2, PL 5.35 Item 8.
• DADH PWB, PL 5.10 Item 5.

Open the DADH top cover. Enter dC330 code 05-330 to check the DADH feed sensor, Q05-
330. Activate Q05-330. The display changes.
Y N
Go to Flag 3. Check Q05-330.
References:
• GP 11 How to Check a Sensor.
A
Status Indicator RAPs February 2010
05K 2-134 Xerox WorkCentre 5790 Family
 DADH registration sensor
Q05-340 DADH width sensor
Q05-325

Arm
DADH width guides

DADH length sensor 2

DADH feed sensor DADH length sensor 1 Q05-320
Q05-330 Q05-315
Figure 2 Component location
Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-135 05K
 Figure 3 Circuit diagram

Status Indicator RAPs February 2010

05K 2-136 Xerox WorkCentre 5790 Family
 A B
06-020 ROS Motor Failure RAP Go to Flag 1. Check the following voltages at P/J18 on the LVPS:
• +24V between pins 1 and 2.
06-020. This fault code has two failure modes.
• +3.3V between pins 3 and 4.
1. The ROS motor ready signal was not received by the IOT PWB within the set time of the
ROS being powered on. The voltages are good.
Y N
2. The IOT PWB recognizes a change of state of the ROS motor ready signal during opera-
tion. Go to the relevant RAP:
• 01B 0V Distribution RAP, refer to the 3.3V return and 24V return.
• 01D +3.3V Distribution RAP.
Initial Actions
• 01G +24V Distribution RAP.
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Enter the dC330 output code 06-020 to run the ROS motor. Go to Flag 2. 0V is avail-
customer supply while performing tasks that do not need electricity. Electricity can able at P/J2 pin 1 on the IOT PWB.
cause death or injury. Moving parts can cause injury. Y N
WARNING Go to Flag 3. 0V is available at P/J2 pin 6 on the IOT PWB.
Y N
Avoid exposure to laser beam. Invisible laser radiation. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
• Figure 1. Check that the harness connector at PJ2 on the IOT PWB is fully inserted. PL 1.10 Item 2.
• Figure 1. Check that the harness connector at PJ121 on the ROS is fully inserted.
NOTE: The ROS must be removed from the machine, REP 6.1, to disconnect P/
Procedure J120 and P/J121. The ROS PWB where P/J120 and P/J121 are connected may
not be marked with the correct PJ numbers. P/J120 can be identified as a four way
power harness. P/J121 can be identified as a seven way signal harness.

Go to Flag 1, Flag 2 and Flag 3. Disconnect P/J120 and P/J121 and check the wir-
ing. The wiring is good.
Y N
Repair the wiring.

Install a new ROS, PL 6.10 Item 4.

Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
2.

Go to Flag 2. 0V is available at P/J2 pin 1.

Y N

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

A B
February 2010 Status Indicator RAPs
Xerox WorkCentre 5790 Family 2-137 06-020
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
2.
• Install a new ROS, PL 6.10 Item 4.

P/J121

P/J120

ROS

P/J2 (harness) P/J18 (harness)

Figure 1 Component location

Figure 2 Circuit diagram

Status Indicator RAPs February 2010

06-020 2-138 Xerox WorkCentre 5790 Family
 A B
06-340 ROS Laser Failure RAP NOTE: The ROS must be removed from the machine, REP 6.1, to disconnect P/J122
and P/J121. The ROS PWB where P/J122 and P/J121 are connected may not be
06-340. The IOT PWB has not detected the ROS laser reaching the operating speed.
marked with the correct PJ numbers. P/J122 can be identified as a four way power har-
ness. P/J121 can be identified as a seven way signal harness.
Procedure
Check the wiring at Flag 1, Flag 2 and Flag 3. The wiring is good.
WARNING Y N
Avoid exposure to laser beam. Invisible laser radiation. Repair the wiring or install new harness PL 6.10 Item 5.

Install a new ROS, PL 6.10 Item 4.

Go to Flag 4. Check P/J113 on the single board controller PWB is securely connected. If the
fault is still present, remove the ROS, REP 6.1. Go to Flag 4 and ensure that PJ122 on the
ROS is securely connected. If the fault is still present, go to Flag 4 and check the continuity of
the ROS data cable ( P/J113 to P/J122). The ROS data cable is good
Y N
Install a new ROS power distribution/communications harness, PL 6.10 Item 5.

Install new parts in the following order:

• ROS, PL 6.10 Item 4.
• Single board controller PWB, PL 3.24 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item
2.

Go to Flag 3, connect a service meter to P/J2 pin 7 and make a set of 5 copies. 0V is mea-
sured at P/J2 pin 7 on the IOT PWB during run. P/J121
Y N
The xerographic module is fully home and the front door is fully closed or the front
door interlock is cheated. P/J122
Y N
Correct the condition.

Go to Flag 1. Disconnect P/J18 from the LVPS. Check the following voltages on the P/J120
LVPS:
• +24V between pins 1 and 2.
• +3.3V between pins 3 and 4.
The voltages are good.
Y N
ROS
Go to the relevant RAP:
• 01B 0V Distribution RAP, refer to the 3.3V return and 24V return.
• 01D +3.3V Distribution RAP. P/J2 (harness) P/J18 (harness)
• 01G +24V Distribution RAP.
Figure 1 Component Location
Enter the dC330 output code 06-020. Go to Flag 2. The ROS motor gives a distinctive
ascending frequency sound, of a short duration (5 to 6 seconds) during transition
from standby to run.
Y N
Go to the 06-020 ROS Motor Failure RAP.

A B
February 2010 Status Indicator RAPs
Xerox WorkCentre 5790 Family 2-139 06-340
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

06-340 2-140 Xerox WorkCentre 5790 Family
06-350 ROS Laser Not Under Control RAP
06-350. The IOT monitor has not received a reset command from the IOT ROS controller for
more than 5 seconds during print.

Procedure
Perform the 03-395, 396, 852, 853 IOT PWB Faults RAP.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-141 06-350
Status Indicator RAPs February 2010
06-350 2-142 Xerox WorkCentre 5790 Family
07-301 Tray 1 Open During Run RAP
07-301 Tray 1 was opened during run when the paper is fed from tray 1.

Initial Actions
• Ensure the tray is pushed fully home, Figure 1.
• Check for obstructions behind the tray.

Procedure
Enter dC330 code 07-301 tray 1 home switch, S07-301. Press Start. Open and fully close the
tray. The display changes.
Y N
Go to Flag 1. Check S07-301. Refer to:
• GP 13 How to Check a Switch.
• Tray 1 home (H) +5V. Check at the switch terminal on the PWB, Figure 2.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 and 2 control PWB, PL 7.10 Item 2. Tray 1 and 2
control PWB
Perform the following:
• Check the paper size leaf spring is mounted correctly, PL 7.10 Item 3.
• Check for Mod/Tag 101. If Mod/TAG 101 has not been struck then install a paper feed Tray 1 home switch
module frame repair kit, PL 31.14 Item 4. (top switch)
Tray home actuator
• Check the actuator cam on the paper tray, Figure 1. S07-301
cam
• If the problem continues, install new Tray 1 and 2 control PWB, PL 7.10 Item 2.

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-143 07-301
 Check the voltage at the
switch terminal

Tray 1 home switch

Figure 3 Tray 1 circuit diagram

Figure 2 Tray 1 home switch test point

Status Indicator RAPs February 2010

07-301 2-144 Xerox WorkCentre 5790 Family
07-302 Tray 2 Open During Run RAP
07-302 Tray 2 was opened during run when the paper is fed from tray 2.

Initial Actions
• Ensure that the tray is pushed fully home, Figure 1.
• Check for obstructions behind the tray.

Procedure
Enter dC330 code 07-302 tray 2 home switch, S07-302. Press Start. Open and fully close the
tray. The display changes.
Y N
Go to Flag 1. Check S07-302. Refer to:
• GP 13 How to Check a Switch.
• Tray 1 home (H) +5V. Check at the switch terminal on the PWB, Figure 2.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 and 2 control PWB, PL 7.10 Item 2. Tray 1 and 2
control PWB
Perform the following:
• Check the paper size leaf spring is mounted correctly, PL 7.10 Item 3.
Check for Mod/Tag 101. If Mod/TAG 101 has not been struck then install a paper feed Tray home actuator Tray 2 home switch
module frame repair kit, PL 31.14 Item 4. cam (top switch)
• Check the actuator on the paper tray, Figure 1. S07-302
• If the problem continues, install new Tray 1 and 2 control PWB, PL 7.10 Item 2.

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-145 07-302
 Check the voltage at the switch
terminal

Tray 2 home switch Figure 3 Tray 2 circuit diagram

Figure 2 Home switch test point

Status Indicator RAPs February 2010

07-302 2-146 Xerox WorkCentre 5790 Family
07-303 Tray 3 Open During Run RAP
07-303 Tray 3 open during run when the paper is fed from tray 3.

Tray 3 home switch

Initial Actions S07-303
• Check for obstructions behind the tray.
• Ensure that the tray is pushed fully home.
• Check the switch actuator, Figure 1.

Procedure
Enter dC330 code 07-303 tray 3 home switch, S07-303. Press Start. Open and fully close the
tray. The display changes.
Y N
Go to Flag 1. Check S07-303. Refer to:
• GP 13 How to Check a Switch.
• P/J392, HCF control PWB. Switch actuator
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 3 home switch, PL 7.20 Item 4.
• HCF control PWB, PL 7.20 Item 2.

Check the switch holder, PL 7.20 Item 3.

If the problem continues, install new components as necessary:
• Tray 3 home switch, PL 7.20 Item 4.
• HCF control PWB, PL 7.20 Item 2.

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-147 07-303
 07-304 Tray 4 Open During Run RAP
07-304 Tray 4 0pen during run when the paper is fed from tray 4.

Initial Actions
• Check for obstructions behind the tray.
• Ensure that the tray is pushed fully home.
• Check the switch actuator, Figure 1.

Procedure
Enter dC330 code 07-304 tray 4 home switch, S07-304. Press Start. Open and fully close the
tray. The display changes.
Y N
Go to Flag 1. Check S07-304. Refer to:
• GP 13 How to Check a Switch.
• P/J392, HCF control PWB.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 4 home switch, PL 7.20 Item 4.
• HCF control PWB, PL 7.20 Item 2.
Figure 2 Circuit diagram
Check the switch holder, PL 7.20 Item 3.
If the problem continues, install new components as necessary:
• Tray 4 home switch, PL 7.20 Item 4.
• HCF control PWB, PL 7.20 Item 2.

Status Indicator RAPs February 2010

07-303, 07-304 2-148 Xerox WorkCentre 5790 Family
 Tray 4 home switch
S07-304

Switch actuator

Figure 2 Circuit diagram

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-149 07-304
07-306 Tray 5 Door Open During Run RAP
07-306 Tray 5 door open during run when the paper is fed from tray 5.

Initial Actions
• Ensure that the door is pushed fully home.
• Check the switch actuator, Figure 1.

Procedure
Enter dC330 code 07-306 tray 5 door switch, S07-306 Press Start. Open and fully close the
door The display changes.
Y N
Go to Flag 1. Check S07-306. Refer to:
• GP 13 How to Check a Switch.
• 01E +5V Distribution RAP
• P/J507, Tray 5 control PWB.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 5 door switch, PL 7.60 Item 6.
• Tray 5 control PWB, PL 7.68 Item 8.

If the problem continues, install new components as necessary:

Tray 5 door switch
• Tray 5 door switch, PL 7.60 Item 6 Switch actuator S07-306
• Tray 5 control PWB, PL 7.68 Item 8.

Figure 1 Component location

Status Indicator RAPs February 2010

07-306 2-150 Xerox WorkCentre 5790 Family
 07-353 Tray 1 Elevator Lift Failure RAP
07-353 Tray 1 stack height sensor did not actuate within the correct time after the feed / eleva-
tor motor turned on.

Initial Actions
• Check for obstructions behind the tray.
• Ensure that the tray is pushed fully home.
Check the stack height mechanism actuator on the back of the tray, Figure 1.
• Check the drive gears and coupling on the tray.
• Check the elevator drive coupling on the feeder assembly.

Procedure
Enter dC330 code 07-336 tray 1 stack height sensor, Q07-336. Press Start. Pull out tray 1 and
push fully home. The display changes
Y N
Go to Flag 1. Check Q07-383. Refer to:
• GP 11 How to Check a Sensor.
• P/J274, Tray 1 and 2 control PWB
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 stack height sensor, PL 8.26 Item 8.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

CAUTION
To prevent damage to the elevator and paper feed mechanism, the paper tray must be pulled
Figure 2 Circuit diagram out before MOT07-010 is run in diagnostics.
Enter dC330 code 07-010 tray 1 feed / elevator motor, MOT07-010. Pull out tray 1. Press
Start. The motor runs
Y N
Go to Flag 2. Check MOT07-010. Refer to:
• GP 10 How to Check a Motor.
• P/J274, Tray 1 and 2 control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP
Install new components as necessary:
• Tray 1 Feed / elevator motor, PL 8.26 Item 8.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Perform the following:

• Check the feeder / elevator motor drive gears, Figure 1.
• Check the tray 1 stack height mechanism on the feeder assembly,
If the fault still occurs then go to 07A Tray 1 and Tray 2 False Paper Level RAP.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-151 07-306, 07-353
 Stack height mechanism
actuator

Drive gears

Figure 1 Component location

Figure 2 Circuit diagram

Status Indicator RAPs February 2010

07-353 2-152 Xerox WorkCentre 5790 Family
07-354 Tray 2 Elevator Lift Failure RAP
07-354 Tray 2 stack height sensor did not actuate within the correct time after the feed / eleva-
tor motor turned on.

Initial Actions
• Check for obstructions behind the tray.
• Ensure that the tray is pushed fully home.
Check the stack height mechanism actuator on the back of the tray, Figure 1.
• Check the drive gears and coupling on the tray.
• Check the elevator drive coupling on the feeder assembly.

Procedure
Enter dC330 code 07-337 tray 2 stack height sensor, Q07-337. Press Start. Pull out tray 1 and
push fully home. The display changes
Y N
Go to Flag 1. Check Q07-337. Refer to:
• GP 11 How to Check a Sensor.
• P/J275, Tray 1 and 2 control PWB.
• 01E +5V Distribution RAP. Stack height mechanism
• 01B 0V Distribution RAP. actuator
Install new components as necessary:
• Tray 2 stack height sensor, PL 8.26 Item 8.
• Tray 1 and 2 control PWB, PL 7.10 Item 2. Drive gears

CAUTION
To prevent damage to the elevator and paper feed mechanism, the paper tray must be pulled
out before MOT07-020 is run in diagnostics. Figure 1 Component location
Enter dC330 code 07-020 tray 1 feed / elevator motor, MOT07-020. Pull out tray 1. Press
Start. The motor runs
Y N
Go to Flag 2. Check MOT07-020. Refer to:
• GP 10 How to Check a Motor.
• P/J275, Tray 1 and 2 control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP
Install new components as necessary:
• Tray 2 Feed / elevator motor, PL 8.26 Item 6.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Perform the following:

• Check the feeder / elevator motor drive gears, Figure 1.
• Check the tray 2 stack height mechanism on the feeder assembly,
If the fault still occurs then go to 07A Tray 1 and Tray 2 False Paper Level RAP.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-153 07-354
 07-355 Tray 3 Elevator Lift Failure RAP
07-355 Tray 3 stack height sensor did not actuate within the correct time after the elevator
motor turned on.

NOTE: Rapid closure of tray 4 when tray 3 is being elevated may cause this fault.

Initial Actions
• Check that the tray elevator cables and mechanisms are located correctly.
• Ensure that the tray is pushed fully home.
• Check for obstructions behind the tray.
• Check the tray 3 home switch, Figure 1.
• If the tray only elevates up by 25mm (1 inch) and stops. Go to 07E RAP and check the
tray empty actuator.

Procedure
Enter dC330 code 07-303 tray 3 home switch, S07-303. Press Start. Pull out the tray and push
back in. The display changes.
Y N
Go to Flag 1. Check S07-303. Refer to:
• GP 13 How to Check a Switch.
• P/J392, HCF control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP
Install new components as necessary:
• Tray 3 home switch, PL 7.20 Item 4.
• HCF control PWB, PL 7.20 Item 2.

Enter dC330 code 07-383 tray 3 stack height sensor, Q07-383. Press Start. Pull out tray 3 and
manually activate the stack height sensor on the paper feed assembly. The display changes
Y N
Go to Flag 2. Check Q07-383. Refer to:
• GP 11 How to Check a Sensor.
• P/J392, HCF control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 3 stack height sensor, PL 8.30 Item 21
• HCF control PWB, PL 7.20 Item 2.

Go to P/J396 pin 1 on the HCF control PWB, Flag 4. Manually activate the tray 3 stack limit
switch (S07-393) on the paper feed assembly. The voltage changes.
Y N
Go to Flag 3. Check S07-393. Refer to:
Figure 2 Circuit diagram • GP 13 How to Check a Switch.
• P/J396, HCF control PWB.
• 01G +24V Distribution RAP.

A
Status Indicator RAPs February 2010
07-354, 07-355 2-154 Xerox WorkCentre 5790 Family
A
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 3 paper feeder, PL 8.30 Item 2.
• HCF control PWB, PL 7.20 Item 2.

CAUTION
To prevent damage to the elevator and paper feed mechanism, the paper tray must be pulled
out before MOT07-030 is run in diagnostics.
Enter dC330 code 07-030 tray 3 elevator motor, MOT07-030. Pull out tray 3. Press Start. The Stack limit switch
S07-393
motor runs
Y N
Go to Flag 4. Check MOT07-030. Refer to: Stack height sensor
Q07-383
• GP 10 How to Check a Motor.
• P/J395, HCF control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP
Install new components as necessary:
• Tray 3 elevator motor, PL 7.20 Item 1.
• HCF control PWB, PL 7.20 Item 2.

Perform the following:

• Check elevator cables, PL 7.15 Item 4, PL 7.15 Item 6, PL 7.15 Item 7.
• Check elevator motor drive coupling, PL 7.20 Item 1.
• Check tray elevator drive gears and drive coupling, PL 7.15.
• Check the tray 3 empty sensor actuator, PL 8.30 Item 1.
If the fault still occurs then go to 07E Tray 3 or Tray 4 Out of Paper RAP.

Tray 3 feed sen-

sor
Q08-103

HCF control
PWB
Tray 3 elevator Tray 3 home
MOT07-030 switch Tray 3 feed assembly
S07-303

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-155 07-355
 07-360 Tray 4 Elevator Lift Failure RAP
07-360 Tray 4 stack height sensor does not actuate within 7 seconds after the elevator motor is
turned on.

NOTE: Rapid closure of tray 3 when tray 4 is being elevated may cause this fault.

Initial Actions
CAUTION
Failure of the tray 4 feed motor, MOT 08-840 can cause damage the 24V circuit of the HCF
Control PWB. Before replacing a HCF Control PWB ensure the tray 4 feed motor is opera-
tional.
• Check the tray 4 feed motor, MOT08-840. Go to 08-104, 08-114 Tray 4 Misfeed RAP.
• Check that the tray elevator cables and mechanisms are located correctly.
• Ensure that the tray is pushed fully home.
• Check for obstructions behind the tray.
• If the tray only elevates up by 25mm (1 inch) and stops. Go to 07E RAP and check the
tray empty actuator.

Procedure
Enter dC330 code 07-304 tray 4 home switch, S07-304. Press Start. Pull out the tray and push
back in. The display changes.
Y N
Go to Flag 1. Check S07-304. Refer to:
• GP 13 How to Check a Switch.
• P/J392, HCF control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 4 home switch, PL 7.20 Item 4.
• HCF control PWB, PL 7.20 Item 2.

Enter dC330 code 07-384 tray 4 stack height Sensor, Q07-384. Press Start. Pull out tray 4 and
manually actuate the stack height sensor on the paper feed assembly. The display changes.
Y N
Go to Flag 2. Check Q07-384. Refer to:
• GP 11 How to Check a Sensor.
• P/J392, HCF control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 4 stack height sensor, PL 8.31 Item 13.
• HCF control PWB, PL 7.20 Item 2.

Figure 2 Circuit diagram Go to P/J398 pin 6 on the HCF control PWB, Flag 4. Manually activate the tray 4 stack limit
switch (S07-394) on the paper feed assembly. The voltage changes.

Status Indicator RAPs February 2010

07-355, 07-360 2-156 Xerox WorkCentre 5790 Family
Y N
Go to Flag 3. Check S07-394. Refer to:
• GP 13 How to Check a Switch.
• P/J398, HCF control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP. Tray 4 feed
Install new components as necessary: assembly
Stack limit switch
• Tray 4 paper feeder, PL 8.31 Item 4. S07-394
• HCF control PWB, PL 7.20 Item 2.
Stack height sensor
Q07-384
CAUTION
To prevent damage to the elevator and paper feed mechanism, the paper tray must be pulled
out before MOT07-040 is run in diagnostics.
Enter dC330 code 07-040 tray 4 elevator motor, MOT07-040. Pull out tray 4. Press Start. The
motor runs.
Y N
Go to Flag 4. Check MOT07-040. Refer to:
• GP 10 How to Check a Motor.
• P/J397, HCF control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 4 elevator motor, PL 7.20 Item 1.
• HCF control PWB, PL 7.20 Item 2.

Perform the following:

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

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-157 07-360
 07-372 Tray 5 Undocked During Run RAP
07-372 Tray 5 was undocked during run when the paper is fed from tray 5.

Initial Actions
• Ensure the tray is pushed fully home, Figure 1.
• Check for obstructions between the tray and the machine.

Procedure
Enter dC330 code 07-372 tray 5 docking switch, S07-372. Press Start. Undock and dock tray
5, refer to REP 7.19. The display changes.
Y N
Go to Flag 1. Check S07-372. Refer to:
• GP 13 How to Check a Switch.
• P/J507, Tray 5 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 5 docking switch, PL 7.64 Item 1
• Tray 5 control PWB, PL 7.68 Item 8

Perform the following:

• Check the docking latch on tray 5 is latched onto the machine, Figure 2.
• Check the that the rail assembly is located correctly to the machine.

Figure 2 Tray 4 Circuit diagram

Status Indicator RAPs February 2010

07-360, 07-372 2-158 Xerox WorkCentre 5790 Family
 Tray 5 docking
switch S07-372

Docking latch

Rail assembly

Figure 2 Component location

Tray 5 docking location pin

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-159 07-372
 07-373 Tray 5 Elevator Lift Failure RAP
07-373 A signal was not detected by the encoder when the elevator motor was driving up.

Initial Actions
• Check for obstructions behind the tray.

Procedure
Figure 1. Ensure the cable holder PL 7.68 Item 23 is not trapped behind the elevator motor
bracket PL 7.68 Item 6. The cable holder is correctly positioned.
Y N
Reposition the cable holder so that it does not become trapped behind the elevator motor
bracket.
Install new components as necessary:
• Cable holder PL 7.68 Item 23.

Open and close the tray 5 door. The tray moves up.
Y N
Enter dC330 code 07-306 tray 5 door interlock switch. Press Start. Manually toggle the
the door interlock switch. The display changes.
Y N
Check the wiring to the switch, REP 1.2.
Go to Flag 1. Check S07-306. Refer to:
• GP 13 How to Check a Switch.
• P/J507, Tray 5 control PWB
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
Figure 3 Tray 1 circuit diagram • Tray 5 door interlock switch, PL 7.60 Item 6
• Tray 5 control PWB, PL 7.68 Item 8.

Enter dC330 code 07-402 tray 5 stack height sensor, Q07-402. Press Start. Manually acti-
vate the stack height sensor on the paper feed assembly. The display changes
Y N
Go to Flag 2. Check Q07-402. Refer to:
• GP 11 How to Check a Sensor.
• P/J505, Tray 5 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 5 stack height sensor, PL 8.45 Item 7
• Tray 5 control PWB, PL 7.68 Item 8.

Go to PJ504 pin 4 on the Tray 5 control PWB, Flag 3. Manually activate the tray upper
limit switch (S07-412) on the paper feed assembly. The voltage changes.
Y N
Go to Flag 3. Check S07-412. Refer to:
• GP 13 How to Check a Switch.
A B
Status Indicator RAPs February 2010
07-372, 07-373 2-160 Xerox WorkCentre 5790 Family
A B
• P/J504, Tray 5 control PWB
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP. Stack height sensor
Q07-402
Install new components as necessary:
• Tray 5 stack upper limit switch, PL 7.68 Item 12
Tray upper limit
• Tray 5 control PWB, PL 7.68 Item 8. switch
S07-412
Enter dC330 code 07-406 tray 5 elevator motor encoder sensor, Q07-406. Press Start.
Manually lift the motor to activate the sensor. The display changes Cable holder
Y N
Go to Flag 4. Check Q07-406. Refer to:
• GP 11 How to Check a Sensor. Tray 5 elevator
• P/J506, Tray 5 control PWB. motor encoder
Q07-406
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary: Tray 5 elevator
MOT07-373
• Elevator motor encoder sensor, PL 7.68 Item 5
• Tray 5 control PWB, PL 7.68 Item 8

Enter dC330 code 07-373 tray 5 elevator motor, MOT07-373. Press Start. The motor
runs
Y N
Go to Flag 5. Check MOT07-373. Refer to:
Tray 5 control PWB
• GP 10 How to Check a Motor.
• P/J504, Tray 5 control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP
Figure 1 Component location
Install new components as necessary:
• Tray 5 elevator motor, PL 7.68 Item 4
• Tray 5 control PWB, PL 7.68 Item 8

The tray 5 elevator motor is operating correctly.

The tray 5 elevator motor is operating correctly.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-161 07-373
 Door interlock switch
S07-306

Tray upper limit switch

actuator
S07-412

Figure 2 Component location

Status Indicator RAPs February 2010

07-373 2-162 Xerox WorkCentre 5790 Family
 Figure 3 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-163 07-373
 A B
07-374 Tray 5 Elevator Lower Failure RAP • P/J504, Tray 5 control PWB.
• 01G +24V Distribution RAP.
07-374 A signal was not detected by the encoder when the elevator motor was driving down.
• 01B 0V Distribution RAP.
Initial Actions Install new components as necessary:
• Check for obstructions behind the tray. • Tray 5 down limit switch, PL 7.70 Item 2.
• Tray 5 control PWB, PL 7.68 Item 8.
Procedure
Enter dC330 code 07-406 tray 5 elevator motor encoder sensor, Q07-406. Press Start.
Figure 1. Ensure the cable holder PL 7.68 Item 23 is not trapped behind the elevator motor Manually lift the motor to activate the sensor. The display changes
bracket PL 7.68 Item 6. The cable holder is correctly positioned.
Y N
Y N
Go to Flag 4. Check Q07-406. Refer to:
Reposition the cable holder so that it does not become trapped behind the elevator motor
bracket. • GP 11 How to Check a Sensor.
Install new components as necessary: • P/J506, Tray 5 control PWB.
• Cable holder PL 7.68 Item 23. • 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Open and close the tray 5 door. The tray moves down. Install new components as necessary:
Y N
• Elevator motor encoder sensor, PL 7.68 Item 5.
Enter dC330 code 07-306 tray 5 door interlock switch. Press Start. Manually toggle the
the door interlock switch. The display changes. • Tray 5 control PWB, PL 7.68 Item 8.
Y N
Enter dC330 code 07-373 tray 5 elevator motor, MOT07-373. Press Start. The motor
Check the wiring to the switch and if necessary install a new switch, PL 7.60 Item 6.
Go to Flag 1. Check S07-306. Refer to: runs
Y N
• GP 13 How to Check a Switch.
Go to Flag 5. Check MOT07-373. Refer to:
• P/J507, Tray 5 control PWB.
• GP 10 How to Check a Motor.
• 01E +5V Distribution RAP.
• P/J504, Tray 5 control PWB.
• 01B 0V Distribution RAP.
• 01G +24V Distribution RAP.
Install new components as necessary:
• 01B 0V Distribution RAP
• Tray 5 door interlock switch, PL 7.60 Item 6.
Install new components as necessary:
• Tray 5 control PWB, PL 7.68 Item 8.
• Tray 5 elevator motor, PL 7.68 Item 4.
• Tray 5 control PWB, PL 7.68 Item 8.
Enter dC330 code 07-405 tray 5 stack down sensor, Q07-405, Figure 1. Press Start. Man-
ually activate the stack down sensor actuator. The display changes
The tray 5 elevator motor is operating correctly.
Y N
Go to Flag 2. Check Q07-405. Refer to:
The tray 5 elevator motor is operating correctly.
• GP 11 How to Check a Sensor.
• P/J505, Tray 5 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 5 stack down sensor, PL 7.68 Item 9.
• Tray 5 control PWB, PL 7.68 Item 8.

Go to PJ504 pin 6 on the Tray 5 control PWB, Flag 3. Manually activate the tray 5 down
limit switch (S07-415) on the paper tray, Figure 2. The voltage changes.
Y N
Go to Flag 3. Check S07-415. Refer to:
• GP 13 How to Check a Switch.
A B
Status Indicator RAPs February 2010
07-374 2-164 Xerox WorkCentre 5790 Family
 Cable holder

Tray 5 elevator motor

encoder sensor Tray down limit switch
Q07-406 S07-415
Located in the paper tray,
press the plate under the
paper tray to actuate the
Tray 5 elevator motor switch.
MOT07-373

Tray 5 control PWB

Stack down sensor

Q07-405

Figure 1 Component location Figure 2 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-165 07-374
 Figure 3 Circuit diagram

Status Indicator RAPs February 2010

07-374 2-166 Xerox WorkCentre 5790 Family
07A Tray 1 and Tray 2 Empty RAP
Use this RAP when the copier display instructs the operator to add paper to the tray that is not
empty.

NOTE: Tray 1 and tray 2 feed mechanisms are identical.

Procedure
Pull out the relevant tray.
Enter the relevant code to monitor the tray empty sensor:
Tray 1 empty sensor, Q07-331. Enter dC330 code 07-331. Press Start.
Tray 2 empty sensor, Q07-332. Enter dC330 code 07-332. Press Start.
Manually actuate the tray empty sensor. The display changes.
Y N
Tray 1: Go to Flag 1. Check S07-331. Tray 2: Go to Flag 2. Check Q07-332. Refer to:
• GP 11 How to Check a Sensor.
• Tray 1 P/J274, Tray 1 and 2 control PWB.
Tray 1 empty sensor Q07-331
• Tray 2 P/J275,Tray 1 and 2 control PWB Tray 2 empty sensor Q07- 342
• 01E +5 V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary. Figure 1 Component location
• Tray 1 empty sensor, Figure 1, PL 8.26 Item 8.
• Tray 2 empty sensor, Figure 1, PL 8.26 Item 8.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Perform the following:

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

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-167 07A
 Figure 2 Tray 1 circuit diagram Figure 3 Tray 2 circuit diagram

Status Indicator RAPs February 2010

07A 2-168 Xerox WorkCentre 5790 Family
07B Tray 3 and Tray 4 False Low Paper Level RAP
Use this RAP when the copier displays tray 3 or tray 4 is low on paper when the tray is full. The
tray is low on paper message will appear when the tray capacity is at 10%.

The machine measurers the time taken for the tray to elevate after being closed, to determine
the amount of paper remaining in tray 3 or tray 4. This measurement only occurs if the tray has
been open for a minimum of 30 seconds. If the tray is closed within 30 seconds the time-out of
the last known paper level is used and no new timing is calculated.

NOTE: A low paper condition will be declared if the stack is below approximately 190 sheets.

Procedure
Pull out the relevant tray and allow it to move fully down. Close the tray. The tray moves up.
Y N
Go to 07-355 Tray 3 Elevator Lift Up Failure RAP.
Go to 07-360 Tray 4 Elevator Lift Up Failure RAP.

Pull out the tray and load a ream of paper or 500 sheets. Wait for 30 seconds before closing
the tray. The message tray is low on paper has changed.
Y N
Tray 3: Go to Flag 1. Check low paper sensor, Q07-343. Tray 4: Go to Flag 2. Check low
paper sensor, Q07-344. Refer to:
• GP 11 How to Check a Sensor. Tray 4 low paper sensor
NOTE: In this check place a piece of paper between the sensor. The check is diffi- HCF control PWB
P/J 390
cult due to the problem in moving the timing disc. Tray 3 low paper sensor
• Figure 1.
• P/J390, HCF control PWB.
• 01E +5V Distribution RAP. Figure 1 Component location
• 01B 0V Distribution RAP.
Install new components as necessary.
• Tray 3 elevator motor, PL 7.20 Item 1.
• Tray 4 elevator motor, PL 7.20 Item 1.
• HCF control PWB, PL 7.20 Item 2.

The low paper sensor appears to be working correctly. If the customer is only adding small
amounts of paper at a time then the message (Tray is low on paper) will be displayed. If the
tray is filled with 190 sheets or more, the message is cancelled.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-169 07B
 07C Bypass Tray RAP
Use this RAP to identify and correct problems when using the bypass tray.

Initial Actions
• Check the condition of the media used in the bypass tray. Refer to IQ1 and GP 20.
• Check that the width sensor guide is up to the edge of the paper, Figure 1.
• If there is a width sensing problem, then check that the bypass tray width sensing potenti-
ometer is not damaged, part of input tray assembly, PL 7.30 Item 1.

Procedure
Enter dC330 code 07-335 to bypass tray empty sensor Q07-335. Press Start. Manually actuate
the sensor. The display changes.
Y N
Go to Flag 2.Check Q07-335. Refer to:
• GP 11 How to Check a Sensor.
• P/J10, IOT PWB.
• 01D +3.3 V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary.
• Bypass tray empty sensor, PL 7.30 Item 7.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Go to Flag 1. Monitor the voltage on the IOT PWB at PJ10 pin 1 and move the guide in and
out. The voltage varies from 0V to +3V.
Y N
Go to Flag 1. Check Q07-350. Refer to:
• The width sensor is a potentiometer. The arm on the potentiometer is attached to the
bypass tray side guide. This gives a variable voltage to indicate the paper width set-
ting.
• P/J10, IOT PWB.
• 01D +3.3 V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary.
• Bypass tray width sensor, part of input tray assembly, PL 7.30 Item 1.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Figure 2 Circuit Diagram 1.10 Item 2.

Enter dC330 code 08-050 feed solenoid, SOL08-050. Press Start. The solenoid energized.
Y N
Go to Flag 3. Check SOL08-050. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• P/J10, IOT PWB.
• 01G +24 V Distribution RAP.
• 01B 0V Distribution RAP.

A
Status Indicator RAPs February 2010
07B, 07C 2-170 Xerox WorkCentre 5790 Family
A
Install new components as necessary.
• Feed solenoid, PL 7.30 Item 4.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Perform the following:

• Ensure that the customer is not filling the tray above the max fill line.
• Clean the feed roll and retard pad with a cloth dampened with water.
• If necessary install a new feed roll and retard pad assembly, PL 7.30 Item 21.

Feed solenoid
SOL08-050

PJ636

PJ36

Feed roll

Width sensor guide Tray empty sensor

Q07-350 Q07-335

Figure 1 Component location

Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-171 07C
07D Tray 1 and 2 Wrong Size Paper RAP
Use this RAP when the paper fed from the tray does not match the paper size indicated by the
tray paper size switch. Tray 1 and tray 2 feed mechanisms are identical.

Initial Actions
• Check that the tray paper guides are set up to the edges of the paper.
• The guides are located in the slots in the base of the tray if a standard paper size is used.
• Check the actuator ribbon on the side of the tray, Figure 1.

Procedure
Check the relevant tray:
Tray 1, Go to Table 1. Compare the paper size in the tray to the size switches actuated.
Tray 2. Go to Table 2. Compare the paper size in the tray to the size switches actuated.
Enter dC330 and relevant component control code as shown in the table. Press Start. Manually
activate the paper size switch. The display changes.
Y N
Tray 1: Go to Flag 1. Tray 2: Go to Flag 2. Check the relevant size switch. Refer to:
• GP 13 How to Check a Switch.
• Tray 1 size switch 1, 2, 3 and 4 at the switch on the PWB, Figure 2.
• Tray 2 size switch 1, 2, 3 and 4 at the switch on the PWB, Figure 4, Tray 1 and 2
• 01E +5V Distribution RAP. control PWB
• 01B 0V Distribution RAP.
Tray actuator ribbon
Install new components as necessary: Paper size leaf
• Tray 1 and 2 control PWB, PL 7.10 Item 2. spring

Check the following:

• Paper tray, PL 7.10 Item 1. Figure 1 Component location
• Paper size leaf spring, PL 7.10 Item 3.

Status Indicator RAPs February 2010

07D 2-172 Xerox WorkCentre 5790 Family
 Size switch 4 test point Table 1 Tray 1 paper size table
Size Size Size Size
switch 4 switch 3 switch 2 switch 1
Paper (S07-314) (S07-313) (S07-312) (S07-311)
Size switch 3 test point
A4 LEF +5V +5V 0V +5V
A4 SEF 0V +5V 0V +5V
A5 LEF 0V 0V 0V +5V
Size switch 2 test point A3 SEF +5V 0V +5V +5V
216 x 315 mm SEF 0V +5V +5V 0V
216 x 330 mm SEF 0V 0V +5V 0V
Size switch 1 test point
8.5 x 11 LEF 0V +5V 0V 0V
8.5 x 11 SEF 0V 0V +5V +5V
8.5 x 5.5 LEF 0V +5V +5V +5V
11 x 17 SEF +5V 0V +5V 0V
8.5 x 14 SEF +5V +5V 0V 0V
8.5 x 12.4 SEF 0V +5V +5V 0V
8.5 x 13 SEF 0V 0V +5V 0V

Figure 2 Tray 1 size switch test points

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-173 07D
 Size switch 4 test point

Size switch 3 test point

Figure 3 Tray 1 circuit diagram

Size switch 2 test point

Size switch 1 test point

Figure 4 Tray 2 size switch test point

Table 2 Tray 2 paper size table

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

Status Indicator RAPs February 2010

07D 2-174 Xerox WorkCentre 5790 Family
 Table 2 Tray 2 paper size table 07E Tray 3 or Tray 4 Out of Paper RAP
Size Size Size Size Use this RAP when the copier display instructs the operator to add paper to the tray that is not
switch 4 switch 3 switch 2 switch 1 empty.
Paper (S07-324) (S07-323) (S07-322) (S07-321)
A4 SEF 0V +5V 0V +5V 07-543 Tray 3 out of service.
A5 LEF 0V 0V 0V +5V
07-544 Tray 4 out of service.
A3 SEF +5V 0V +5V +5V
216 x 315 mm SEF 0V +5V +5V 0V The above status codes and messages may be generated if the actuator is missing from the
216 x 330 mm SEF 0V 0V +5V 0V tray empty sensor.
8.5 x 11 LEF 0V +5V 0V 0V
8.5 x 11 SEF 0V 0V +5V +5V NOTE: Tray 3 and tray 4 feed mechanisms are identical.
8.5 x 5.5 LEF 0V +5V +5V +5V Initial Actions
11 x 17 SEF +5V 0V +5V 0V • Check the tray empty actuator moves freely and located correctly, Figure 1.
8.5 x 14 SEF +5V +5V 0V 0V • Check that the feed head drops when the tray is pushed fully home.
8.5 x 12.4 SEF 0V +5V +5V 0V
8.5 x 13 SEF 0V 0V +5V 0V Procedure
Enter the relevant code to monitor the tray empty sensor:
Tray 3 empty sensor, Q07-333. Enter dC330 code 07-333. Press Start.
Tray 4 empty sensor, Q07-334. Enter dC330 code 07-334. Press Start.
Manually actuate the tray empty sensor. The display changes.
Y N
Tray 3: Go to Flag 1. Check Q07-333. Tray 4: Go to Flag 2. Check Q07-334. Refer to:
• GP 11 How to Check a Sensor.
• Tray 3 P/J399, HCF control PWB.
• Tray 4 P/J391, HCF control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 3 empty sensor Figure 1, part of PL 8.30 Item 1.
• Tray 4 empty sensor Figure 1, part of PL 8.30 Item 1, PL 8.31 Item 1.
• HCF Control PWB, PL 7.20 Item 2.

The fault may be intermittent. Perform the following:

• Check the ribbon harnesses, GP 7.
• Check that the ribbon cables are connected correctly into P/J391 and P/J399. Refer to
REP 8.3 Tray 4 Paper Feed Assembly and REP 8.2 Tray 3 Paper Feed Assembly.

Figure 5 Tray 2 circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-175 07D, 07E
 Tray 3 empty sensor Q07-333
Tray 4 empty sensor Q07-334

Figure 1 Component location

Figure 2 Circuit diagram

Status Indicator RAPs February 2010

07E 2-176 Xerox WorkCentre 5790 Family
07F Tray Out of Service RAP 07G Tray 5 Empty RAP
The IOT has detected a fault in the tray and determines that the tray is out of service. The fol- Use this RAP to solve problems associated with the tray 5 empty sensor.
lowing status codes and messages will be displayed.
Initial Actions
07-541 Tray 1 out of service.
• Check that the hole in the tray, directly under the sensor is clear and empty, Figure 1.
07-542 Tray 2 out of service. • Check the sensor for contamination.

07-543 Tray 3 out of service. Procedure

Enter dC330 code 07-401 tray 5 empty sensor. Press Start.
07-544 Tray 4 out of service. Manually actuate the tray empty sensor. The display changes.
Y N
07-546 Tray 5 out of service. Go to Flag 1. Check Q07-401. Refer to:
• GP 11 How to Check a Sensor.
Initial Actions • P/J505, Tray 5 control PWB.
• Switch off the machine, then switch on the machine, GP 14. • 01E +5V Distribution RAP.
• Check that the tray elevator cables and mechanisms are located correctly. • 01B 0V Distribution RAP.
• Check that the tray is pushed fully home. Install new components as necessary:
• Check for obstructions behind the tray. • Tray 5 empty sensor, PL 8.45 Item 6.
• Check the feed heads. • Tray 5 control PWB, PL 7.68 Item 8.

Procedure The fault may be intermittent. Perform the steps that follow:
If tray 3 or tray 4 are out of service. Go to 07E Tray 3 or Tray 4 Out of Paper RAP. • Check the wiring harness for damaged wire, GP 7.
• Check that Tray 5 empty sensor is located correctly.
If tray 1 or tray 2 are out of service. Check the following and install new components as neces-
sary:
• Paper tray 1 and 2 assembly, PL 7.10 Item 1.
• Tray 1 and 2 paper feed assembly, PL 8.26 Item 1, PL 8.26 Item 2.
If tray 5 is out of service, go to 07G Tray 5 Empty RAP

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-177 07F, 07G
 Tray 5 empty sensor
Q07-401

Check the hole in the

tray is clear

Figure 1 Component location Figure 2 Circuit diagram

Status Indicator RAPs February 2010

07G 2-178 Xerox WorkCentre 5790 Family
08-100 Wait Sensor Jam Entry RAP 08-100A Wait Sensor Jam RAP (35-55 ppm)
08-100 The lead edge of the paper failed to actuate the wait sensor within the correct time from 08-100 The lead edge of the paper failed to actuate the wait sensor within the correct time from
feed sensor 1. feed sensor 1.

Procedure Initial Actions

Identify the speed of the machine, refer to SCP 7 Machine features. Perform one of the steps • Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08-
that follow: 100 Wait Sensor Jam Entry.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
• If the speed of the machine is 35-55 ppm, go to 08-100A Wait Sensor RAP (35-55 ppm)
• Check for obstructions in the paper path.
• If the speed of the machine is 65-90 ppm, go to 08-100B Wait Sensor RAP (65-90 ppm).
• Check wait sensor actuator, Figure 1.
• Check that the left hand door is latched correctly.
• Check that the interlock cover has not come loose. PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws.
• Make sure the correct paper size is displayed for the size of paper in the tray.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.

Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.

Manually actuate the wait sensor. The display changes.
Y N
Go to Flag 1. Check Q08-100. Refer to:
• GP 11 How to Check a Sensor.
• P/J5, IOT PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Wait sensor, (35-55 ppm) PL 8.15 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 08-101 tray 1 feed sensor, Q08-101. Press Start. Open left hand door and
manually actuate the sensor. The display changes.
Y N
Go to Flag 2. Check Q08-101. Refer to:
• GP 11 How to Check a Sensor.
• P/J276, Tray 1 and 2 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 feed sensor, PL 7.30 Item 25.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Enter dC330 code 08-025 tray 1 and 2 transport motor, MOT08-025. Press Start. The motor
runs.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-179 08-100, 08-100A
Y N
Go to Flag 3. Check MOT08-025. Refer to:
• GP 10 How to Check a Motor.
• P/J273, Tray 1 and 2 control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 and 2 transport motor, (35-55 ppm) PL 8.25 Item 5.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

The transport rolls rotate.

Y N
Check the drive belt and gears, GP 7, PL 8.25 Item 2, PL 8.25 Item 3.

Check the following:

• The bearing, shaft and rolls on the transport roll assembly, GP 7, (35-55 ppm) PL 8.25 Tray 1 and 2 transport motor
Item 8. MOT08-025
• The idler rolls in the left hand door, GP 7, PL 7.30 Item 2.
• The transport drive belt, (35-55 ppm) PL 8.25 Item 2.
• The transport rolls for wear, PL 8.25 Item 8.
Install new components as necessary.

Tray 1 feed sensor

Q08-101
Wait sensor
Q08-100

Figure 1 Component location

Status Indicator RAPs February 2010

08-100A 2-180 Xerox WorkCentre 5790 Family
 08-100B Wait Sensor Jam RAP (65-90 ppm)
08-100 The lead edge of the paper failed to actuate the wait sensor within the correct time from
feed sensor 1.

Initial Actions
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08-
100 Wait Sensor Jam Entry RAP.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
• Check for obstructions in the paper path.
• Check that the left hand door is latched correctly.
• Check that the interlock cover has not come loose. PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws.
• Make sure the correct paper size is displayed for the size of paper in the tray.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.

Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.

Manually actuate the wait sensor. The display changes.
Y N
Go to Flag 1. Check Q08-100. Refer to:
• GP 11 How to Check a Sensor.
• P/J16, IOT PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Wait sensor, PL 7.30 Item 25.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 08-101 tray 1 feed sensor, Q08-101. Press Start. Open left hand door and
manually actuate the sensor. The display changes.
Y N
Go to Flag 2. Check Q08-101. Refer to:
• GP 11 How to Check a Sensor.
• P/J276, Tray 1 and 2 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 feed sensor, PL 7.30 Item 24.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Enter dC330 code 08-025 tray 1 and 2 transport motor, MOT08-025. Press Start. The motor
Figure 2 Circuit diagram runs.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-181 08-100A, 08-100B
Y N
Go to Flag 3. Check MOT08-025. Refer to:
• GP 10 How to Check a Motor.
• P/J276, Tray 1 and 2 control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 and 2 transport motor, PL 8.25 Item 5.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

The transport rolls rotate.

Y N
Check the drive belt and gears, GP 7, PL 8.25.

Check the following:

• The bearing, shaft and rolls on the transport roll assembly, GP 7, PL 8.25 Item 8. Tray 1 and 2 transport motor
MOT08-025
• The idler rolls in the left hand door, GP 7, PL 7.30 Item 2.
• The transport drive belt, PL 8.25 Item 2.
• The transport rolls for wear, PL 8.25 Item 8.
Install new components as necessary.

Tray 1 feed sensor

Q08-101
Wait sensor
Q08-100

Figure 1 Component location

Status Indicator RAPs February 2010

08-100B 2-182 Xerox WorkCentre 5790 Family
 08-101 Tray 1 Misfeed RAP
08-101 The lead edge of the paper failed to actuate the tray 1 feed sensor within the correct
time after feeding paper from tray 1.

Initial Actions
• Check the condition of the paper in tray 1. Refer to IQ1 and GP 20.
• Check that the paper guides are set correctly.
• Observe the feeder and check for obstructions.
• Turn and change the paper in the tray.
• Check that the tray elevates to the feed position. Refer to 07-353 Tray 1 Elevator Lift Fail-
ure RAP.
• Check that the left hand door is latched correctly.
• Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws
• Check for damage to the chamfered edge on the left side of the tray. Repair the damaged
edge or install a new paper tray, PL 7.10 Item 1.
• If the paper has excessive curl and is causing the paper to be skewed when fed from the
tray. Install TAG 002 on the paper tray to constrain the effect of the curl.
• Check the paper feeder PL 8.26 Item 2 fully descends. If the paper feeder shaft is binding
with the edge of the housing slot, apply plastislip grease to the contact areas.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.

NOTE: To help fault diagnosis, install the tray 1 paper feed assembly in the tray 2 paper feed
assembly position. With tray 1 removed, the operation of the feed assembly can be observed.
Refer to REP 8.1.

Enter dC330 code 08-101 tray 1 feed sensor, Q08-101. Figure 1. Press Start. Open the left
hand door and manually actuate the sensor. The display changes.
Y N
Go to Flag 1. Check Q08-101. Refer to:
• GP 11 How to Check a Sensor.
• P/J276, Tray 1 and 2 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 feed sensor, PL 7.30 Item 25.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Enter dC330 code 08-025 tray 1 and 2 transport motor, MOT08-025. Press Start. The motor
runs.
Y N
Figure 2 Circuit diagram Go to Flag 2. Check MOT08-025. Refer to:
• GP 10 How to Check a Motor.
• P/J273, Tray 1 and 2 control PWB.
• 01G +24V Distribution RAP.
A

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-183 08-100B, 08-101
A
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 and 2 transport motor, PL 8.25 Item 5.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

The transport rolls rotate.

Y N
Check the drive belt and gears, PL 8.25 Item 2.

CAUTION
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 08-
010 is run in diagnostics.
Enter dC330 code 08-010 tray 1 paper Feed motor, MOT08-010, Pull out the tray. Press Start.
The feed rolls rotate.
Y N
Remove the feed assembly from the machine. Manually rotate the feed roll shaft. The Tray 1 and 2 transport motor
drive gears rotate. MOT08-025
Y N
Check the drive gears for damage. If necessary install new components, PL 8.26.

Install the tray 1 feed assembly.

Go to Flag 3. Check MOT08-010. Refer to:
• GP 10 How to Check a Motor.
• P/J274, Tray 1 and 2 control PWB.
• 01D +3.3V Distribution RAP.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Instal new Components as necessary:
• Tray 1 feed motor, PL 8.26 Item 6.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

The nudger roll rotates.

Y N
Check the nudger roll drive belt and drive coupling for damage. If necessary install new
components, PL 8.26.

Remove the paper tray. Manually activate the retard nip split mechanism. The retard roll
moves against the feed roll.
Y N
Check the retard roll drive coupling and mechanism for damage.
If necessary install new components, PL 8.26.
Tray 1 feed sensor
Perform the following: Q08-101 Tray 1 and 2 transport rolls
• Clean the feed roll using a cloth dampened with water.
• Check the feed roll assembly, PL 8.26 Item 3.
• Check the feed assembly, PL 8.26 Item 1. Figure 1 Component location

Status Indicator RAPs February 2010

08-101 2-184 Xerox WorkCentre 5790 Family
 08-102 Tray 2 Misfeed RAP
08-102 The lead edge of the paper failed to actuate the tray 2 feed sensor within the correct
time after feeding paper from tray 2.

Initial Actions
• Check the condition of the paper in tray 2. Refer to IQ1 and GP 20.
• Check that the paper guides are set correctly.
• Observe the feeder and check for obstructions.
• Turn and change the paper in the tray.
• Check that the tray elevates to the feed position. Refer to 07-354 Tray 2 Elevator Lift Fail-
ure RAP.
• Check that the left hand door is latched correctly.
• Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws
• Check for damage to the chamfered edge on the left side of the tray. Repair the damaged
edge or install a new paper tray, PL 7.10 Item 1.
• If the paper has excessive curl and is causing the paper to be skewed when fed from the
tray. Install TAG 002 on the paper tray to constrain the effect of the curl.
• Check the paper feeder PL 8.26 Item 1 fully descends. If the paper feeder shaft is binding
with the edge of the housing slot, apply plastislip grease to the contact areas.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.

Enter dC330 code 08-102 tray 2 feed sensor, Q08-102. Figure 1. Press Start. Open the left
hand door and manually actuate the sensor. The display changes.
Y N
Go to Flag 1.Check Q08-102. Refer to:
• GP 11 How to Check a Sensor.
• P/J276, Tray 1 and 2 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 2 feed sensor, PL 7.30 Item 24.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Enter dC330 code 08-025 tray 1 and 2 transport motor, MOT08-025. Press Start. The motor
runs.
Y N
Go to Flag 2. Check MOT08-025. Refer to:
• GP 10 How to Check a Motor.
Figure 2 Circuit diagram • P/J273, Tray 1 and 2 control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 and 2 transport motor, PL 8.25 Item 5.
A

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-185 08-101, 08-102
A
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

The transport rolls rotate.

Y N
Check the drive belt and gears, GP 7, PL 8.25 Item 2.

CAUTION
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 08-
020 is run in diagnostics.
Enter dC330 code 08-020 tray 2 paper feed motor, MOT08-020. Pull out the tray. Press Start.
The motor runs.
Y N
Remove the feed assembly from the machine. Manually rotate the feed roll shaft. The
feed rolls rotate.
Y N
Check the drive gears for damage. If necessary install new components, PL 8.26.
Tray 1 and 2 transport motor
MOT08-025
Install the tray 2 feed assembly.
Go to Flag 3. Check MOT08-020. Refer to:
• GP 10 How to Check a Motor.
• P/J275, Tray 1 and 2 control PWB.
• 01E +5V Distribution RAP.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Instal new Components as necessary:
• Tray 2 feed motor, PL 8.26 Item 6.
• Tray 1 and 2 control PWB PL 7.10 Item 2.

The nudger roll rotates.

Y N
Check the nudger roll drive belt and drive coupling for damage.
If necessary install new components, PL 8.26.

Remove the paper tray. Manually activate the retard nip split mechanism. The retard roll
moves against the feed roll.
Y N
Check the retard roll drive coupling and mechanism for damage.
If necessary install new components, PL 8.26.

Perform the following:

• Clean the feed roll using a cloth dampened with water.
• Check the feed roll assembly, PL 8.26 Item 3.
Tray 2 feed sensor
• Check the feed assembly, PL 8.26 Item 1. Q08-102 Transport rolls

Figure 1 Component location

Status Indicator RAPs February 2010

08-102 2-186 Xerox WorkCentre 5790 Family
 08-103, 08-113 Tray 3 Misfeed RAP
08-103 The lead edge of the paper failed to actuate the tray 3 feed sensor within the correct
time after feeding paper from tray 3.

08-113 Tray 3 sensor did not de-actuate within the correct time after the sensor was actuated.

Initial Actions
• Check the condition of the paper in tray 3. Refer to IQ1 and GP 20.
• Check the tray 3 feed sensor actuator arm, PL 7.15 Item 9.
• Check that the spacers are on the paper feed assembly, refer to REP 8.2.
• Ensure that the tray is pushed fully home.
• If the misfeed occurs between 15 and 20 paper feeds, then go to 07-355 Tray 3 Elevator
Lift Failure RAP.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.

Remove the rear cover, PL 7.25 Item 1. Locate tray 3 feed sensor, Q08-103. Figure 1.
Enter dC330 code 08-103 tray 3 Feed Sensor, Q08-103. Press Start. Manually block and
unblock the sensor. The display changes.
Y N
Go to Flag 1. Check Q08-103. Refer to:
• GP 11 How to Check a Sensor.
• P/J393, HCF control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 3 feed sensor, PL 8.30 Item 15.
• HCF control PWB, PL 7.20 Item 2.

Enter dC330 code 08-045 tray 3 and 4 transport motor, MOT08-045. Press Start. The motor
runs.
Y N
Go to Flag 2. Check MOT08-045. Refer to:
• GP 10 How to Check a Motor.
• P/J398, HCF control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 3 and 4 transport motor, PL 8.30 Item 7.
• HCF control PWB, PL 7.20 Item 2.
Figure 2 Circuit diagram
The transport rolls rotate.
Y N
Check the gears and drive belt, GP 7, PL 8.30 Item 8, PL 8.30 Item 9.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-187 08-102, 08-103, 08-113
A
CAUTION – The takeaway roll assembly, PL 8.35 Item 2.
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 08- – The transport roll assembly, PL 8.35 Item 11.
030 is run in diagnostics. – The transport roll bearing, PL 8.35 Item 3.
Enter dC330 code 08-030 tray 3 feed motor, MOT08-030. Pull out the tray. Press Start. The
motor runs.
Y N
Go to Flag 3. Check MOT08-030. Refer to:
• GP 10 How to Check a Motor.
• P/J399, HCF control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 3 paper feed assembly, PL 8.30 Item 1.
• HCF control PWB, PL 7.20 Item 2.

Perform the following:

• Clean the feed roll using a cloth dampened with water.
• Check the feed roll assembly, PL 8.30 Item 6.
1. Check for TAG 110.
2. If W/O TAG 110, install feed roll kit PL 8.30 Item 20.
3. Strike TAG 110.

NOTE: TAG 110, PL 8.30 Item 20 feed roll kit must be installed to trays 3 and 4 simulta- Tray 3 feed motor
neously. Refer to RAP 08-104, RAP 08-114, PL 8.31 Item 10. MOT08-030 Tray 3 and 4
transport motor
• Check the tray 3 feed assembly, PL 8.30 Item 1. Refer to REP 8.2 and check the feed MOT08-045
head housing location.
• Check the tray 3 stack height sensor actuator on the feed assembly, PL 8.30. Tray 3 feed sensor
HCF control Q08-103
• Check the tray is level. PWB
1. Remove the tray front cover.
2. Elevate the tray to the stack height position.
Figure 1 Component location
3. Hold the elevator drive gear and pull out the tray. Check that the tray is level.
4. If the tray is not level then install new elevator cables, PL 7.15 Item 10.
• Check the stack height.
1. Remove the front tray cover.
2. Elevate the tray to the stack height position.
3. Hold the elevator drive gear and pull out the tray.
4. Check that the paper stack does not stop below the separator strips.
Also check in the run mode that the stack does not fall below the separator strips.
5. If the paper stack stops below the separator strips, then install new elevator cables,
PL 7.15 Item 10.
• Check the tray 3 corner separation strip for paper cut damage. If necessary, install new
components, PL 7.15 Item 22.
• Check the tray 3 top edge flexure spring for paper cut damage. If necessary, install new
components, PL 7.17 Item 12.
• If the fault still occurs, check the following, GP 7:

Status Indicator RAPs February 2010

08-103, 08-113 2-188 Xerox WorkCentre 5790 Family
 08-104, 08-114 Tray 4 Misfeed RAP
08-104 The lead edge of the paper failed to actuate the tray 4 feed sensor within the correct
time after feeding paper from tray 4.

08-114 Tray 4 sensor did not de-actuate within the correct time after the sensor was actuated.

Initial Actions
• Check the condition of the paper in tray 4. Refer to IQ1 and GP 20.
• Check that the paper feed assembly is installed correctly, refer to REP 8.3.
• Ensure that the tray is pushed fully home.
• If the misfeed occurs between 15 and 20 paper feeds, then go to 07-360 Tray 4 Elevator
Lift Failure RAP.
• Check that the left hand door is latched correctly.
• Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.

Enter dC330 code 08-104 tray 4 feed sensor, Q08-104, Figure 1. Press Start. Pull out tray 4
and manually actuate the sensor. The display changes.
Y N
Go to Flag 1. Check Q08-104. Refer to:
• GP 11 How to Check a Sensor.
• P/J392, HCF control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 4 feed sensor, PL 8.31 Item 12.
• HCF control PWB, PL 7.20 Item 2.

Enter dC330 code 08-045 tray 3 and 4 transport motor, MOT08-045. Press Start. The motor
runs.
Y N
Go to Flag 2. Check MOT08-045. Refer to:
• GP 10 How to Check a Motor.
• P/J398, HCF control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 3 and 4 transport motor, PL 8.30 Item 7.
• HCF control PWB, PL 7.20 Item 2.
Figure 2 Circuit diagram
The transport rolls rotate.
Y N
Check the drive belt and gears, GP 7, PL 8.30 Item 9, PL 8.30 Item 8.
A

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-189 08-103, 08-113, 08-104, 08-114
A
CAUTION • Check the tray 4 corner separation strip for paper cut damage. If necessary, install new
To prevent damage to the feed mechanism, the paper tray must be pulled out before MOT 08- components, PL 7.15 Item 22.
040 is run in diagnostics. • Check the tray 4 top edge flexure spring for paper cut damage. If necessary, install new
Enter dC330 code 08-040 tray 4 feed motor, MOT08-040. Pull out the tray. Press Start. The components, PL 7.17 Item 12.
motor runs.
Y N
Tray 4 feed sensor
Go to Flag 3. Check MOT08-040. Refer to: Q08-104
• GP 10 How to Check a motor.
• P/J391, HCF control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 4 feed assembly, PL 8.31 Item 4.
• HCF control PWB, PL 7.20 Item 2.

Perform the following:

• Clean the feed roll using a cloth dampened with water.
• Check the feed roll assembly, PL 8.31 Item 2.
1. Check for TAG 110.
2. If W/O TAG 110, install feed roll kit PL 8.31 Item 10.
3. Strike TAG 110.

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

Status Indicator RAPs February 2010

08-104, 08-114 2-190 Xerox WorkCentre 5790 Family
 08-106 Late to Tray 1 Feed Sensor RAP
08-106 The lead edge of the paper was late to tray 1 feed sensor when feeding from tray 2.
The fault will also occur when feeding from tray 3 or tray 4 providing the trail edge of the sheet
has cleared the tray 4 feed sensor.

Initial Actions
• Check the condition of the paper in tray 2. Refer to IQ1 and GP 20.
• Check for obstructions in the paper path.
• Check that the left hand door is latched correctly.
• Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws
• Ensure that the tray is pushed fully home.
• Ensure that the correct size of paper is displayed.
• If the jam occurs when feeding from tray 2. Check if the paper has excessive curl and is
causing the paper to be skewed when fed from the tray. Install TAG 002 on the paper tray
to constrain the effect of the curl.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.
Enter dC330 code 08-101 tray 1 feed sensor, Q08-101. Press Start. Open the left hand door
and manually actuate the sensor, Figure 1. The display changes.
Y N
Go to Flag 1. Check Q08-101. Refer to:
• Component location, Figure 1.
• GP 11 How to Check a Sensor.
• P/J276, Tray 1 and 2 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 feed sensor, PL 7.30 Item 24.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Enter dC330 code 08-102 tray 2 feed sensor, Q08-102. Press Start. Manually actuate the sen-
sor, Figure 2. The display changes.
Y N
Go to Flag 2. Check Q08-102. Refer to:
• GP 11 How to Check a Sensor.
• P/J276, Tray 1 and 2 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Figure 2 Circuit diagram Install new components as necessary:
• Tray 2 feed sensor, PL 7.30 Item 24.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-191 08-104, 08-114, 08-106
A
Enter dC330 code 08-025 tray 1 and 2 transport motor, MOT08-025. Press Start. The motor
runs.
Y N
Go to Flag 3. Check MOT08-025. Refer to:
• GP 10 How to Check a Motor.
• P/J273, Tray 1 and 2 control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 1 and 2 transport motor, PL 8.25 Item 5.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

The transport rolls rotate.

Y N
Check the drive belt and pulleys, PL 8.25 Item 2, PL 8.25 Item 3.
Tray 1 and 2 Transport motor
MOT08-025
Check the following:
• The bearing, shaft and rolls on the transport roll assembly, GP 7, PL 8.25 Item 8.
• The idler rolls in the left hand door, GP 7, PL 7.30 Item 2.
• The transport drive belt, PL 8.25 Item 2.
• If the fault occurs when feeding from tray 3 or tray 4 but not tray 2 then check the position-
ing of the tray 3 / 4 transport pinch rolls, PL 8.30 Item 18, and the transport motor bracket,
PL 8.30 Item 14, REP 8.11.
Install new components as necessary.

Tray 1 feed sensor

Q08-101

Tray 2 feed sensor Tray 1 and 2 transport rolls

Q08-102

Figure 1 Component location

Status Indicator RAPs February 2010

08-106 2-192 Xerox WorkCentre 5790 Family
 08-107 Tray 3 Paper Feed Jam RAP
08-107 The lead edge of the paper was late to tray 4 feed sensor when feeding from tray 3.

Initial Actions
• Check the condition of the paper in tray 3. Refer to IQ1 and GP 20.
• Check for obstructions in tray 3 paper path, Figure 2.
• Check the tray 4 feed sensor, Figure 1.
• Ensure that the tray is pushed fully home.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.

Enter dC330 code 08-104 tray 4 feed sensor, Q08-104. Press Start. Manually actuate the tray
4 sensor. The display changes.
Y N
Go to Flag 1. Check Q08-104. Refer to:
• GP 11 How to Check a Sensor.
• P/J392, HCF control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 4 feed sensor, PL 8.31 Item 12.
• HCF control PWB, PL 7.20 Item 2.

Enter dC330 code 08-045 tray 3 and 4 transport motor, MOT08-045. Press Start. The motor
runs.
Y N
Go to Flag 2. Check MOT08-045. Refer to:
• GP 10 How to Check a Motor.
• P/J398, HCF control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 3 and 4 transport motor, PL 8.30 Item 7.
• HCF control PWB, PL 7.20 Item 2.

The transport rolls rotate.

Y N
Figure 2. Check drive belt and drive coupling, PL 8.30 Item 9.

Perform the following:

• Figure 2. Check tray 3 transport rolls, PL 8.35, PL 8.30.
Figure 2 Circuit diagram • Go to RAP 08-103, 08-113 Tray 3 Misfeed RAP.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-193 08-106, 08-107
 Drives coupling

Drive belt

Tray 4 feed
sensor
Q08-104
Tray 3 paper path
rolls
Tray 3 and 4 trans-
port motor
MOT08-045 Tray 4 paper path
rolls

Figure 1 Component location Figure 2 Component location

Status Indicator RAPs February 2010

08-107 2-194 Xerox WorkCentre 5790 Family
 08-108 Tray 3 or Tray 4 Paper Feed Jam RAP
08-108 The lead edge of the paper was late to tray 2 feed sensor when feeding from tray 3 or
tray 4.

Initial Actions
• Check the condition of the paper in tray 3 and tray 4. Refer to IQ1 and GP 20.
• Check for obstructions in the paper path.
• Check that the left hand door is latched correctly.
• Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws
• Ensure that the tray is pushed fully home.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.
Enter dC330 code 08-102 tray 2 feed sensor, Q08-102. Press Start. Manually actuate the sen-
sor. The display changes.
Y N
Go to Flag 1. Check Q08-102. Refer to:
• GP 11 How to Check a Sensor.
• P/J276, Tray 1 and 2 control PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tray 2 feed sensor, PL 7.30 Item 24.
• Tray 1 and 2 control PWB, PL 7.10 Item 2.

Enter dC330 code 08-045 tray 3 and 4 transport motor, MOT08-045. Press Start. The motor
runs.
Y N
Go to Flag 2. Check MOT08-045. Refer to:
• GP 10 How to Check a Motor.
• P/J398, HCF control PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Figure 3 Circuit diagram Install new components as necessary:
• Tray 3 and 4 transport motor, PL 8.30 Item 7.
• HCF control PWB, PL 7.20 Item 2.

The transport rolls rotate.

Y N
Check the gears and drive belt, PL 8.30 Item 8, PL 8.30 Item 9, GP 7.

Perform the following:

• Check the tray 3 and tray 4 transport rolls, PL 8.30 Item 18, GP 7.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-195 08-107, 08-108
• If the fault occurs when feeding from tray 4. Go to RAP 08-104, 08-114 Tray 4 Misfeed
RAP.
• If the fault occurs when feeding from tray 3. Check the following, GP 7:
– The takeaway roll assembly, PL 8.35 Item 2.
– The transport roll assembly, PL 8.35 Item 11.
– The transport roll bearing, PL 8.35 Item 3.
– Go to RAP 08-103, 08-113 Tray 3 Misfeed RAP

Tray 3 and 4 transport motor

MOT08-045

Tray 2 feed sensor

Q08-102

Figure 1 Component location

Status Indicator RAPs February 2010

08-108 2-196 Xerox WorkCentre 5790 Family
 08-115, 08-117 Tray 5 Misfeed RAP
08-115 The lead edge of the paper was late to the wait point sensor.

08-117 The lead edge of the paper failed to reach the feed sensor within the correct time after
paper feed.

Procedure
Identify the speed of the machine, refer to SCP 7 Machine features. Perform one of the steps
that follow:

• If the speed of the machine is 35-55 ppm, go to 08-115A, 08-117A Tray 5 Misfeed RAP
(35-55 ppm)
• If the speed of the machine is 65-90 ppm, go to 08-115B, 08-117B Tray 5 Misfeed RAP
(65-90 ppm).

Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-197 08-108, 08-115, 08-117
 A
08-115A, 08-117A Tray 5 Misfeed RAP (35-55 ppm) • Clutch, PL 8.45 Item 13.
• Feed roll, PL 8.45 Item 12.
08-115 The lead edge of the paper was late to the wait point sensor.
The nudger roll rotates
08-117 The lead edge of the paper failed to reach the feed sensor within the correct time after Y N
paper feed. Check the nudger roll and the one way gear. Check the drive belt between the feed roll
Initial Actions and the nudger roll. Install new components as necessary:
• One way gear, PL 8.45 Item 3.
• Check the condition of the paper in tray 5. Refer to IQ1 and GP 20.
• Drive belt, PL 8.40 Item 7.
• Check that the left hand door is correctly latched, Figure 2.
• Nudger roll, PL 8.45 Item 10.
• Check that the paper tray is set to the correct paper size.
The retard roll rotates
• Check that tray 5 is set to the correct paper configuration. Enter dC131 NVM chain 8, at
Y N
location 08-313 Tray 5 Configuration. Check the retard roll, retard clutch and clutch. Install new components as necessary:
Procedure • Retard clutch, PL 8.47 Item 11.
• Clutch, PL 8.47 Item 7.
NOTE: The front door interlock must be cheated when checking +24V components.
• Retard roll, PL 8.47 Item 2.
Enter dC330 code 08-105 tray 5 feed sensor, Q08-105, Figure 1. Press Start. Manually actuate
Enter dC330 code 08-046 tray 5 transport motor, MOT08-046. Press Start. The motor runs.
the sensor. The display changes. Y N
Y N
Go to Flag 3. Check MOT08-046. Refer to:
Go to Flag 1. Check Q08-105. Refer to:
• GP 10 How to Check a Motor.
• GP 11 How to Check a Sensor.
• P/J503, Tray 5 control PWB
• P/J505, Tray 5 control PWB
• 01G +24V Distribution RAP.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
Install new components as necessary:
• Tray 5 transport motor, PL 8.40 Item 2.
• Tray 5 feed sensor, PL 8.45 Item 6.
• Tray 5 control PWB, PL 7.68 Item 8.
• Tray 5 control PWB, PL 7.68 Item 8.
Run the motor for 30 seconds. The motor runs at a constant speed, without slowing.
Enter dC330 code 08-117 tray 5 feed motor, MOT08-117. Open the door. Press Start. The Y N
motor runs. Install a new tray 5 transport motor, PL 8.40 Item 2.
Y N
The take away roller rotates.
Go to Flag 4. Check MOT08-117. Refer to: Y N
• GP 10 How to Check a motor. Check the drive belt and the one way pulley clutch for damage, GP 7. Check the belt ten-
• P/J511, Tray 5 control PWB. sioner. Install new components as necessary:
• 01G +24V Distribution RAP. • Drive belt, PL 8.40 Item 7.
• 01B 0V Distribution RAP. • One way pulley clutch, PL 8.47 Item 4.
Install new components as necessary: • Take away roller, PL 8.47 Item 5.
• Tray 5 feed motor, PL 8.40 Item 3. Enter dC330 code 08-110 T5 wait point sensor, Q08-110. Press Start.
• Tray 5 control PWB, PL 7.68 Item 8. NOTE: For trays 1 to 5 the input code 08-100 wait sensor is used to check the operation of the
The feed shaft rotates. wait sensor. In addition tray 5 uses the input code 08-110 T5 wait point sensor, to check the
Y N paper present signal from the IOT PWB to the tray 5 control PWB.
Check the drive gears between the motor and the feed shaft. Install new components as
necessary: Open the left hand door and manually actuate the wait sensor, Figure 2. The display
• Motor drive gear, PL 8.40 Item 5. changes.
• Gear 30T bearing, PL 8.40 Item 21. Y N
• Gear, PL 8.45 Item 14. Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.
Manually actuate the wait sensor, Figure 2. The display changes.
The feed roll rotates
Y N Y N
Go to Flag 2. Check Q08-100. Refer to:
Check the one way coupling, feed roll and clutch. Install new components as necessary:
• One way coupling, PL 8.45 Item 4. • GP 11 How to Check a Sensor.
• P/J5, IOT PWB.
A B C
Status Indicator RAPs February 2010
08-115A, 08-117A 2-198 Xerox WorkCentre 5790 Family
B C
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Wait sensor, PL 8.15 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
PL 1.10 Item 2.
Go to Flag 5. Manually actuate the wait sensor.
Check for a signal change on the IOT PWB at P/J12 pin 10 and on the tray 5 control
PWB at P/J512 pin 5.
Check the wiring between the IOT PWB and the tray 5 control PWB.
Install new components as necessary:
• Tray 5 control PWB, PL 7.68 Item 8.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
Perform the steps that follow:
• Clean the feed roll using a cloth dampened with water.
• Install a new feed, nudger and retard roll, PL 8.45 Item 21.

Tray 5 feed sensor

Q08-105

Left hand door Wait sensor

Q08-100
Tray 5 feed motor
MOT08-117

Figure 2 Component location

Tray 5 transport
motor
MOT08-046

Tray 5 control PWB

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-199 08-115A, 08-117A
 Figure 3 Circuit diagram

Status Indicator RAPs February 2010

08-115A, 08-117A 2-200 Xerox WorkCentre 5790 Family
 A
08-115B, 08-117B Tray 5 Misfeed RAP (65-90 ppm) • Gear, PL 8.45 Item 14.

08-115 The lead edge of the paper was late to the wait point sensor.
The feed roll rotates
Y N
08-117 The lead edge of the paper failed to reach the feed sensor within the correct time after
Check the one way coupling, feed roll and clutch. Install new components as necessary:
paper feed.
• One way coupling, PL 8.45 Item 4.
• Clutch, PL 8.45 Item 13.
Initial Actions
• Feed roll, PL 8.45 Item 12.
• Check the condition of the paper in tray 5. Refer to IQ1 and GP 20.
• Check that the left hand door is correctly latched, Figure 2. The nudger roll rotates
• Check that the paper tray is set to the correct paper size. Y N
• Check that tray 5 is set to the correct paper configuration. Enter dC131 NVM chain 8, at Check the nudger roll and the one way gear. Check the drive belt between the feed roll
location 08-313 Tray 5 Configuration. and the nudger roll. Install new components as necessary:
• One way gear, PL 8.45 Item 3.
Procedure • Drive belt, PL 8.40 Item 7.
• Nudger roll, PL 8.45 Item 10.
NOTE: The front door interlock must be cheated when checking +24V components.
The retard roll rotates
Enter dC330 code 08-105 tray 5 feed sensor, Q08-105, Figure 1. Press Start. Manually actuate
the sensor. The display changes. Y N
Check the retard roll, retard clutch and clutch. Install new components as necessary:
Y N
• Retard clutch, PL 8.47 Item 11.
Go to Flag 1. Check Q08-105. Refer to:
• Idler roll, PL 8.47 Item 7.
• GP 11 How to Check a Sensor.
• Retard roll, PL 8.47 Item 2.
• P/J505, Tray 5 control PWB
• 01E +5V Distribution RAP. Enter dC330 code 08-046 tray 5 transport motor, MOT08-046. Press Start. The motor runs.
• 01B 0V Distribution RAP. Y N
Install new components as necessary: Go to Flag 3. Check MOT08-046. Refer to:
• Tray 5 feed sensor, PL 8.45 Item 6. • GP 10 How to Check a Motor.
• Tray 5 control PWB, PL 7.68 Item 8. • P/J503, Tray 5 control PWB
• 01G +24V Distribution RAP.
Enter dC330 code 08-117 tray 5 feed motor, MOT08-117. Open the door. Press Start. The
• 01B 0V Distribution RAP.
motor runs.
Y N Install new components as necessary:
Go to Flag 4. Check MOT08-117. Refer to: • Tray 5 transport motor, PL 8.40 Item 2.
• GP 10 How to Check a motor. • Tray 5 control PWB, PL 7.68 Item 8.
• P/J511, Tray 5 control PWB.
Run the motor for 30 seconds. The motor runs at a constant speed, without slowing.
• 01G +24V Distribution RAP.
Y N
• 01B 0V Distribution RAP. Install a new tray 5 transport motor, PL 8.40 Item 2.
Install new components as necessary:
• Tray 5 feed motor, PL 8.40 Item 3. The take away roller rotates.
Y N
• Tray 5 control PWB, PL 7.68 Item 8.
Check the drive belt and the one way pulley clutch for damage, GP 7. Check the belt ten-
The feed shaft rotates. sioner. Install new components as necessary:
• Drive belt, PL 8.40 Item 7.
Y N
Check the drive gears between the motor and the feed shaft. Install new components as • One way pulley clutch, PL 8.47 Item 4.
necessary: • Take away roller, PL 8.47 Item 5.
• Motor drive gear, PL 8.40 Item 5.
• Gear 30T bearing, PL 8.40 Item 21. Enter dC330 code 08-110 T5 wait point sensor, Q08-110. Press Start.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-201 08-115B, 08-117B
NOTE: For trays 1 to 5 the input code 08-100 wait sensor is used to check the operation of the
wait sensor. In addition tray 5 uses the input code 08-110 T5 wait point sensor, to check the
Tray 5 feed sensor
paper present signal from the IOT PWB to the tray 5 control PWB.
Q08-105
Open the left hand door and manually actuate the wait sensor, Figure 2. The display
changes.
Y N
Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.
Manually actuate the wait sensor, Figure 2. The display changes. Tray 5 feed motor
Y N MOT08-117

Go to Flag 2. Check Q08-100. Refer to:

• GP 11 How to Check a Sensor.
• P/J16, IOT PWB.
Tray 5 transport
• 01E +5V Distribution RAP. motor
• 01B 0V Distribution RAP. MOT08-046
Install new components as necessary:
• Wait sensor, PL 7.30 Item 24.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
PL 1.10 Item 2.
Tray 5 control PWB
Go to Flag 5. Manually actuate the wait sensor.
Check for a signal change on the IOT PWB at P/J12 pin 10 and on the Tray 5 control
PWB at P/J512 pin 5.
Check the wiring between the IOT PWB and the tray 5 control PWB.
Install new components as necessary:
• Tray 5 control PWB, PL 7.68 Item 8.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2. Figure 1 Component location

Perform the steps that follow:

• Clean the feed roll using a cloth dampened with water.
• Install a new feed, nudger and retard roll, PL 8.45 Item 21.

Status Indicator RAPs February 2010

08-115B, 08-117B 2-202 Xerox WorkCentre 5790 Family
 Wait sensor
Left hand door Q08-100

Figure 2 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-203 08-115B, 08-117B
 Figure 3 Circuit diagram

Status Indicator RAPs February 2010

08-115B, 08-117B 2-204 Xerox WorkCentre 5790 Family
08-150, 08-151 Registration Jam Entry RAP 08-150A, 08-151A Registration Jam RAP (35-55 ppm)
08-150 The lead edge of the paper failed to actuate the registration sensor within the correct 08-150 The lead edge of the paper failed to actuate the registration sensor within the correct
time after the paper was released from the wait point. time after the paper was released from the wait point.

08-151 The trail edge of the paper was late to the registration sensor after the registration 08-151 The trail edge of the paper was late to the registration sensor after the registration
clutch, CL08-070 on. clutch, CL08-070 on.

Procedure Initial Actions

Identify the speed of the machine, refer to SCP 7 Machine features. Perform one of the steps • Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08-
that follow: 150, 08-151 Registration Jam Entry RAP.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
• If the speed of the machine is 35-55 ppm, go to 08-150A, 08-151A Registration Jam RAP
• Check for obstructions in the paper path.
(35-55 ppm)
• Check the registration sensor actuator and the wait sensor actuator, Figure 1.
• If the speed of the machine is 65-90 ppm, go to 08-150B, 08-151B Registration Jam RAP
• Check that the left hand door is latched correctly.
(65-90 ppm).
• Check that the interlock cover has not come loose, PL 7.30 Item 23. Push the cover to the
right and tighten the screws
• Check that the short paper path assembly latches without excessive force, PL 10.25 Item
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism.
• If the fault code is 08-151 and two sheets of paper are jammed at the registration rolls. Go
to OF8 Multifeed RAP.
• If the fault code 08-151 occurs from the bypass tray. Go to the 07C Bypass Tray RAP.
• If the power and control assembly has been moved prior to a 08-150. Check that PJ148 is
pushed fully home on the Main Drives PWB.
• Check the transport drive belt.
• Ensure that all connectors on the tray 1 and 2 Control PWB, PL 7.10 Item 2 and on the
IOT PWB, PL 1.10 Item 2 are correctly and securely seated.
• If the fault is 08-150 and the paper is fed from tray 1 or tray 2. Check if the paper has
excessive curl and is causing the paper to be skewed when fed from the tray. Install TAG
002 on the paper tray to constrain the effect of the curl.

Procedure
NOTE: Ensure that the front door interlock is cheated when checking +24V components.

Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Open the left hand door
and manually actuate the registration sensor. The display changes.
Y N
Go to Flag 1. Check Q08-150. Refer to:
• GP 11 How to check a Sensor.
• P/J16, IOT PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Registration sensor, (35-55 ppm) PL 8.15 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-205 08-150, 08-151, 08-150A, 08-151A
A
Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.
Open the left hand door and manually actuate the wait sensor. The display changes.
Y N Registration rolls
Go to Flag 2. Check Q08-100. Refer to:
• GP 11 How to Check a Sensor.
• P/J16, IOT PWB.
Registration sensor
• 01D +3.3V Distribution RAP. Q08-150
• 01B 0V Distribution RAP.
Install new components as necessary:
• Wait sensor, (35-55 ppm) PL 8.15 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 04-010 main drive motor. Press Start. The motor runs. Registration clutch
Y N Registration transport
CL08-070
Go to the 04A Main Drive Motor and Photoreceptor Motor RAP. rolls

While the motor is running, add code 08-070 registration clutch, CL08-070. Press Start.

NOTE: The registration clutch will switch off after 5 seconds.

Switch the registration clutch on / off up to 10 times. The jam clearance knob 4c, PL 8.15
Item 10, rotates when the registration clutch is energized.
Y N
Go to Flag 3. Check CL08-070. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• P/J5, IOT PWB.
• P/J17, LVPS.
• Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Registration clutch, (35-55 ppm) PL 8.15 Item 7.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Perform the following:

• Check the registration transport rolls and registration rolls, (35-55 ppm) PL 8.15 Item 1,
GP 7.
• Check the drives plate on the registration clutch for damage and contamination. Refer to
the replacement procedure in REP 8.5. If necessary, install a new registration clutch, PL
8.15 Item 7.
Left hand door
• Check the tray 1 and 2 transport motor, PL 8.25 Item 5. Ensure that the motor runs cor- Wait sensor
rectly. Q08-100
• Check the tray 1 and 2 transport roll assemblies, transport drive belt and pulleys, PL 8.25
Item 2, PL 8.25 Item 3, GP 7. Install new components as necessary. Figure 1 Component location
• Install a new tray 1 and 2 control PWB, PL 7.10 Item 2.
• Refer to Figure 2. Make sure PJ44 is securely connected.

Status Indicator RAPs February 2010

08-150A, 08-151A 2-206 Xerox WorkCentre 5790 Family
 08-150B, 08-151B Registration Jam RAP (65-90 ppm)
08-150 The lead edge of the paper failed to actuate the registration sensor within the correct
time after the paper was released from the wait point.

08-151 The trail edge of the paper was late to the registration sensor after the registration
clutch, CL08-070 on.

Initial Actions
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08-
150, 08-151 Registration Jam Entry RAP.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
• Check for obstructions in the paper path.
• Check that the left hand door is latched correctly.
• Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws
• Check that the short paper path assembly latches without excessive force, PL 10.25 Item
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism.
• If the fault code is 08-151 and two sheets of paper are jammed at the registration rolls. Go
to OF8 Multifeed RAP.
• If the fault code 08-151 occurs from the bypass tray. Go to the 07C Bypass Tray RAP.
• If the power and control assembly has been moved prior to a 08-150. Check that PJ148 is
pushed fully home on the Main Drives PWB.
• Check the transport drive belt.
• Ensure that all connectors on the tray 1 and 2 Control PWB, PL 7.10 Item 2 and on the
IOT PWB, PL 1.10 Item 2 are correctly and securely seated.
• If the fault is 08-150 and the paper is fed from tray 1 or tray 2. Check if the paper has
excessive curl and is causing the paper to be skewed when fed from the tray. Install TAG
002 on the paper tray to constrain the effect of the curl.

Procedure
NOTE: Ensure that the front door interlock is cheated when checking +24V components.

Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Figure 1. Open the left
hand door and activate the registration sensor. The display changes.
Y N
Go to Flag 1. Check Q08-150. Refer to:
• GP 11 How to check a Sensor.
• P/J16, IOT PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Registration sensor, (65-90 ppm) PL 8.17 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Figure 2 Circuit diagram 1.10 Item 2.

Enter dC330 code 08-100 wait sensor, Q08-100. Press Start.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-207 08-150A, 08-151A, 08-150B, 08-151B
Open the left hand door and activate the wait sensor. The display changes.
Y N
Go to Flag 2. Check Q08-100. Refer to: Registration nip
• GP 11 How to Check a Sensor. rolls
• P/J16, IOT PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Wait sensor, PL 7.30 Item 25.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 04-010 main drive motor. Press Start. The motor runs.
Y N
Go to the 04A Main Drive Motor and Photoreceptor Motor RAP. Registration clutch
CL08-070
While the motor is running, add code 08-070 registration clutch, CL08-070. Press Start.
Registration transport Registration sensor
NOTE: The registration clutch will switch off after 5 seconds. rolls Q08-150
Switch the registration clutch on / off up to 10 times. The jam clearance knob 4c, PL 8.17
Item 10, rotates when the registration clutch is energized.
Y N
Go to Flag 3. Check CL08-070. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• P/J5, IOT PWB.
• P/J17, LVPS.
• Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Registration clutch, (65-90 ppm) PL 8.17 Item 7.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Perform the following:

• Check the registration transport rolls and registration rolls, (65-90 ppm) PL 8.17 Item 1,
GP 7.
• Check the drives plate on the registration clutch for damage and contamination. Refer to
the replacement procedure in REP 8.5. If necessary, install a new registration clutch, PL
8.17 Item 7.
• Check the tray 1 and 2 transport motor, PL 8.25 Item 5. Ensure that the motor runs cor-
Left hand door
rectly. Wait sensor
• Check the tray 1 and 2 transport roll assemblies, transport drive belt and pulleys, PL 8.26 Q08-100
Item 1, GP 7. Install new components as necessary.
• Install a new tray 1 and 2 control PWB, PL 7.10 Item 2. Figure 1 Component location
• Refer to Figure 2. Make sure PJ44 is securely connected.

Status Indicator RAPs February 2010

08-150B, 08-151B 2-208 Xerox WorkCentre 5790 Family
 08-155, 08-156 Bypass Tray Registration Jam Entry RAP
08-155 The lead edge of the paper failed to actuate the registration sensor within the correct
time after start of feed from the bypass tray.

08-156 The IOT detects that a sheet fed from the bypass has arrived to early at the registration
sensor.

Procedure
Identify the speed of the machine, refer to SCP 7 Machine features. Perform one of the steps
that follow:

• If the speed of the machine is 35-55 ppm, go to 08-155A, 08-156A Bypass Tray Registra-
tion Jam RAP (35-55 ppm)
• If the speed of the machine is 65-90 ppm, go to 08-155B, 08-156B Bypass Tray Registra-
tion Jam RAP (65-90 ppm).

Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-209 08-150B, 08-151B, 08-155, 08-156
08-155A, 08-156A Bypass Tray Registration Jam RAP (35- Y N
Go to Flag 2. Check SOL08-050. Refer to:
55 ppm) • GP 12 How to Check a Solenoid or Clutch.
08-155 The lead edge of the paper failed to actuate the registration sensor within the correct
• Figure 1.
time after start of feed from the bypass tray.
• P/J10, IOT PWB.
08-156 The IOT detects that a sheet fed from the bypass has arrived to early at the registration • 01G +24V Distribution RAP.
sensor. • 01B 0V Distribution RAP.
Install new components as necessary:
Initial Actions • Feed solenoid, PL 7.30 Item 4.
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08- • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
155, 08-156 Bypass Tray Registration Jam Entry RAP. 1.10 Item 2.
• Check the condition of the paper in the bypass tray. Refer to IQ1 and GP 20.
• Check for obstructions in the paper path. Perform the following:
• Check that the left hand door is latched correctly. • Check the registration transport rolls and registration nip rolls, Figure 2, PL 8.15 Item 1.
• Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the • If the fault still occurs, check the drives plate on the registration clutch for damage and
right and tighten the two screws contamination. Refer to the replacement procedure in REP 8.5.
• Check that the short paper path assembly latches without excessive force, PL 10.25 Item • Check the idler roll and upper guide on the feed head, Figure 1.
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism. • Clean the feed roll and retard pad using a cloth dampened with water.
• If 08-155 is displayed, check the bypass tray empty actuator, 07C Bypass Tray RAP. • If necessary install a new feed and retard pad, PL 7.30 Item 21.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.

Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Figure 2. Manually actu-
ate the registration sensor. The display changes.
Y N
Go to Flag 1. Check Q08-150. Refer to:
• GP 11 How to Check a Sensor.
• P/J5, IOT PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Registration sensor, PL 8.15 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 04-010 main drive motor, code 08-070 registration clutch, CL08-070. Press
Start. The jam clearance knob, 4c, PL 8.15 Item 10, rotates.
Y N
Go to Flag 3. Check CL08-070. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• P/J5, IOT PWB.
• P/J17 LVPS.
• Fuse, PL 1.10 Item 9, GP 7.

Enter dC330 code 08-050 feed solenoid, SOL08-050. Press Start. The solenoid energizes.

Status Indicator RAPs February 2010

08-155A, 08-156A 2-210 Xerox WorkCentre 5790 Family
 Registration nip rolls

Feed roll drive

gear Registration sensor
Q08-150

Feed solenoid
SOL08-050
Registration clutch
CL08-070 Registration transport
rolls

Feed roll

Bypass tray

Left hand door

Upper guide and Wait sensor

idler rolls Q08-100

Figure 1 Component location Figure 2 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-211 08-155A, 08-156A
 08-155B, 08-156B Bypass Tray Registration Jam RAP (65-
90 ppm)
08-155 The lead edge of the paper failed to actuate the registration sensor within the correct
time after start of feed from the bypass tray.

08-156 The IOT detects that a sheet fed from the bypass has arrived to early at the registration
sensor.

Initial Actions
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08-
155, 08-156 Bypass Tray Registration Jam Entry RAP.
• Check the condition of the paper in the bypass tray. Refer to IQ1 and GP 20.
• Check for obstructions in the paper path.
• Check that the left hand door is latched correctly.
• Check that the interlock cover has not come loose, PL 7.30 Item 23. Bias the cover to the
right and tighten the two screws
• Check that the short paper path assembly latches without excessive force, PL 10.25 Item
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism.
• If 08-155 is displayed, check the bypass tray empty actuator, 07C Bypass Tray RAP.

Procedure
NOTE: The front door interlock must be cheated when checking +24V components.

Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Figure 2. Activate the reg-
istration sensor. The display changes.
Y N
Go to Flag 1. Check Q08-150. Refer to:
• GP 11 How to Check a Sensor.
• P/J16, IOT PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Registration sensor, (65-90 ppm) PL 8.17 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 04-010 main drive motor, code 08-070 registration clutch, CL08-070. Press
Start. The jam clearance knob, 4c, PL 8.17 Item 10, rotates.
Y N
Go to Flag 3. Check CL08-070. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• P/J5, IOT PWB.
• P/J17 LVPS.
Figure 3 Circuit diagram
• Fuse, PL 1.10 Item 9, GP 7.

Enter dC330 code 08-050 feed solenoid, SOL08-050. Press Start. The solenoid energizes.

Status Indicator RAPs February 2010

08-155A, 08-156A, 08-155B, 08-156B 2-212 Xerox WorkCentre 5790 Family
Y N
Go to Flag 2. Check SOL08-050. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• Figure 1.
• P/J10, IOT PWB. Feed roll drive
• 01G +24V Distribution RAP. gear
• 01B 0V Distribution RAP.
Install new components as necessary:
• Feed solenoid, PL 7.30 Item 4.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
Feed solenoid
Perform the following: SOL08-050
• Check the registration transport rolls and registration nip rolls, Figure 2, PL 8.17 Item 1.
• If the fault still occurs, check the drives plate on the registration clutch for damage and
contamination. Refer to the replacement procedure in REP 8.5.
• Check the idler roll and upper guide on the feed head, Figure 1.
• Clean the feed roll and retard pad using a cloth dampened with water.
• If necessary install a new feed and retard pad, PL 7.30 Item 21. Feed roll

Bypass tray

Upper guide and

idler rolls

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-213 08-155B, 08-156B
 Registration nip
rolls

Registration clutch
CL08-070 Registration transport Registration sensor
rolls Q08-150

Left hand door

Wait sensor
Q08-100

Figure 2 Component location

Figure 3 Circuit diagram

Status Indicator RAPs February 2010

08-155B, 08-156B 2-214 Xerox WorkCentre 5790 Family
08-160, 08-161 Duplex Paper Path Jam Entry RAP 08-160A, 08-161A Duplex Paper Path Jam RAP (35-55 ppm)
08-160 The lead edge of the first sheet of a job fed into the duplex path failed to actuate the 08-160 The lead edge of the first sheet of a job fed into the duplex path failed to actuate the
Duplex sensor in the correct time. Duplex sensor in the correct time.

08-161 The trail edge is late to the duplex sensor after of the first sheet of a job fed into the 08-161 The trail edge is late to the duplex sensor after of the first sheet of a job fed into the
duplex path failed to actuate the duplex sensor in the correct time. duplex path failed to actuate the duplex sensor in the correct time.

Procedure Initial Actions

Identify the speed of the machine, refer to SCP 7 Machine features. Perform one of the steps • Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08-
that follow: 160, 08-161 Duplex Paper Path Jam Entry RAP.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
• If the speed of the machine is 35-55 ppm, go to 08-160A, 08-161A Duplex Paper Path
• Check for paper in the inverter and duplex transport.
Jam RAP (35-55 ppm)
• Check for obstructions in the paper path.
• If the speed of the machine is 65-90 ppm, go to 08-160B, 08-161B Duplex paper path
• If skew occurs when A5 paper is duplexed. Check for contact between the drive rolls and
Jam RAP (65-90 ppm).
the nip rolls, (35-55 ppm) PL 8.22 Item 13.

Procedure
WARNING
Take care during this procedure. Motors will become hot during normal operation.

NOTE: The front door interlock must be cheated when checking +24V components.
Enter dC330 code 08-160 duplex sensor, Q08-160. Press Start. Manually actuate the sensor,
Figure 1. The display changes.
Y N
Go to Flag 1. Check Q08-160. Refer to:
• GP 11 How to Check a Sensor.
• P/J5, IOT PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Duplex sensor, (35-55 ppm) PL 8.22 Item 4.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 08-060 duplex motor, MOT08-060, Figure 1. Press Start. The motor runs.
Y N
Go to Flag 2. Check MOT08-060. Refer to:
• GP 10 How to Check a Motor.
• P/J4, IOT PWB.
• P/J50, P/J91, duplex motor driver PWB.
• 01G +24V Distribution RAP.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Duplex motor, (35-55 ppm) PL 8.22 Item 8.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-215 08-160, 08-161, 08-160A, 08-161A
A B
• Duplex motor driver PWB, (35-55 ppm) PL 8.22 Item 9. • P/J5, IOT PWB.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL • P/J17, LVPS.
1.10 Item 2. • Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
The transport rolls rotate.
• 01B 0V Distribution RAP.
Y N
Check the drive belt and pulleys, (35-55 ppm) PL 8.22 Item 2, PL 8.22 Item 10. Install new components as necessary:
• Inverter path solenoid, PL 10.11 Item 14.
Enter dC330 code 10-030 Inverter Motor, 10-030, Figure 1. Press Start. The motor runs. • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Y N 1.10 Item 2.
Go to Flag 3. Check MOT10-030. Refer to:
• GP 10 How to Check a Motor. Check the following, refer to GP 7:
• P/J4, IOT PWB. • Duplex nip rolls, (35-55 ppm) PL 8.22 Item 7.
• P/J45, P/J55. • Nip split shaft assembly, PL 10.11 Item 4.
• 01G +24V Distribution RAP. • Idler rolls, PL 10.12 Item 15.
• 01E +5V Distribution RAP. • If the fault still occurs, check the drives plate on the registration clutch for damage and
• 01B 0V Distribution RAP. contamination. Refer to the replacement procedure in REP 8.5.
Install new components as necessary:
• Inverter motor, PL 10.11 Item 11.
• Inverter motor driver PWB, PL 10.11 Item 22.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

The transport rolls rotate.

Y N
Check drive gears, GP 7, PL 10.15.

Enter dC330 code 10-050 inverter nip solenoid, SOL10-050, Figure 1. Press Start. The sole-
noid energizes.
Y N
Go to Flag 4. Check SOL10-050. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• P/J5, IOT PWB.
• P/J17, LVPS.
• Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Inverter Nip Solenoid, PL 10.11 Item 6.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 10-045 inverter path solenoid, SOL10 045, Figure 1. Press Start. The sole-
noid energizes.
Y N
Go to Flag 5. Check SOL10-045. Refer to:
• GP 12 How to check a Solenoid or Clutch.

B
Status Indicator RAPs February 2010
08-160A, 08-161A 2-216 Xerox WorkCentre 5790 Family
 Duplex motor
MOT08-060
Inverter nip
solenoid
SOL10-050

Duplex sensor Inverter motor

Q08-160 MOT10-030
Inverter path
solenoid
SOL10-045

Figure 1 Component location

Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-217 08-160A, 08-161A
 08-160B, 08-161B Duplex Paper Path Jam RAP (65-90 ppm)
08-160 The lead edge of the first sheet of a job fed into the duplex path failed to actuate the
Duplex sensor in the correct time.

08-161 The trail edge is late to the duplex sensor after of the first sheet of a job fed into the
duplex path failed to actuate the duplex sensor in the correct time.

Initial Actions
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to the 08-
160, 08-161 Duplex Paper Path Jam Entry RAP.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
• Check for paper in the inverter and duplex transport.
• Check for obstructions in the paper path.
• If skew occurs when A5 paper is duplexed. Check for contact between the drive rolls and
the nip rolls, (65-90 ppm) PL 8.20 Item 14.

Procedure
WARNING
Take care during this procedure. Motors will become hot during normal operation.

NOTE: The front door interlock must be cheated when checking +24V components.
Enter dC330 code 08-160 duplex sensor, Q08-160. Press Start. Activate the sensor, Figure 1.
The display changes.
Y N
Go to Flag 1. Check Q08-160. Refer to:
• GP 11 How to Check a Sensor.
• P/J5, IOT PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Duplex sensor, (65-90 ppm) PL 8.20 Item 4.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 08-060 duplex motor, MOT08-060, Figure 1. Press Start. The motor runs.
Y N
Go to Flag 2. Check MOT08-060. Refer to:
• GP 10 How to Check a Motor.
• P/J4, IOT PWB.
• P/J50, P/J91, duplex motor driver PWB.
• 01G +24V Distribution RAP.
• 01E +5V Distribution RAP.
Figure 3 Circuit diagram • 01B 0V Distribution RAP.
Install new components as necessary:
• Duplex motor, (65-90 ppm) PL 8.20 Item 8.

A
Status Indicator RAPs February 2010
08-160A, 08-161A, 08-160B, 08-161B 2-218 Xerox WorkCentre 5790 Family
A B
• Duplex motor driver PWB, (65-90 ppm) PL 8.20 Item 9. • P/J5, IOT PWB.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL • P/J17, LVPS.
1.10 Item 2. • Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
The transport rolls rotate.
• 01B 0V Distribution RAP.
Y N
Check the drive belt and pulleys, (65-90 ppm) PL 8.20 Item 2, PL 8.20 Item 10. Install new components as necessary:
• Inverter path solenoid, PL 10.11 Item 14.
Enter dC330 code 10-030 Inverter Motor, 10-030, Figure 1. Press Start. The motor runs. • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Y N 1.10 Item 2.
Go to Flag 3. Check MOT10-030. Refer to:
• GP 10 How to Check a Motor. Check the following, refer to GP 7:
• P/J4, IOT PWB. • Duplex nip rolls, (65-90 ppm) PL 8.20 Item 7.
• P/J45, P/J55. • Nip split shaft assembly, PL 10.11 Item 4.
• 01G +24V Distribution RAP. • Idler rolls, PL 10.12 Item 15.
• 01E +5V Distribution RAP. • If the fault still occurs, check the drives plate on the registration clutch for damage and
• 01B 0V Distribution RAP. contamination. Refer to the replacement procedure in REP 8.5.
Install new components as necessary:
• Inverter motor, PL 10.11 Item 11.
• Inverter motor driver PWB, PL 10.11 Item 22.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

The transport rolls rotate.

Y N
Check drive gears, GP 7, PL 10.15.

Enter dC330 code 10-050 inverter nip solenoid, SOL10-050, Figure 1. Press Start. The sole-
noid energizes.
Y N
Go to Flag 4. Check SOL10-050. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• P/J5, IOT PWB.
• P/J17, LVPS.
• Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Inverter Nip Solenoid, PL 10.11 Item 6.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 10-045 inverter path solenoid, SOL10 045, Figure 1. Press Start. The sole-
noid energizes.
Y N
Go to Flag 5. Check SOL10-045. Refer to:
• GP 12 How to check a Solenoid or Clutch.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-219 08-160B, 08-161B
 Duplex motor
MOT08-060
Inverter nip
solenoid
SOL10-050

Duplex sensor Inverter motor

Q08-160 MOT10-030
Inverter path
solenoid
SOL10-045

Figure 1 Component location

Figure 2 Circuit diagram

Status Indicator RAPs February 2010

08-160B, 08-161B 2-220 Xerox WorkCentre 5790 Family
 08-171 Unexpected Time Out RAP
08-171 The IOT detects an unexpected event for a known sheet. A sheet left in the machine
after jam clearance.

Initial Actions
• Enter the machine status mode and check for the active messages. Refer to OF4 Status
Codes and Message RAP for the jam clearance procedure.
• Check the condition of the paper in all trays, Refer to IQ1 and GP 20.
• Check for obstructions in the paper path.
• Make sure that all covers and paper guides are closed, and latch correctly.
• Check for paper in the output device.

Procedure
If the initial actions did not resolve the problem. Switch off the machine, then switch on the
machine, GP 14. If a fault code is displayed then go to the appropriate RAP.

Figure 3 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-221 08-160B, 08-161B, 08-171
08-174 Missing Pre-release Sheet RAP 08-180 Unable to Feed Next Sheet RAP
08-174 The IOT detected a missing pre-release sheet. 08-180 The machine has detected that the previous sheet has not correctly fed through the
paper path.
Initial Actions
• Enter the machine status mode and check for the active messages. Refer to OF4 Status Initial Actions
Codes and Message RAP for the jam clearance procedure. • Clear the paper path.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
• Check for obstructions in the registration paper path. Procedure
• Make sure that all covers and paper guides are closed, and latch correctly. 35-55 ppm - Perform the following:
• Check tray 1 feed sensor, Q80-101. Refer to 08-101 Tray 1 Misfeed RAP.
Procedure Install new components as necessary.
If the initial actions did not resolve the problem. Switch off the machine, then switch on the • Check tray 2 feed sensor, Q08-102. Refer to 08-102 Tray 2 Misfeed RAP.
machine, GP 14. If a fault code is displayed then go to the appropriate RAP. Install new components as necessary.
• Check the registration sensor, Q08-150 and the wait sensor, Q08-100, refer to 08-150A,
08-151A Registration Jam RAP (35-55 ppm).
Install new components as necessary.
65-90 ppm - Perform the following:
• Check tray 1 feed sensor, Q80-101. Refer to 08-101 Tray 1 Misfeed RAP.
Install new components as necessary.
• Check tray 2 feed sensor, Q08-102. Refer to 08-102 Tray 2 Misfeed RAP.
Install new components as necessary.
• Check the registration sensor, Q08-150 and the wait sensor, Q08-100, refer to 08-150B,
08-151B Registration Jam RAP (65-90 ppm).
Install new components as necessary.

Status Indicator RAPs February 2010

08-174, 08-180 2-222 Xerox WorkCentre 5790 Family
08-181 Unexpected Time Out in Simplex Inverted Mode 08-182 Unexpected Time Out in Duplex Mode RAP
RAP 08-182 The IOT detected an unexpected time out for a known duplex sheet of paper.
08-181 The IOT detected an unexpected time out for a known simplex inverted sheet of paper.
Initial Actions
Initial Actions • Enter the machine status mode and check for the active messages. Refer to OF4 Status
Codes and Message RAP for the jam clearance procedure.
• Enter the machine status mode and check for the active messages. Refer to OF4 Status
Codes and Message RAP for the jam clearance procedure. • Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20. • Check for obstructions in the duplex paper path.
• Check for obstructions in the simplex and inverted paper path.
• Make sure that all covers and paper guides are closed, and latch correctly. Procedure
If the initial actions did not resolve the problem. Switch off the machine, then switch on the
Procedure machine, GP 14. If a fault code is displayed then go to the appropriate RAP.

If the initial actions did not correct the problem, perform the following:
• Switch off the machine, then switch on the machine, GP 14.
• If a fault code is displayed then go to the appropriate RAP.
• Enter dC330, code 10-045 and check the operation of the inverter gate, PL 10.12 Item 7.
It should move freely without binding.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-223 08-181, 08-182
08-190 Post Jam Clearance Initialization RAP
08-190 A stray sheet has been detected in either the IOT or finisher device during the post jam
clearance initialization routine.

Initial Action
• Enter the machine status mode and check for the active messages. Refer to OF4 Status
Codes and Message RAP for the jam clearance procedure.
• Check for paper in the machine paper path at all the sensor locations.
• Check for paper in the finisher paper path at all the sensor locations. Use a flashlight to
check that the hole punch sensor is clear.
– 2K LCSS, PL 11.6 Item 7.
– HVF, PL 11.153.
• Make sure that all the covers and paper guides are closed, and latched correctly.
Procedure
If the initial actions did not correct the problem. Switch off the machine, then switch on the
machine, GP 14. If a fault code is displayed then go to the appropriate RAP.

Status Indicator RAPs February 2010

08-190 2-224 Xerox WorkCentre 5790 Family
09-060 HVPS Fault RAP NOTE: The charge, transfer and detack corotron have 47k Ohms arc suppression resistors
within their harnesses.
09-060 The HVPS fault sensor has detected a high voltage fault.
Check that the F1 surface mounted fuse on the IOT PWB is good. Refer to OF7 IOT PWB
The HVPS fault will occur when: Diagnostics RAP, for the location of the F1 surface mounted fuse. The surface mounted
• The (C) charge high voltage supply has a short or open circuit. fuse is good.
• The (G) charge grid high voltage supply has a short or open circuit. Y N
Perform the procedures that follow:
• The (T) transfer high voltage supply has a short circuit.
• 01G +24V Distribution RAP and refer to the 01G Fused Distribution Check.
• The (DT) detack high voltage supply has a short circuit.
• 01H Short Circuit and Overload RAP.
• The (DB) developer bias high voltage supply has a short circuit.
• The +24V supply to the HVPS has a short or open circuit. Enter dC330. Select component code 09-060 HVPS fault and press save. Press start. A high
• The 24 volt supply is momentarily overloaded. signal indicates a fault or the front door interlock open.
The HVPS fault will deactivate within 100 milliseconds after the removal of the fault. Add Component code 09-061 charge scorotron. Press start. Time out after 3 seconds. The
display for code 09-060 is Low.
Initial Actions Y N
Go to the Flag 1. Check the charge scorotron harness for open circuit or short circuit to
• Switch off the machine, then switch on the machine, GP 14.
ground, GP 7. The scorotron harness and connectors are good.
• Clean the charge scorotron, ADJ 9.1. Y N
• Clean the transfer / detack corotron and check the corotron wire, ADJ 9.1. Install a new charge scorotron harness, (35-55 ppm) PL 4.17 Item 18, (65-90 ppm)
• Reseat the high voltage connections on the HVPS, (40-90 ppm) Figure 1, (35 ppm) Figure PL 4.12 Item 20.
2.
Install a new xerographic module, (35 ppm) PL 9.22 Item 2, (40-90 ppm) PL 9.20 Item 2.
• Check the registration transport bias contact, PL 8.15 Item 23, Figure 3.
If the fault continues, install a new HVPS, PL 1.10 Item 5.
• Check the bias connection, Figure 3.
• Reseat the developer bias connection, Figure 4. Add component code 09-062 charge grid. Press start. Time out after 3 seconds. The display
• If the machine is above 750 metres above sea level, check the transfer / detack assembly for code 09-060 is Low.
for arcing. If necessary go to dC131 NVM Read / Write location 09-098 and select the Y N
appropriate altitude. Go to the Flag 1. Check the charge grid harness for open circuit or short circuit to ground,
• Check for any cause of an overload to the 24V supply. For example, very thick multi-feeds GP 7. The grid harness and connectors are good.
causing the main drive motor to stall, or a possible short circuit. Y N
Install a new charge grid harness, (35-55 ppm) PL 4.17 Item 19, (65-90 ppm) PL
4.12 Item 21.
Procedure
WARNING Install a new xerographic module, (35 ppm) PL 9.22 Item 2, (40-90 ppm) PL 9.20 Item 2.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the If the fault continues, install a new HVPS, PL 1.10 Item 5.
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury. Add component code 09-063 transfer corotron. Press start. Time out after 3 seconds. The
If you were directed from IQ8 Defect RAP, continue below. If the following checks do not display for code 09-060 is Low.
Y N
resolve the image quality problem, return to IQ3 Xerographic RAP.
Go to the Flag 2. Check the transfer corotron harness for short circuit to ground, GP 7.
NOTE: The following are the only values that can be measured from the HVPS. The transfer corotron harness and connectors are good.
• Charge scorotron grid, -425V +/- 21V. Y N
Install a new transfer / detack harness, (35 ppm) PL 9.22 Item 9, (40-90 ppm) PL
• The two terminals identified as G are the same output.
9.20 Item 9.
• Registration chute bias, -490V +/- 25V.
• The two terminals identified as CB are the same output. Install a new transfer / detack corotron, (35 ppm) PL 9.22 Item 8, (40-90 ppm) PL 9.20
• Developer bias, -370V +20V / -50V. Item 8.
If the fault continues, install a new HVPS PL 1.10 Item 5.

Add component code 09-064 detack corotron. Press start. Time out after 3 seconds. The dis-
play for code 09-060 is low.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-225 09-060
Y N
Go to Flag 2. Check the detack corotron harness for short circuit to ground, GP 7. The
detack corotron harness and connectors are good. Transfer corotron connector
Y N
Install a new transfer / detack harness, (35 ppm), PL 9.22 Item 9, (40-90), PL 9.20
Item 9. Detack corotron connector

On the 30 ppm machine, install a new transfer / detack corotron, PL 9.22 Item 8. On the
40-90 ppm machine, install a new short paper path assembly, PL 9.20 Item 3. Charge Grid connector. The two
If the fault continues, install a new HVPS PL 1.10 Item 5. terminals identified as G are the
same output.
Add component code 09-065 registration chute bias. Press start. Time out after 90 seconds.
The display for code 09-060 is low.
Y N
Install a new HVPS PL 1.10 Item 5.
Charge scorotron connector
Add component code 09-066 developer bias. Press start. Time out after 3 seconds. The dis-
play for code 09-060 is low.
Y N P/J55
Go to Flag 3. Check the developer bias harness for short circuit to ground, GP 7. The
developer harness and connectors are good. Developer bias connector
Y N
Install a new developer bias harness, (35-55 ppm) PL 9.17 Item 6, (65-90 ppm) PL
Registration and transfer chute bias
9.15 Item 6.
connector. The two terminals identi-
fied as CB are the same output.
Install a new HVPS PL 1.10 Item 5.

Complete SCP 6 Final Actions.

Figure 1 Component location (40-90 ppm)

Status Indicator RAPs February 2010

09-060 2-226 Xerox WorkCentre 5790 Family
 Transfer corotron connector Registration guide

Detack corotron connector

Halo guide

Charge Grid connector. The

two terminals identified as G
are the same output.

Charge scorotron connector

P/J55

Developer bias connector

Registration and transfer chute

bias connector. The two termi-
nals identified as CB are the
same output. Registration chute
bias connection
Bias contact

Figure 2 Component location (35 ppm) Figure 3 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-227 09-060
 Developer bias connection

Figure 4 Component location

Figure 5 Circuit diagram

Status Indicator RAPs February 2010

09-060 2-228 Xerox WorkCentre 5790 Family
 A
09-310, 09-390 Low Toner Sensor Failure RAP • P/J6, IOT PWB.
• 01B 0V Distribution RAP.
09-310 The toner cartridge motor continues to dispense toner for a period greater than 12 sec-
onds after the low toner sensor detects that the toner dispense module is full. • 01E +5V Distribution RAP.
Install new components as necessary:
09-390 The low toner sensor detects that the toner level is low for a period greater than 70 sec- • Low toner sensor, (35-55 ppm) PL 9.17 Item 5, (65-90 ppm) PL 9.15 Item 5.
onds after toner cartridge motor start. • Developer assembly, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15 Item 2.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Initial Actions 1.10 Item 2.
Figure 1. Ensure the toner cartridge is not empty. If the toner cartridge is empty, install a new
toner cartridge, (35-55 ppm) PL 9.17 Item 4, (65-90 ppm) PL 9.15 Item 4. The fault may be intermittent, due to toner bridging inside the toner cartridge. Install a new
toner cartridge, (35-55 ppm) PL 9.17 Item 4, (65-90 ppm) PL 9.15 Item 4.
Procedure Check the image quality and complete SCP 6 Final Actions.

NOTE: The door interlock switch must be cheated when checking +24V components.
NOTE: The toner cartridge motor will time out after 5 seconds.

Cheat the door interlock switch. Enter dC330 code 09-045 toner cartridge motor, MOT09-045.
Press start. Observe the toner cartridge. The toner cartridge rotates.
Y N
The motor runs.
Y N
Go to Flag 1. Check MOT09-045. Refer to:
• GP 10 How to Check a Motor.
• Figure 2.
• P/J6, IOT PWB.
• 01G +24V Distribution RAP
• 01B 0V Distribution RAP.
Install new components as necessary:
• Toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90 ppm) PL 9.15 Item
1.
• Developer assembly, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15 Item 2.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
PL 1.10 Item 2.
Toner cartridge
drive gears Toner cartridge
Check the toner dispense drive gears, Figure 1 and Figure 2. PJ93
If necessary install a new toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90
ppm) PL 9.15 Item 1.

Enter dC330 code 09-040 toner dispense motor and add the code 09-310 low toner sensor,
Q09-310. Press Start.

NOTE: It may necessary to enter the codes several times to ensure that the toner dispense Figure 1 Component location
motor does actuate and deactuate the low toner sensor. It may be necessary to make several
copies to prevent over toning the developer.

The display changes from high to low or low to high.

Y N
Go to Flag 2. Check Q09-310. Refer to:
• Figure 2.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-229 09-310, 09-390
 Toner cartridge
drive gears

Toner cartridge motor

MOT 09-045

Toner dispense motor

MOT 09-040 In-line connector PJ75
Low toner sensor
Q09-310

Figure 2 Component Location

Figure 3 Circuit diagram

Status Indicator RAPs February 2010

09-310, 09-390 2-230 Xerox WorkCentre 5790 Family
09-341, 09-342 Scorotron Cleaning Failure RAP
09-341 The scorotron cleaning routine has failed to complete.

09-342 A scorotron cleaning warning detected.

Initial Actions Scorotron cleaner motor

• Check that the xerographic module is correctly installed.
• Check the scorotron cleaner drive coupling, Figure 1.

Procedure
Enter dC330 code 09-071 or 09-072 scorotron cleaner motor. A clicking sound is heard.
Y N
Go to Flag 2. Check MOT09-043. Refer to:
• GP 10 How to Check a motor.
• P/J64, IOT PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Main drive module, (35-55 ppm) PL 4.15 Item 1, (65-90 ppm) PL 4.10 Item 1.
Drive
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL coupling
1.10 Item 2.

Enter dC330 code 09-070 scorotron cleaner home sensor, Figure 2. Press Start. Enter dC330
code 09-071 or 09-072 scorotron motor. Actuate the sensor by entering the appropriate code.
The display changes.
Y N
Go to Flag 1. Check Q09-070. Refer to:
• GP 13 How to Check a Switch.

NOTE: The scorotron cleaner home sensor is a magnetic reed switch.

• P/J64, IOT PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Scorotron cleaner home sensor, (40-55 ppm) PL 4.17 Item 16, (65-90 ppm) PL 4.12
Item 19. Scorotron cleaner home sensor
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2. Figure 1 Component location

The fault may be intermittent, perform the following:

• Check the wiring, GP 7. Repair if necessary, REP 1.2.
• Ensure that P/J64 is correctly and securely connected.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-231 09-341, 09-342
 09-350 Erase Lamp Failure RAP
09-350 The photoreceptor erase lamp has failed.

Procedure
NOTE: The xerographic module must be in the machine for the lamp to illuminate.

CAUTION
Do not illuminate the erase lamp for an extended length of time as this may cause damage to
the xerographic drum.

NOTE: The door interlock switch must be cheated when checking +24V components.

Cheat the door interlock switch. Enter dC330 code 09-022, photoreceptor erase lamp. Press
start. Figure 1. Observe the erase lamp. All the LEDs of the erase lamp are lit.
Y N
Some of the LEDs of the erase lamp are lit.
Y N
Go to Flag 1. +24V is available at P/J17 pin 1 on the LVPS.
Y N
Install a new LVPS and base module, PL 1.10 Item 3.

Go to Flag 2. +24V is available at P/J41 pin 1.

Y N
Go to Flag 1. Check the inline fuse. The fuse is good.
Y N
Install a new fuse, GP 7, PL 1.10 Item 9.
If the fuse blows again, go to 01G Fused Distribution Check.

Go to 01G +24V Distribution RAP.

Go to Flag 3. +13V is available at P/J5 pin 14.

Y N

NOTE: To gain access to the erase lamp wiring, remove the main drive module,
(35-55 ppm) PL 4.15 Item 1, (65-90 ppm) PL 4.10 Item 1.

Check the wiring, GP 7, from the in-line fuse to P/J41, pin 2. The wiring is
good.
Y N
Repair the wiring.

Perform the steps that follow:

Figure 2 Circuit diagram • Check that the connector PJ41 is located correctly in the IOT frame, Fig-
ure 1.
• Install a new erase lamp, (35 ppm) PL 9.22 Item 1, (40-90 ppm) PL 9.20
Item 1.

Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Install a new erase lamp, (35 ppm) PL 9.22 Item 1, (40-90 ppm) PL 9.20 Item 1.

A
Status Indicator RAPs February 2010
09-341, 09-342, 09-350 2-232 Xerox WorkCentre 5790 Family
A
The fault may be intermittent. Perform the steps that follow:
• Check the wiring, GP 7 between P/J41 and P/J17 on the LVPS.
• Ensure that the P/Js are correctly and securely connected.
• Malfunction of the following associated circuits can cause 09-350 faults.
– The inverter paper path and Inverter nip solenoid, go to 10-120, 10-121, 10-126 IOT
Exit Sensor RAP.
– The vacuum transport fan and Registration clutch, go to 10-101A, 10-102A, 10-103A
Lead Edge Late to Fuser Exit Sensor RAP.

P/J41
Erase lamp

Figure 2 Circuit diagram

Erase lamp

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-233 09-350
 A
09-360, 09-361, 09-362, 09-363 Toner Concentration Sensor • The developer assembly is correctly installed

Failure RAP The voltage at P/J93, pin 8, is less than +0.75V.

09-360 The toner concentration sensor has registered a reading outside the range, +0.75V to Y N
+4.55V for three consecutive sheets. The voltage is greater than +0.7V to +4.5V range. Check the wiring, GP 7. Go to Flag 3.
+24V is present at P/J93, pin 2.
09-361 The toner concentration sensor is reading high. This indicates that the toner concentra- Y N
tion (TC) is low. Disconnect P/J93, Figure 1. +24V is present at the harness end of P/J93, pin 2.
Y N
09-362 The toner concentration sensor is reading low. This indicates that the toner concentra- Go to the 01G +24V Distribution RAP.
tion (TC) is high.
Install a new developer assembly, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15
09-363 This code is generated by the following factors: Item 2. Perform dC905 TC Sensor Calibration.
• The developer is not positioned correctly against the xerographic module.
• The toner concentration is low. Go to Flag 5. 0V is available at P/J93, pin 10.
Y N
• The machine is being installed.
Go to the 01B 0V Distribution RAP.
• On the fifth consecutive occurrence.
GUI message - TONER CONTROL FAILURE Enter dC131, 09-069, TC sensor control voltage, and record the displayed value. (100
displayed equals 1 volt). Go to Flag 4. Check the voltage at P/J93, pin 9. The dis-
Initial Actions played value is within 0.2V of the voltage checked at P/J93, pin 9.
Y N
• Check developer roll area for toner and bead contamination. If necessary, go to IQ1
Disconnect P/J93. Check the voltage at pin 9. The recorded value is within 0.2V
Image Quality Entry RAP.
of the voltage checked at P/J93, pin 9.
• If 09-360 fault, enter dC131 location 09-115, sensor failure lockout flag. Check that it is Y N
set to ‘0’. If set at ‘1’ the toner dispense motor will not run.
Check the wiring, GP 7, between P/J93 and P/J6 on the IOT PWB. The wir-
• If 09-361 fault, enter dC131 location 09-001 TC lockout low. Check that it is set to ‘0’. If ing is good.
set at ‘1’ the toner dispense motor will not run. Y N
– Check that when the xerographic module latch is in the locked position, the devel- Repair the wiring, REP 1.2. Perform the TC increase adjustment.
oper module is correctly installed, REP 9.2.
• If 09-362 fault, enter dC131 location 09-276 TC lockout high. Check that it is set to ‘0’. If Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
set at ‘1’ the toner dispense motor will not run PL 1.10 Item 2.Perform the TC increase adjustment.
• Switch off the machine, then switch on the machine, GP 14.
Install a new developer assembly, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15
Item 2. Perform dC905 TC Sensor Calibration.
Initial Procedure
Make 20 prints. If the following three conditions apply, go to the 09-310, 09-390 Low Toner Enter dC330. Enter the code 04-010, main drive motor. Press start. Add the code 09-040,
Sensor Failure RAP. If not continue at the Procedure. toner dispense motor. Press Start.
1. The prints or copies are faint.
NOTE: The routine 09-040 times out after 5 seconds.
2. The toner cartridge is not rotating.
The toner dispense motor runs.
3. The low toner sensor, 09-310, reading is high.
Y N
Procedure Go to Flag 2. Check MOT09-040. Refer to:
• GP 10 How to Check a Motor.
NOTE: The door interlock switch must be cheated when checking +24V components.
• P/J6, IOT PWB.
Go to Flag 1 and read the voltage at P/J93 pin 8. The voltage is outside the range of +0.7V • Go to 01G +24V Distribution RAP.
to +4.5V.
• Go to 01B 0V Distribution RAP.
Y N
Check the steps that follow: Install new components as necessary:
Toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90 ppm) PL 9.15 Item 1.
• Check the wiring, GP 7, between P/J93 to P/J6 on the IOT PWB.
• Refer to the 01B Ground Distribution RAP. Check the toner dispense drive gears, Figure 1. The gears rotate.
A B
Status Indicator RAPs February 2010
09-360, 09-361, 09-362, 09-363 2-234 Xerox WorkCentre 5790 Family
B
Y N If the 09-360 is intermittent and causes the message Machine unavailable. Perform OF7 IOT
Install a new toner dispense module, (35-55 ppm) PL 9.17 Item 1, (65-90 ppm) PL PWB Diagnostics RAP before a new IOT PWB is installed, PL 1.10 Item 2.
9.15 Item 1. Perform the TC reduction adjustment.

Add the code 09-310, low toner sensor. Energize the components in the following order: TC reduction adjustment
• 04-010, main drive motor. Perform the following:
• 09-010, photoreceptor motor. 1. Enter dC330, code 04-010, main drive motor; code 09-010, photoreceptor motor; 09-066,
• 09-040, toner dispense motor. developer bias.
When the toner dispense motor stops, the toner level sensor display value is LOW. 2. Start the routine. The start will have to be pressed every 5 seconds to restart the devel-
Y N oper bias routine.
Go to the 09-310, 09-390 Low Toner Sensor Failure RAP. 3. Monitor the voltage output, Flag 1, at P/J6 pin 8 on the IOT PWB.

Perform the TC increase adjustment. NOTE: The toner concentration cannot be adjusted and maintained by making high area
coverage prints.

4. Run the routine until the monitored voltage is greater than 0.9 volts.
Check the wiring, GP 7, between P/J6 on the IOT PWB and P/J93 on the developer module,
Figure 1. The wiring is good. 5. Check the image quality.
Y N TC increase adjustment
Repair the wiring. Perform the following:
1. Enter dC330, code 04-010, main drive motor; 09-040, toner dispense motor; 09-045,
Go to Flag 3. +24V is present at P/J93, pin 2.
toner cartridge motor.
Y N
Disconnect P/J93, Figure 1. +24V is present at the harness end of P/J93, pin 2. 2. Start the routine. The start will have to be pressed every 5 seconds to restart the toner
dispense motor and the toner cartridge routines.
Y N
Go to the 01G +24V Distribution. 3. Monitor the voltage output, Flag 1, at P/J6 pin 8 on the IOT PWB.
4. Run the routine until the monitored voltage is between 2.2 and 2.8 volts
Install a new developer assembly, PL 9.15 Item 2. Perform dC905 TC Sensor Calibration. 5. Check the image quality.

Go to Flag 5. 0V is available at P/J93 pin 10.

Y N
Go to the 01B 0V Distribution RAP.

Enter dC131, 09-069, TC sensor control voltage, and record the displayed value. (100 dis-
played equals 1 volt). Go to Flag 4. Check the voltage at P/J93, pin 9. The displayed value
is within 0.2V of the voltage checked at P/J93 pin 9.
Y N
Disconnect P/J93. Check the voltage at pin 9. The displayed value is within 0.2V of
the voltage checked at P/J93 pin 9.
Y N
Check the wiring, GP 7, between P/J93 and P/J6 on the IOT PWB. The wiring is
good.
Y N
Repair the wiring, REP 1.2. Perform the TC increase adjustment

Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2. Perform the TC increase adjustment

Install a new developer assembly, (35-55 ppm) PL 9.17 Item 2, (65-90 ppm) PL 9.15 Item
2. Perform dC905 TC Sensor Calibration.

Perform the TC reduction adjustment.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-235 09-360, 09-361, 09-362, 09-363
 P/J93

TC sensor Q09-360

Toner dispense drive

gears

Toner dispense
motor
MOT 09-040

Figure 1 Component location Figure 2 Circuit diagram

Status Indicator RAPs February 2010

09-360, 09-361, 09-362, 09-363 2-236 Xerox WorkCentre 5790 Family
09-365 Relative Humidity Sensor Failure RAP NOTE: The actual value is not critical. If the reading from Q09-365 is approximately within the
range indicated in column 4, Table 1, the sensor is good.
09-365 Average humidity reading is out of limits.
Table 1 Relative humidity values
Also use this RAP if the relative humidity sensor is suspected of working incorrectly. A faulty
relative humidity sensor can cause image quality problems. External Average relative Cold machine relative Warm machine relative
environment humidity humidity humidity
Initial Actions Wet 80% 80% 40% to 50%
Switch off the machine, then switch on the machine, GP 14. Ambient 50% 50% 15% to 30%
Dry 10% 10% 1% to 7%
Procedure
Enter dC330 code 09-365, relative humidity sensor, Q09-365. Press start. Observe the dis-
played state of Q09-365. Figure 1. Open the bypass tray, gently blow on the relative humidity
sensor PWB. Observe again the displayed state of Q09-365. The displayed state has
changed.
Y N
Go to Flag 1. Check for +5V at P/J7 pin 3 on the IOT PWB. +5V is present.
Y N
Go to the 01E +5V Distribution RAP.

Go to Flag 1. Check for +5V at P/J46 pin 1. +5V is present.

Y N
Check the wiring between P/J7 on the IOT PWB and P/J46, GP 7. Repair wiring as
necessary, REP 1.2.

Install a new relative humidity sensor / ambient temperature sensor, (35 ppm) PL 9.22
Relative humidity sensor
Item 4, (40-90 ppm) PL 9.20 Item 4. Q09-365 / ambient tempera-
If the fault continues, perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is ture sensor Q09-375
installed, PL 1.10 Item 2.

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

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-237 09-365
 09-370 Developer Temperature Sensor Failure RAP
09-370 The average developer temperature reading is out of limits.

Initial Actions
Switch off the machine, then switch on the machine, GP 14.

Procedure
Enter dC330 code 09-370, developer temperature sensor Q09-370. Press start. Observe the
displayed state of Q09-370. Remove the xerographic module. Disconnect P/J47, Figure 1.
Cheat the front door interlock. Observe again the displayed state of Q09-370. The displayed
state has changed.
Y N
Go to Flag 1. Check for +5V at P/J7 pin 5 on the IOT PWB. +5V is present.
Y N
Go to the 01E +5V Distribution RAP.

Go to Flag 1. Check for +5V at P/J47 pin 3. +5V is present.

Y N

NOTE: To gain access to the wiring, remove the main drive module, (35-55 ppm) PL
4.15 Item 1, (65-90 ppm) PL 4.10 Item 1 and the left hand cover, PL 8.10 Item 3.
Figure 2 Circuit diagram
Check the wiring between P/J7 on the IOT PWB and P/J47. Repair the wiring as
necessary, REP 1.2.

Install a new temperature sensor, (35 ppm) PL 9.22 Item 5, (40-90 ppm) PL 9.20 Item 5.
If the fault persists. Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
installed, PL 1.10 Item 2.

Q09-370 is working correctly. Reconnect P/J47.

If the fault is intermittent, perform the steps that follow:
• Check the wiring, GP 7. Repair if necessary, REP 1.2.
• Make sure that the P/Js are correctly and securely connected.

Status Indicator RAPs February 2010

09-365, 09-370 2-238 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

Temperature sensor
Q09-370

P/J47

Figure 1 Component Location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-239 09-370
09-375 Ambient Temperature Sensor Failure RAP
09-375 The average ambient temperature is out of limits.

Initial Actions
Switch off the machine, then switch on the machine, GP 14.

Reposition P/J46 on the relative humidity sensor / ambient temperature sensor and P/J7 on
the IOT PWB.

Procedure
Enter dC330 code 09-375, ambient temperature sensor, Q09-375. Press start. Observe the Relative humidity sensor
displayed state of Q09-375. Figure 1. Open the left hand door, gently blow on the temperature Q09-365 / ambient tempera-
sensor PWB. Observe again the displayed state of Q09-375. The displayed state has ture sensor Q09-375
changed.
Y N
Go to Flag 1. Check for +5V at P/J7 pin 3 on the IOT PWB. +5V is present.
Y N
Go to the 01E +5V Distribution RAP.

Go to Flag 1. Disconnect P/J46. Check for +5V at P/J46, pin 1. +5V is present.
Y N P/J46
Check the wiring between P/J7 on the IOT PWB and P/J46, GP 7. Repair the wiring
as necessary.

Install a new relative humidity sensor / ambient temperature sensor, (35 ppm) PL 9.22
Item 4, (40-90 ppm) PL 9.20 Item 4.
If the fault persists, perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is
installed, PL 1.10 Item 2.
Figure 1 Component location
The ambient temperature sensor is working correctly.
If the fault is intermittent, perform the steps that follow:
• Check the wiring, GP 7. Repair if necessary, REP 1.2.
• Make sure that the P/Js are correctly and securely connected, GP 11.

Status Indicator RAPs February 2010

09-375 2-240 Xerox WorkCentre 5790 Family
 09-380 Waste Toner Door Switch Failure RAP
09-380 The waste toner door switch has detected that the waste toner bottle is missing or the
door is open during run.

Initial Actions
Figure 1. Ensure that the waste toner door is fully closed.

Procedure
Enter dC330 code 09-380 waste toner door switch, S09-380. Press start. Open and close the
waste toner door. The display changes.
Y N
Go to Flag 1. Check S09-380. Refer to:
• GP 13 How to Check a Switch.
• P/J7, IOT PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Waste toner door switch, (35-55 ppm) PL 4.15 Item 8, (65-90 ppm) PL 4.10 Item 8.
Figure 2 Circuit diagram • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
• Main drive module, (35-55 ppm) PL 4.15 Item 1, (65-90 ppm) PL 4.10 Item 1.

Make sure that S09-380 is mounted correctly. Install new components as necessary.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-241 09-375, 09-380
 Waste toner door switch
S09-380

Waste toner
door

Figure 2 Circuit diagram

Waste toner bottle

Figure 1 Component location

Status Indicator RAPs February 2010

09-380 2-242 Xerox WorkCentre 5790 Family
09-399 Incompatible Xerographic Module RAP OpCo ID (Market Region) Validation Criteria
09-399 The xerographic module CRUM failed the authorization check. The xerographic module will be sold in the following market regions.
• NASG-N - North american solutions group.
The authorization check is performed to ensure that the xerographic module installed in the • NASG-S - North american solutions group.
system is compatible with the current machine configuration and the customer service plan.
• ESG - European solutions group.
• DMO-E - Developing markets east.
Initial Actions
• DMO-W - Developing markets west.
CAUTION
For each market region the system will support the xerographic modules configured as indi-
Do not install a new sold xerographic module into a meter service plan machine. This will con- cated by ‘Yes’ in Table 2. e.g. a xerographic module configured as NASG-S will function in the
vert the machine to a sold service plan. But this may not be noticed until the sold xerographic
following machine / market regions: NASG-N, NASG-S and DMO-W.
module has failed and is renewed with a meter xerographic module.
• Check that the xerographic module matches the customer service plan. Xerographic modules configured to ‘world wide’ are for all markets.
• Install a new xerographic module that matches the machine configuration and the cus-
tomer service plan, (35 ppm) PL 9.22 Item 2, (40-90 ppm) PL 9.20 Item 2. The system will not accept a xerographic module that does not match the OpCo ID (market
region) of the system. If there is a mismatch between the system configuration and the OpCo
Procedure ID then an incompatible xerographic module message will be displayed on the GUI.

To check the chosen service plan: Table 2 OpCo ID (Market region)

1. Enter Customer Administration Tools, GP 24. Xerographic
2. Select Consumables Management. module System configuration (Xerox OpCo ID)
3. Select Service Plan.
4. The greyed out icon will indicate the chosen service plan. Refer to Table 1. NASG-N NASG-S DMO-W DMO-E ESG
NOTE: All new machines are configured to metered. A customer with an unmetered plan NASG-N Yes Yes Yes No No
should only have new sold xerographic module. NASG-S Yes Yes Yes No No
DMO-W Yes Yes Yes No No
Table 1 Service plan DMO-E No No No Yes Yes
Service plan type Service plan description ESG No No No Yes Yes
A Sold - Xerox service agreement does not include the cost of World wide Yes Yes Yes Yes Yes
the xerographic module
B Meter - Xerox service agreement does include the cost of
the xerographic module
C Aftermarket -System will accept non-Xerox and OEM sup-
plied xerographic module with no CRUM
D Not used

NOTE: There is no communication with the CRUM when the system is configured to
aftermarket (3rd party).

To Change the Service Plan Type

1. Obtain the machine serial number.
2. Enter the Service Plan, refer to the Procedure.
3. Contact the market region technical specialist for a confirmation number.
4. Enter the confirmation number.
5. Press Enter.
6. Follow the message set to Exit.
7. Check that the service plan is correct.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-243 09-399
09A Photoreceptor Motor RAP 09B Waste Toner Full Sensor RAP
Procedure Use this RAP if the message ‘waste toner bottle nearly full’ appears, when the waste toner bot-
Go to the 04A Main Drive Motor and Photoreceptor Motor RAP. tle is empty.

The waste toner bottle has the capacity to hold the waste toner from over 100K prints at 6%
average area coverage.

The waste toner sensor is an infrared transmission sensor. The sensor consists of an infrared
emitter on one side of the bottle and an infrared detector on the other side of the bottle.

Initial Actions
• Check if the bottle is full, PL 9.10 Item 1.
• Check for toner contamination around the waste toner full sensor, Figure 1.

Procedure
Use thick black card to manually actuate the sensor. Enter dC330 code 09-350 waste toner full
sensor, Q09-350. Pass the black card between the sensor transmitter and receiver. The dis-
play changes.
Y N
Go to Flag 1. Check Q09-350. Refer to:
• GP 11 How to Check a Sensor.
• Figure 1.
• P/J7, IOT PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary.
• Waste toner full sensor, PL 9.10 Item 2.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

The fault may be intermittent. Check that the sensor is located correctly on the support bracket
and on the machine frame. Check for damaged components on the sensor, PL 9.10 Item 2.

Status Indicator RAPs February 2010

09A, 09B 2-244 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

Waste toner full sensor

Q09-350

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-245 09B
09C Photoreceptor Fan RAP
Use this RAP to check the photoreceptor fan.

NOTE: A faulty photoreceptor fan can cause image quality problems.

Procedure

Ensure that the machine is switched on, GP 14. Check the airflow by holding a piece of paper
over the fan intake, PL 9.25 Item 6. The fan is working.
Y N
Go to Flag 1. Check the photoreceptor fan motor. Refer to GP 10, How to Check a Motor.
Check the following:
• +15V at PJ42.
• +15V at P/J17.
• Continuity between PJ42 and P/J17. If necessary repair the harness, REP 1.2.
Install new components as necessary.
• Photoreceptor fan, PL 9.25 Item 6.
• LVPS and base module, PL 1.10 Item 3.

Ensure that the fan is installed correctly. If the fan in installed correctly air will be drawn into the
air intake. Refer to the OF6 Ozone and Air Systems RAP.
The fault may be intermittent. Go to Flag 1. Check the harness and the connectors, GP 7.

Figure 1 Circuit diagram

Status Indicator RAPs February 2010

09C 2-246 Xerox WorkCentre 5790 Family
10-101, 10-102, 10-103 Lead Edge Late to Fuser Exit Switch 10-101A, 10-102A, 10-103A Lead Edge Late to Fuser Exit
Entry RAP Switch RAP (35-55 ppm)
10-101 The lead edge of the paper failed to actuate the fuser exit switch within the correct time 10-101 The lead edge of the paper failed to actuate the fuser exit switch within the correct time
after the registration clutch was energized for a simplex sheet. after the registration clutch was energized for a simplex sheet.

10-102 The lead edge of the paper failed to actuate the fuser exit switch within the correct time 10-102 The lead edge of the paper failed to actuate the fuser exit switch within the correct time
after the registration clutch was energized for a duplex sheet side 1. after the registration clutch was energized for a duplex sheet side 1.

10-103 The lead edge of the paper failed to actuate the fuser exit switch within the correct time 10-103 The lead edge of the paper failed to actuate the fuser exit switch within the correct time
after the registration clutch was energized for a duplex sheet side 2. after the registration clutch was energized for a duplex sheet side 2.

Initial Actions WARNING

Before performing this procedure, check that the paper is not being skewed at any point Do not touch the fuser while it is hot.
between the paper tray and the fuser module. If skew is found, go to IQ8 Skew RAP. Initial Actions
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to 10-101,
Procedure 10-102, 10-103 Lead Edge Late to Fuser Exit Switch Entry RAP.
• If the speed of the machine is 35-55 ppm, go to 10-101A, 10-102A, 10-103A Lead Edge • Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
Late to Fuser Exit Switch RAP.
• Check for obstructions in the registration transport, Figure 2.
• If the speed of the machine is 65-90 ppm, go to 10-101B, 10-102B, 10-103B Lead Edge
• Check for obstructions in the short paper path assembly, Figure 3.
Late to Fuser Exit Switch RAP.
• Check that the short paper path assembly latches without excessive force, PL 10.25 Item
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism.
• Check the stripper fingers on the xerographic module.
• Check for paper in the fuser module.
• Check the fuser stripper fingers for contamination, (35-55 ppm) PL 10.8 Item 4.
• If a 10-101 is caused by paper fed from the bypass tray, check for paper skew.
• If a 10-103 is caused by a skewed sheet on side 2, check the inverter, PL 10.12 Item 1.
Also check the duplex paper path (35-55 ppm) PL 8.22 Item 1. Install new components as
necessary.
• If 10-101 jams, check that all of the HT connectors are pushed fully home on the HVPS.
• If the fault is 10-101 and the paper is fed from tray 1 or tray 2. Check if the paper has
excessive curl and is causing the paper to be skewed when fed from the tray. Install TAG
002 on the paper tray to constrain the effect of the curl.
• Install the XRU skids kit to eliminate paper jams caused by curled copies between the
XRU and the fuser module, (35 ppm) PL 9.22 Item 21, (40-90 ppm) PL 9.20 Item 19.

Procedure
NOTE: The door interlock switch must be cheated when checking +24V components.

Enter dC330 code 10-100 fuser exit switch, S10-100. Press Start. Manually actuate the switch
with a piece of paper, Figure 1. The display changes.
Y N
Go to Flag 1. Check S10-100. Refer to:
• GP 13 How to Check a Switch.
• Figure 1.
• P/J35, IOT PWB.
• 01D +3.3V Distribution RAP.
A

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-247 10-101, 10-102, 10-103, 10-101A, 10-102A, 10-103A
A B
• 01B 0V Distribution RAP. • P/J5, IOT PWB.
Install new components as necessary: • 01D +3.3V Distribution RAP.
• Fuser exit switch, (35-55 ppm) PL 10.8 Item 11. • 01B 0V Distribution RAP.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL Install new components as necessary:
1.10 Item 2. • Registration sensor, (35-55 ppm) PL 8.15 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
Enter dC330 code 10-065 vacuum transport fan, MOT10-065. Figure 3. Press Start, The fan
1.10 Item 2.
runs.
Y N Check the following components, refer to GP 7:
Go to Flag 2. Check MOT10-065. Refer to:
• Registration roll, PL 8.15 Item 9.
• GP 10 How to Check a Motor.
• Roll assembly on the short paper path assembly, PL 10.25 Item 1.
• Figure 3.
• Check the detack corotron and the connection to the HVPS. Refer to 09-060 HVPS Fault
• P/J5, IOT PWB.
RAP
• P/J17, LVPS.
• The drive gear on the fuser module, (35-55 ppm) PL 10.8 Item 1.
• Fuse, PL 1.10 Item 9, GP 7.
• The fuser drive gear on the main drives module, (35-55 ppm) PL 4.17 Item 10.
• 01G +24V Distribution RAP.
• Fuser web motor and the fuser web, 10A Fuser Web Motor RAP.
• 01B 0V Distribution RAP.
• Check the drives plate on the registration clutch for damage and contamination. Refer to
Install new components as necessary: the replacement procedure in REP 8.5.
• Short paper path assembly, PL 10.25 Item 1. • If the fault still occurs, the +24V supply from the LVPS may be faulty. Install a new LVPS,
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL PL 1.10 Item 3.
1.10 Item 2.

Enter dC330 code 04-010 main drive motor. Press Start. Add code 08-070 registration clutch,
CL08-070. Press Start.

NOTE: The clutch will switch off after 5 seconds.

The jam clearance knob 4c, PL 8.15 Item 10, rotates.
Y N
Go to Flag 3. Check CL08-070. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• P/J5, IOT PWB.
• P/J17, LVPS.
• Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Registration clutch, (35-55 ppm) PL 8.15 Item 7.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Manually actuate the sen-
sor Figure 2. The display changes.
Y N
Go to Flag 4. Check Q08-150. Refer to:
• GP 11 How to Check a Sensor.
• Figure 2.

B
Status Indicator RAPs February 2010
10-101A, 10-102A, 10-103A 2-248 Xerox WorkCentre 5790 Family
 Registration rolls

Registration sensor
Q08-150

Fuser exit switch

S10-100
Registration clutch
CL08-070

Figure 1 Component location Figure 2 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-249 10-101A, 10-102A, 10-103A
 Transfer / detack corotron

Transport rolls

Vacuum transport fan

MOT10-065

Figure 3 Component location

Figure 4 Circuit diagram

Status Indicator RAPs February 2010

10-101A, 10-102A, 10-103A 2-250 Xerox WorkCentre 5790 Family
 A
10-101B, 10-102B, 10-103B Lead Edge Late to Fuser Exit • 01B 0V Distribution RAP.
Install new components as necessary:
Switch RAP (65- 90 ppm)
• Fuser exit switch, (65-90 ppm) PL 10.10 Item 11
10-101 The lead edge of the paper failed to actuate the fuser exit switch within the correct time
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
after the registration clutch was energized for a simplex sheet.
1.10 Item 2.
10-102 The lead edge of the paper failed to actuate the fuser exit switch within the correct time
Enter dC330 code 10-065 vacuum transport fan, MOT10-065. Figure 3. Press Start, The fan
after the registration clutch was energized for a duplex sheet side 1.
runs.
10-103 The lead edge of the paper failed to actuate the fuser exit switch within the correct time Y N
Go to Flag 2. Check MOT10-065. Refer to:
after the registration clutch was energized for a duplex sheet side 2.
• GP 10 How to Check a Motor.
WARNING • Figure 3.
Do not touch the fuser while it is hot. • P/J5, IOT PWB.
Initial Actions • P/J17, LVPS.
• Fuse, PL 1.10 Item 9, GP 7.
• Make sure that the correct RAP is used. To identify the correct RAP to use, go to 10-101,
10-102, 10-103 Lead Edge Late to Fuser Exit Switch Entry RAP. • 01G +24V Distribution RAP.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20. • 01B 0V Distribution RAP.
• Check for obstructions in the registration transport, Figure 2. Install new components as necessary:
• Check for obstructions in the short paper path assembly, Figure 3. • Short paper path assembly, PL 10.25 Item 1.
• Check that the short paper path assembly latches without excessive force, PL 10.25 Item • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism. 1.10 Item 2.
• Check the stripper fingers on the xerographic module.
Enter dC330 code 04-010 main drive motor. Press Start. Add code 08-070 registration clutch,
• Check for paper in the fuser module.
CL08-070. Press Start.
• Check the fuser stripper fingers for contamination, (65-90 ppm) PL 10.10 Item 4.
• If a 10-101 is caused by paper fed from the bypass tray, check for paper skew. NOTE: The clutch will switch off after 5 seconds.
• If a 10-103 is caused by a skewed sheet on side 2, check the inverter PL 10.11 Item 23. The jam clearance knob 4c, PL 8.17 Item 10, rotates.
Also check the duplex paper path (65-90 ppm) PL 8.20 Item 1. Install new components as Y N
necessary. Go to Flag 3. Check CL08-070. Refer to:
• If 10-101 jams, check that all of the HT connectors are pushed fully home on the HVPS. • GP 12 How to Check a Solenoid or Clutch.
• If the fault is 10-101 and the paper is fed from tray 1 or tray 2. Check if the paper has • P/J5, IOT PWB.
excessive curl and is causing the paper to be skewed when fed from the tray. Install TAG • P/J17, LVPS.
002 on the paper tray to constrain the effect of the curl.
• Fuse, PL 1.10 Item 9, GP 7.
• Install the XRU skids kit to eliminate paper jams caused by curled copies between the
• 01G +24V Distribution RAP.
XRU and the fuser module, (35 ppm) PL 9.22 Item 21, (40-90 ppm) PL 9.20 Item 19.
• 01B 0V Distribution RAP.
Install new components as necessary:
Procedure
• Registration clutch, (65-90 ppm) PL 8.17 Item 7.
NOTE: The door interlock switch must be cheated when checking +24V components. • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
Enter dC330 code 10-100 fuser exit switch, S10-100. Press Start. Manually actuate the switch
with a piece of paper, Figure 1. The display changes.
Y N Enter dC330 code 08-150 registration sensor, Q08-150. Press Start. Manually actuate the sen-
sor with a piece of paper, Figure 2. The display changes.
Go to Flag 1. Check S10-100. Refer to:
Y N
• GP 13 How to Check a Switch.
Go to Flag 4. Check Q08-150. Refer to:
• Figure 1.
• GP 11 How to Check a Sensor.
• P/J35, IOT PWB.
• Figure 2.
• 01D +3.3V Distribution RAP.
A B

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-251 10-101B, 10-102B, 10-103B
B
• P/J16, IOT PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Registration sensor, PL 8.17 Item 3.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Check the following components, refer to GP 7:

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

Fuser exit switch

S10-100

Figure 1 Component location

Status Indicator RAPs February 2010

10-101B, 10-102B, 10-103B 2-252 Xerox WorkCentre 5790 Family
 Transfer / detack corotron
Registration nip rolls

Transport rolls

Vacuum transport fan

MOT10-065

Figure 3 Component location

Registration clutch Registration sensor
CL08-070 Q08-150

Figure 2 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-253 10-101B, 10-102B, 10-103B
 10-107, 10-108, 10-109, 10-110 Trail Edge Late from Fuser
Exit Switch RAP
10-107 The trail edge of the paper failed to de-actuate the fuser exit switch within the correct
time after the trail edge at the registration sensor, for a simplex non inverted sheet.

10-108 The trail edge of the paper failed to de-actuate the fuser exit switch within the correct
time after the trail edge at the registration sensor, for a simplex inverted sheet.

10-109 The trail edge of the paper failed to de-actuate the fuser exit switch within the correct
time after the trail edge at the registration sensor, for a duplex sheet side 1.

10-110 The trail edge of the paper failed to de-actuate the fuser exit switch within the correct
time after the trail edge at the registration sensor, for a duplex sheet side 2.

WARNING
Do not touch the fuser while it is hot.
Initial Actions
• Check that the paper size information in the UI matches the paper used in the paper trays
and the bypass tray.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20.
• Check that the short paper path assembly latches without excessive force, PL 10.25 Item
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism.
• Check for paper in the fuser module.
• Check the fuser stripper fingers for contamination, (35-55 ppm) PL 10.8 Item 4, (65-90
ppm) PL 10.10 Item 4.
• Check the inverter upper baffle assembly, (65-90 ppm) Figure 1, (35-55 ppm) Figure 2.
• Check the entrance to the output device and the alignment of the device.
(35-55 ppm only) If a OCT is used, check for sticking fingers at the exit to the output tray,
REP 12.1.
• (35-55 ppm 0nly) If the faults occur when feeding a transparency, install TAG 004 inverter
transparency feed kit.
• Install the XRU skids kit to eliminate paper jams caused by curled copies between the
XRU and the fuser module, (35 ppm) PL 9.22 Item 21, (40-90 ppm) PL 9.20 Item 19.

Procedure
WARNING
Take care during this procedure. Motors will become hot during normal operation.

NOTE: The door interlock switch must be cheated when checking +24V components.

Enter dC330 code 10-100 fuser exit switch, S10-100. Press Start. Manually actuate the switch
with a piece of paper. The display changes.
Y N
Go to Flag 1. Check S10-100. Refer to:
Figure 4 Circuit diagram
• GP 13 How to Check a Switch.
• (35-55 ppm) Figure 2.
(65-90) Figure 1.
A
Status Indicator RAPs February 2010
10-101B, 10-102B, 10-103B, 10-107, 10-108, 10-109, 2-254 Xerox WorkCentre 5790 Family
A B
• P/J35, IOT PWB. Check the following components, refer to GP 7:
• 01D +3.3V Distribution RAP. • The drive gear on the fuser module, PL 10.10 Item 1.
• 01B 0V Distribution RAP. • The fuser drive gear on the main drives module, (35-55 ppm) PL 4.17 Item 10, (65-90
Install new components as necessary: ppm) PL 4.12 Item 10.
• Fuser exit switch, (35-55 ppm) PL 10.8 Item 11 or (65-90 ppm) PL 10.10 Item 11 • Fuser web motor and the fuser web, 10A Fuser Web Motor RAP.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL • Drives between inverter and the main drives module, PL 10.15.
1.10 Item 2. • Post fuser exit roller, PL 10.12 Item 9.

Enter dC330 code 10-045 inverter path solenoid, SOL10-045. Press Start. The solenoid NOTE: Excessive post fuser exit roll wear causes buckle between the fuser and the
inverter assembly. This can cause severe ripple on the trail edge of A3 (11x17 inch) sheet
energized.
and paper jams.
Y N
Go to Flag 2. Check SOL10-045. Refer to: • Upper baffle, (35-55 ppm) PL 10.12 Item 23, (65-90 ppm) PL 10.12 Item 22.
• GP 12 How to Check a Solenoid or Clutch. • Baffle guide, PL 10.13 Item 3.
• (35-55 ppm) Figure 2. If the fault still occurs, the +24V supply from the LVPS may be faulty. Install a new LVPS, PL
(65-90 ppm) Figure 1. 1.10 Item 3.
• P/J5, IOT PWB
• P/J17, LVPS.
• Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Inverter path solenoid, PL 10.11 Item 14.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 10-030 inverter motor, MOT 10-030. Press start. The jam clearance knob,
2B, PL 10.15 Item 13, is stationary and the motor can be heard.
Y N
The jam clearance knob, 2B, PL 10.15 Item 13, rotates counterclockwise.
Y N
Go to Flag 3. Check MOT10-030. Refer to: Fuser exit switch
• GP 10 How to Check a Motor. S10-100
• P/J4, IOT PWB.
• P/J45, P/J55 inverter motor driver PWB
• 01G +24V Distribution RAP.
Inverter path solenoid
• 01E +5V Distribution RAP. Upper baffle SOL10-045
• 01B 0V Distribution RAP.
Install new components as necessary:
• Inverter motor, PL 10.11 Item 11.
• Inverter motor driver PWB, PL 10.11 Item 22.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
PL 1.10 Item 2. Figure 1 Component location (65-90 ppm)

Install a new inverter motor driver PWB, PL 10.11 Item 22.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-255 10-107, 10-108, 10-109, 10-110
 Fuser exit switch
S10-100

Inverter path solenoid

Upper baffle
SOL10-045

Figure 2 Component location (35-55 ppm)

Status Indicator RAPs February 2010

10-107, 10-108, 10-109, 10-110 2-256 Xerox WorkCentre 5790 Family
 Figure 3 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-257 10-107, 10-108, 10-109, 10-110
10-120, 10-121, 10-126 IOT Exit Sensor RAP Procedure
10-120 The lead edge of the paper failed to reach the IOT exit sensor within the correct time WARNING
after the trail edge at the fuser exit switch for an inverted sheet. Take care during this procedure. Motors will become hot during normal operation.

10-121 The lead edge of the paper failed to reach the IOT exit sensor within the correct time NOTE: Ensure that the door interlock switch is cheated when checking +24V components.
after the trail edge at the fuser exit switch for an non inverted sheet. Enter dC330 code 10-120 IOT exit sensor, Q10-120. Press Start. Manually actuate the sensor.
The display changes.
10-126 The trail edge of the paper failed to clear the IOT exit sensor within the correct time.
Y N
Go to Flag 1. Check Q10-120. Refer to:
WARNING • GP 11 How to Check a Sensor.
Do not touch the fuser while it is hot. • (35-55 ppm) Figure 1.
Initial Actions (65-90 ppm) Figure 2.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20. • P/J5, IOT PWB.
NOTE: If the fault occurs only with heavy weight paper of 120 gsm (32 lb.) or greater that • 01D +3.3V Distribution RAP.
are being inverted. Then Enter the Tools Mode and Stock Settings. Change the stock type • 01B 0V Distribution RAP.
to heavyweight for the respective tray. If the problem persists, perform the RAP. Install new components as necessary:
• If the faults occur when feeding transparency, install TAG 004 inverter transparency feed • IOT exit sensor, PL 10.11 Item 13.
kit. • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
• If the fault is 10-120 and the paper is fed from tray 1 or tray 2. Check if the paper has 1.10 Item 2.
excessive curl and is causing the paper to be skewed when fed from the tray. Install TAG
002 on the paper tray to constrain the effect of the curl. Enter dC330 code 10-050 inverter nip solenoid, SOL10-050. Press Start. The solenoid ener-
gises.
• Check for obstructions in the inverter area, (35-55 ppm) Figure 1, (65-90 ppm) Figure 2.
Y N
• Check the upper and lower gravity fingers in the inverter, Figure 3, GP 7. Go to Flag 2. Check SOL10-050. Refer to:
• If the paper has dog ear on the inboard corner, install TAG 005 Rear gravity gate mylar kit. • GP 12 How to Check a Solenoid or Clutch.
• Check for obstructions in the exit area. • (35-55 ppm) Figure 1.
• Check that the output device is parallel to the machine. Refer to the appropriate adjust- (65-90 ppm) Figure 2.
ment:
• P/J5, IOT PWB.
– ADJ 11.2-110 Machine to 2K LCSS Alignment.
• P/J17, LVPS.
– ADJ 11.1-171 Machine to HVF/HVF BM, HVF BM to Tri-folder Alignment.
• Fuse, PL 1.10 Item 9, GP 7.
• 35-55 ppm Only. For 10-126 faults. If the machine has a OCT, make sure that the OCT
• 01G +24V Distribution RAP.
fingers are installed correctly. Refer to REP 12.1.
• 01B 0V Distribution RAP.
• For 10-126 faults. If the paper jam is at the entrance to the output device. Go to the rele-
vant output device copy damage RAP: Install new components as necessary:
– 11G-120 Copy Damage in the 1K LCSS RAP. • Inverter nip solenoid, PL 10.11 Item 6.
– 11H-110 Copy Damage in the 2K LCSS RAP. • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
– 11E-171 Copy Damage in the HVF BM RAP.
• For 10-126 faults. If the paper jam is at the entrance to the output device and the output Enter dC330 code 10-045 inverter path solenoid, SOL 10-045. Press Start. The solenoid
device fails to initialize after the front door is closed. Go to the relevant output device ini-
energizes.
tialization RAP.
Y N
– 11B-120 1K LCSS Initialization Failure RAP. Go to Flag 3. Check SOL 10-045. Refer to:
– 11C-110 2K LCSS Initialization Failure RAP. • GP 12 How to Check a Solenoid or Clutch.
– 11K-171 HVF Initialization Failure RAP. • (35-55 ppm) Figure 1.
• If the fault is caused by a multifeed of sheets, go to OF8 Multifeed RAP. (65-90 ppm) Figure 2.
• P/J5, IOT PWB
• P/J17, LVPS.
A
Status Indicator RAPs February 2010
10-120, 10-121, 10-126 2-258 Xerox WorkCentre 5790 Family
A
• Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Inverter path solenoid, PL 10.11 Item 14.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 code 10-030 inverter motor, MOT10-030. Press Start. The jam clearance knob,
2B, PL 10.15 Item 13, is stationary and the motor can be heard.
Y N
The jam clearance knob, 2B, PL 10.15 Item 13, rotates counterclockwise.
Y N
Go to Flag 4. Check MOT10-030. Refer to: Fuser exit switch
• GP 10 How to Check a Motor. S10-100
• P/J4, IOT PWB
Inverter path solenoid
• P/J45, P/J55 SOL10-045
• 01G +24V Distribution RAP
• 01E +5V Distribution RAP. IOT exit sensor
• 01B 0V Distribution RAP. Q10-120
Install new components as necessary: Inverter nip solenoid
SOL10-050
• Inverter motor, PL 10.11 Item 11.
• Inverter motor driver PWB, PL 10.11 Item 22.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
PL 1.10 Item 2.

Install a new inverter motor driver PWB, PL 10.11 Item 22.

Figure 1 Component location 35-55 ppm
Check the following components, refer to GP 7:
• Idler roll, PL 10.12 Item 15.
• Upper baffle, (35-55 ppm) PL 10.12 Item 23, (65-90 ppm) PL 10.12 Item 22.
• Double exit nip roll, PL 10.11 Item 8.
• Exit shaft assembly, PL 10.13 Item 4.
• Nip split shaft assembly, PL 10.11 Item 4.
• The drive gear on the fuser module, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL 10.10
Item 1.
• The fuser drive gear on the main drives module, (35-55 ppm) PL 4.17 Item 10, (65-90
ppm) PL 4.12 Item 10.
• Check the IOT exit sensor mounting bracket on the nip roll guide, PL 10.11 Item 10. The
bracket holds the IOT exit sensor in the correct position, PL 10.11 Item 13.
If the fault still occurs, the +24V supply from the LVPS may be faulty. Install a new LVPS, PL
1.10 Item 3.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-259 10-120, 10-121, 10-126
 Fuser exit switch
S10-100
Inverter path solenoid
SOL10-045

Inverter nip solenoid

IOT exit sensor SOL10-050
Q10-120

Figure 2 Component location 65-90 ppm

5 Upper gravity
fingers

4 Lower gravity fingers

Figure 3 Component location

Status Indicator RAPs February 2010

10-120, 10-121, 10-126 2-260 Xerox WorkCentre 5790 Family
 Figure 4 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-261 10-120, 10-121, 10-126
10-132, 10-133, 10-134 Lead Edge Late to Inverter Sensor Y N
Go to Flag 2. Check Q10-105. Refer to:
RAP (65-90 ppm) • GP 11. How to Check a Sensor.
10-132 The lead edge of the paper failed to actuate the inverter sensor within the correct time
• Figure 2.
after the fuser exit switch is made, for a simplex sheet.
• P/J61, IOT PWB
10-133 The lead edge of the paper failed to actuate the inverter sensor within the correct time • 01E +5V Distribution RAP.
after the fuser exit switch is made, for a duplex 1 sheet. • 01B 0V Distribution RAP.
Install new components as necessary:
10-134 The lead edge of the paper failed to actuate the inverter sensor within the correct time
• Inverter sensor, PL 10.12 Item 19.
after the fuser exit switch is made, for a duplex 2 sheet.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
WARNING
Do not touch the fuser while it is hot. Check the following components, refer to GP 7:
Initial Actions • The drive gear on the fuser module, PL 10.10 Item 1.
• Check that the paper size information in the UI matches the paper used in the paper trays • The fuser drive gear on the main drives module, PL 4.12 Item 10.
and the bypass tray. • Fuser web motor and the fuser web, 10A Fuser Web Motor RAP.
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20. • Drives between inverter and the main drives module, PL 10.15.
• Check that the short paper path assembly latches without excessive force, PL 10.25 Item • Post fuser exit roller, PL 10.12 Item 9.
1. Go to REP 10.1. In Replacement Step 5, check the latch mechanism.
• Check for paper in the fuser module. NOTE: Excessive post fuser exit roll wear causes buckle between the fuser and the
inverter assembly. This can cause severe ripple on the trail edge of A3 (11x17 inch) sheet
• Check the fuser stripper fingers for contamination, PL 10.10 Item 4.
and paper jams.
• Check the inverter upper baffle assembly, Figure 1.
• Upper baffle, PL 10.12 Item 22.
Procedure • Baffle guide, PL 10.13 Item 3.

WARNING
Take care during this procedure. Motors will become hot during normal operation.

NOTE: The door interlock switch must be cheated when checking +24V components.

Enter dC330 code 10-100 fuser exit switch, S10-100. Press Start. Manually actuate the switch
with a piece of paper. The display changes.
Y N
Go to Flag 1. Check S10-100. Refer to:
• GP 13 How to Check a Switch.
• Figure 1.
• P/J35, IOT PWB.
• 01D +3.3V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Fuser exit switch, PL 10.10 Item 11.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Enter dC330 sensor code 10-105 inverter sensor, Q10-105. Press Start. Manually actuate the
sensor with a piece of paper. The display changes.

Status Indicator RAPs February 2010

10-132, 10-133, 10-134 2-262 Xerox WorkCentre 5790 Family
 Inverter sensor
Q10-105

Fuser exit switch

Inverter nip split solenoid
S10-100
SOL10-055

Figure 2 Component location

Upper baffle

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-263 10-132, 10-133, 10-134
 10-135, 10-136, 10-137, 10-138 Trail edge Late from Inverter
Sensor RAP
10-135 The trail edge of the paper failed to de-actuate the inverter sensor within the correct
time, for a simplex non invert sheet.

10-136 The trail edge of the paper failed to de-actuate the inverter sensor within the correct
time, for a simplex inverted sheet.

10-137 The trail edge of the paper failed to de-actuate the inverter sensor within the correct
time, for a duplex sheet side 1.

10-138 The trail edge of the paper failed to de-actuate the inverter sensor within the correct
time, for a duplex sheet side 2.

WARNING
Do not touch the fuser while it is hot.
Initial Actions
• Check the condition of the paper in all trays. Refer to IQ1 and GP 20.

NOTE: If the fault occurs only with heavy weight paper of 120 gsm (32 lb.) or greater that
are being inverted, enter the Tools Mode and Stock Settings. Change the stock type to
heavyweight for the appropriate tray. If the problem persists, perform the procedure in this
RAP.

• Check for obstructions in the inverter area, Figure 1.

• Check the upper and lower gravity fingers in the inverter, Figure 3, GP 7.
• Check for obstructions in the exit area.
Figure 3 Circuit diagram • If the fault is caused by a multifeed of sheets, go to OF8 Multifeed RAP.

Procedure
WARNING
Take care during this procedure. Motors will become hot during normal operation.

NOTE: Ensure that the door interlock switch is cheated when checking +24V components.

Enter dC330 code 10-105 inverter sensor, Q10-105. Press Start. Manually actuate the sensor.
The display changes.
Y N
Go to Flag 1. Check Q10-120. Refer to:
• GP 11 How to Check a Sensor.
• Figure 3.
• P/J61, IOT PWB.
• 01E +5V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Inverter sensor, PL 10.12 Item 19.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.
A
Status Indicator RAPs February 2010
10-132, 10-133, 10-134, 10-135, 10-136, 10-137, 10-138 2-264 Xerox WorkCentre 5790 Family
A B
Enter dC330 code 10-050 inverter nip solenoid, SOL10-050. Press Start. The solenoid ener- • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
gises. 1.10 Item 2.
Y N
Go to Flag 2. Check SOL10-050. Refer to: Enter dC330 code 10-030 inverter motor, MOT10-030. Press Start. The jam clearance knob,
• GP 12 How to Check a Solenoid or Clutch. 2B, PL 10.15 Item 13, is stationary and the motor can be heard.
• Figure 1. Y N
The jam clearance knob, 2B, PL 10.15 Item 13, rotates counterclockwise.
• P/J5, IOT PWB.
Y N
• P/J17, LVPS. Go to Flag 4. Check MOT10-030. Refer to:
• Fuse, PL 1.10 Item 9, GP 7. • GP 10 How to Check a Motor.
• 01G +24V Distribution RAP. • P/J4, IOT PWB
• 01B 0V Distribution RAP. • P/J45, P/J55
Install new components as necessary: • 01G +24V Distribution RAP
• Inverter nip solenoid, PL 10.11 Item 6. • 01E +5V Distribution RAP.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL • 01B 0V Distribution RAP.
1.10 Item 2.
Install new components as necessary:
Enter dC330 code 10-045 inverter path solenoid, SOL 10-045. Press Start. The solenoid • Inverter motor, PL 10.11 Item 11.
energizes. • Inverter motor driver PWB, PL 10.11 Item 22.
Y N • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed,
Go to Flag 3. Check SOL 10-045. Refer to: PL 1.10 Item 2.
• GP 12 How to Check a Solenoid or Clutch.
• Figure 1. Install a new inverter motor driver PWB, PL 10.11 Item 22.
• P/J5, IOT PWB
Check the following components, refer to GP 7:
• P/J17, LVPS.
• Idler roll, PL 10.12 Item 15.
• Fuse, PL 1.10 Item 9, GP 7.
• Upper baffle, (65-90ppm) PL 10.12 Item 22, (35-55ppm) PL 10.12 Item 23.
• 01G +24V Distribution RAP.
• Double exit nip rolls, PL 10.11 Item 8.
• 01B 0V Distribution RAP.
• Exit shaft assembly, PL 10.13 Item 4.
Install new components as necessary:
• Nip split shaft assembly, PL 10.11 Item 4.
• Inverter path solenoid, PL 10.11 Item 14.
• The drive gear on the fuser module, PL 10.10 Item 1.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
• The fuser drive gear on the main drives module, PL 4.12 Item 10.
1.10 Item 2.
If the fault still occurs, the +24V supply from the LVPS may be faulty. Install a new LVPS, PL
Enter dC330 code 10-055 tri-roll nip split solenoid, SOL 10-055. Press Start. The solenoid 1.10 Item 3.
energizes.
Y N
Go to Flag 5. Check SOL 10-055. Refer to:
• GP 12 How to Check a Solenoid or Clutch.
• Figure 3.
• P/J61, IOT PWB
• P/J17, LVPS.
• Fuse, PL 1.10 Item 9, GP 7.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Tri-roll nip split solenoid, PL 10.14 Item 1.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-265 10-135, 10-136, 10-137, 10-138
 Inverter path solenoid
SOL10-045

Inverter nip solenoid

SOL10-050

Figure 1 Component location

5 Upper gravity
fingers

4 Lower gravity fingers

Figure 2 Component location

Status Indicator RAPs February 2010

10-135, 10-136, 10-137, 10-138 2-266 Xerox WorkCentre 5790 Family
 Inverter sensor
Q10-105

Inverter nip split solenoid

SOL10-055

Figure 3 Inverter assembly

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-267 10-135, 10-136, 10-137, 10-138
 Figure 4 Circuit diagram

Status Indicator RAPs February 2010

10-135, 10-136, 10-137, 10-138 2-268 Xerox WorkCentre 5790 Family
 A
10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 10- Before new components are installed, restore the NVM values to default.
Install new components as necessary:
365, 10-380 Fuser Over Temperature RAP • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
10-315 The difference between 2 consecutive thermistor readings exceeds a given value. 1.10 Item 2.
• LVPS and base module, PL 1.10 Item 3.
10-320 During standby or run mode, the thermistor reading is not within the target temperature
range. • Fuser Module, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL 10.10 Item 1.

Perform SCP 6 Final Actions.

10-321 Over temperature during standby mode, the thermistor reading is not within the target
temperature range

10-323 Over temperature during run mode, the thermistor reading is not within the target tem- Web drive Pin 1
gear Pin 5
perature range.

10-340 Fuser temperature sensor A reading monitors above its normal operating temperature.
Pin 6
10-350 The hardware comparator detects a fuser reading greater than 240 degrees centigrade
or a short circuit thermistor. Pin 8

10-360 Fuser temperature sensor B reading is greater than the normal operating temperature.
Pin 7
Pin 2
10-365 The fuser module is above the recommended operating temperature.

10-380 The fuser delta value between the temperature sensors A and B is to high. Pin 9
Pin 3
WARNING
Pin 4 Pin 10
Do not touch the fuser while it is hot.
Initial Actions
• If a number of 10-321 fault codes, are in the fault history. Check if the customer has been PJ100
running transparency jobs of nominal papers at card stock settings. This fault can be gen-
erated when the temperature changes between the standby and run. This is a normal
function of the machine and should not effect the customer operation.
• Check that the fuser temperature NVM settings in dC131, are set to default. Refer to NVM
location 10-028 though to 10-061 and location 08-282 through to 08-295. Ensure that the
CRUM
values are set to the default level. If the values are not at default then, 10-320, 10-321, Fuser drive
10-340 and 10-360 may appear in the fault log. gear
• Check the fuser module connector, Figure 1.
• Check the fuser connector assembly, Figure 2.
Figure 1 Component location

Procedure
Switch off the machine, then switch on the machine, GP 14. The display shows Ready to
Copy.
Y N
Refer to Figure 5. Go to Flag 1. The voltage at the temperature sensors A and B should
be 2.9 volts when the sensors are cold. In standby mode the voltage should be 0.78 to
0.98 volts. Refer to:
• P/J35, IOT PWB.
• 01D +3.3 V Distribution RAP.
• 01B 0V Distribution RAP
A

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-269 10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-
 Pin 5

Pin 6

LVPS
Pin 8
Pin 1

Pin 7
Pin 2

Pin 3 Pin 9

Pin 4 Pin 10
P/J100

IOT PWB

PJ24
HVPS

Figure 3 Component location 35 ppm

Figure 2 Component location

Status Indicator RAPs February 2010

10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 2-270 Xerox WorkCentre 5790 Family
 IOT PWB
HVPS PJ24

Figure 4 Component location 40-90 ppm

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-271 10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-
 Figure 5 Circuit diagram

Status Indicator RAPs February 2010

10-315, 10-320, 10-321, 10-323, 10-340, 10-350, 10-360, 2-272 Xerox WorkCentre 5790 Family
10-322, 10-324, 10-325, 10-330, 10-370 Fuser Under WARNING
Temperature RAP Take care when measuring AC mains (line) voltage. Electricity can cause death or injury.

10-322 Under temperature during standby mode, the thermistor reading is not within the target NOTE: The voltage will be 100% of the ACL voltage when the machine is switched on from
temperature range cold and pulse between 60% and 100% during standby.

10-324 under temperature during run mode, the thermistor reading is not within the target tem- Go to Flag 2 and check for ACL at PJ24. Switch on the machine, GP 14. ACL is available at
PJ24 between pin 1 and 3, and between pin 4 and 6.
perature range
Y N
10-325 The fuser control task watchdog timer has not been reset within a specified period. Install new components as necessary.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
10-330 The initial fuser temperature rise was not achieved within 30 seconds from the start of 1.10 Item 2.
warm up mode or the standby temperature was not reached within 150 seconds. • If the fault still occurs, install a new LVPS and base module, PL 1.10 Item 3

10-370 During power save mode, the thermistor reading is not within the target value, after the Go to Flag 1. With the fuser cold, check for +2.9V at pin 1 and at pin 2. +2.9V is available at
fuser has cooled to the power save temperature. both pins.
Y N
WARNING Go to Flag 1. Refer to:
Do not touch the fuser while it is hot. • P/J35, IOT PWB.
Initial Actions • 01D +3.3 V Distribution RAP.
• Switch off the machine, then switch on the machine, GP 14. • 01B 0V Distribution RAP
• If a number of 10-322 fault codes, are in the fault history. Check if the customer has been Install new components as necessary.
running transparency jobs of nominal papers at card stock settings. This fault can be gen- • Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
erated when the temperature changes between the standby and run. This is a normal 1.10 Item 2.
function of the machine and should not effect the customer operation.
• Check that the fuser temperature NVM settings in dC131, are set to default. If the fuser Perform SCP 6 Final Actions.
temperatures are not set to default, 10-322 may appear in the fault log.

Procedure
Switch off the machine GP 14. Remove the fuser module and check the continuity between pin
1 and pin 2 and between pin 3 and pin 4 on the fuser module connector, Figure 1. There is
continuity.
Y N
Install a new fuser module, (35-55 ppm) PL 10.8 Item 1 or (65-90 ppm) PL 10.10 Item 1.

Install the fuser module and disconnect PJ24, (35 ppm) Figure 3, (40-90 ppm) Figure 4. Go to
Flag 2 and check for continuity between pin 1 and 3 and between pins 4 and 6 at the harness
end. There is continuity.
Y N
Check the fuser connector assembly, Figure 2. If necessary, install a new fuser connector
assembly, (35-55 ppm) PL 4.15 Item 9, (65-90 ppm) PL 4.10 Item 9.

Connect PJ24, (35 ppm) Figure 3, (40-90 ppm) Figure 4.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-273 10-322, 10-324, 10-325, 10-330, 10-370
 Web drive Pin 1
Pin 5

Pin 5
Pin 6

Pin 6
Pin 7

Pin 7
Pin 2 Pin 8 Pin 1

Pin 2 Pin 8
Pin 9
Pin 3

Pin 10 Pin 3 Pin 9

Pin 4

P/J 100 Pin 4 Pin 10

P/J 100

CRUM
Fuser drive
gear

Figure 1 Component location

Figure 2 Component location

Status Indicator RAPs February 2010

10-322, 10-324, 10-325, 10-330, 10-370 2-274 Xerox WorkCentre 5790 Family
 LVPS

IOT PWB

P/J24 IOT PWB

PJ24
HVPS HVPS

Figure 3 Component location 35 ppm Figure 4 Component location 40-90 ppm

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-275 10-322, 10-324, 10-325, 10-330, 10-370
 Figure 5 Circuit diagram

Status Indicator RAPs February 2010

10-322, 10-324, 10-325, 10-330, 10-370 2-276 Xerox WorkCentre 5790 Family
10-399 Fuser Authorization Failure RAP 10A Fuser Web Motor RAP
10-399 The fuser CRUM failed the authorization check. Use this RAP when the fuser web motor is suspected of having failed. Indications of motor fail-
ure are contaminated stripper fingers and fuser roll. This fault may also cause paper jams in
The authorization check is performed to ensure that the fuser installed in the system is compat- the inverter.
ible with the machine configuration: 50Hz or 60Hz.
WARNING
WARNING Do not touch the fuser while it is hot.
Do not touch the fuser while it is hot. Initial Actions
Procedure • Check the fuser web motor drive coupling, Figure 2.
Install a new Fuser module that matches the machine configuration. • Check the fuser drawer connector, Figure 1.
• Fuser module (35-55 ppm), PL 10.8 Item 1.
• Fuser module (65-90 ppm), PL 10.10 Item 1. Procedure
NOTE: The door interlock switch must be cheated when checking +24V components.

The web motor does not run continuously. It is pulsed on for multiples of 0.9 seconds duration.
The pulsing of the motor is felt or heard during the print mode.
Enter dC330 code 10-010 fuser web motor, MOT10-010. The movement is very slow (approxi-
mately 0.1 rev per minute). The motor runs.
Y N
Go to Flag 1. Check MOT10-010. Refer to:
• Figure 1.
• GP 10 How to Check a Motor.
• P/J154, Main Drives PWB.
• 01G +24V Distribution RAP.
• 01B 0V Distribution RAP.
Install new components as necessary:
• Fuser web motor assembly, (35-55 ppm) PL 4.17 Item 1.
• Fuser web motor assembly, (65-90 ppm) PL 4.12 Item 1.
• Main drives module, (35-55 ppm) PL 4.15 Item 1.
• Main drives module, (65-90 ppm) PL 4.10 Item 1.
• Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed, PL
1.10 Item 2.

Check the following:

• Drive coupling on the fuser web motor shaft, (65-90 ppm) PL 4.12 Item 1.
• Drive coupling on the fuser web motor shaft, (35-55 ppm) PL 4.17 Item 1.
• Drive coupling on the web assembly, Figure 2.
The life expectancy of the fuser web is the same as the Fuser module. Install new Fuser mod-
ule, (35-55 ppm) PL 10.8 Item 1, (65-90 ppm) PL 10.10 Item 1.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-277 10-399, 10A
 Fuser drawer
connector
P/J100

Drive coupling for

the web assembly

Fuser drawer
connector Fuser module
Fuser web motor P/J100
assembly Fuser drive gear
(MOT10-010)

Figure 2 Component location

Figure 1 Component location

Figure 3 Circuit diagram

Status Indicator RAPs February 2010

10A 2-278 Xerox WorkCentre 5790 Family
 A
11-005-110, 11-006-110, 11-310-110, 11-311-110 Front Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
Tamper Move Failure RAP
• GP 10 How to Check a Motor.
11-005-110 Front tamper fails to move to the front position.
• P/J312, 2K LCSS PWB.
11-006-110 Front tamper fails to move to the rear position. • 11D-110 2K LCSS Power Distribution RAP.
11-310-110 Front tamper not at the front home position. Repair or install new components as necessary:
• Tamper assembly, PL 11.16 Item 1.
11-311-110 Front tamper not at the rear home position.
• 2K LCSS PWB, PL 11.26 Item 1.
WARNING
Take care not to topple the LCSS. Enter dC330 code 11-310, actuate the front tamper home sensor. The display changes.
Y N
The LCSS is unstable when un-docked from the machine.
Go to Flag 1. Check the sensor.
Do not show the customer how to un-dock the LCSS. Refer to:
Initial Actions • 11G-110 2K LCSS PWB Damage RAP.
• Figure 1. Check for damage or obstructions that would prevent the tamper assembly from • GP 11 How to Check a Sensor.
operating correctly. If necessary, install a new tamper assembly, PL 11.16 Item 1. • P/J312, 2K LCSS PWB.
• Jams can be caused by removing prints from bin 1 before the machine has finished print- • 11D-110 2K LCSS Power Distribution RAP.
ing. If the tampers are touched while they are moving, they may stall and cause the
Repair or install new components as necessary:
machine to shutdown. The resulting shutdown can cause un-clearable jams in the finisher
and the tray 3 and tray 4 to paper path interface. • Front tamper home sensor, PL 11.16 Item 3.
• Jams can also be caused if the tray settings do not match the paper in the trays. Make • 2K LCSS PWB, PL 11.26 Item 1.
sure the tray settings are correct.
Perform SCP 6 Final Actions.
• Check the condition and the tension of the front tamper drive belt. Tensioning is achieved
by a spring on the motor, the motor should be free to move.
Front tamper home
• If there is a large jam of paper above bin 1 that has obstructed the tampers, this has prob- sensor Q11-310
ably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor.
Perform the following:
– Check the paper for defects that could degrade the tamping operation e.g. curl,
paper condition, buckling or paper type. Refer to IQ1 Image Quality Entry RAP.
– Check the operation of the paddle roll, refer to 11-024-110, 11-025-110 Paddle Roll
Failure RAP.
– Check the operation of the bin 1 upper level sensor, refer to 11-030-110, 11-334-110,
11-335-110, 11-336-110 Bin 1 Movement Failure RAP.
– Refer to the 11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.
– Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP
Switch Settings RAP.

Procedure
NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors. Front tamper motor
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state MOT-003 (located at
the rear)
on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, codes 11-003 and 11-005 alternately The front tamper moves between the
home and inboard positions, Figure 1.
Y N
Figure 1 Component location
Go to Flag 2. Check the front tamper motor, MOT11-003.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-279 11-005-110, 11-006-110, 11-310-110, 11-311-110
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

11-005-110, 11-006-110, 11-310-110, 11-311-110 2-280 Xerox WorkCentre 5790 Family
11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-319-110 Procedure
Rear Tamper Move Failure RAP NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.
11-007-110 Rear tamper fails to move to the front position.
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.
11-008-110 Rear tamper fails to move to the rear position.
Enter dC330, codes 11-004 and 11-006 alternately. The rear tamper moves between the
11-312-110 Rear tamper is not at the front home position. home and inboard positions, Figure 1.
Y N
11-313-110 Rear tamper is not at the rear home position. Go to Flag 3. Check the rear tamper motor, MOT11-004.
Refer to:
11-319-110 Rear tamper is not at the away home position. • 11G-110 2K LCSS PWB Damage RAP.
• GP 10, How to Check a Motor.
NOTE: The away home position is with the rear tamper approximately halfway along it’s travel.
• P/J312, 2K LCSS PWB.
WARNING • 11D-110 2K LCSS Power Distribution RAP.
Take care not to topple the LCSS. Repair or install new components as necessary:
The LCSS is unstable when un-docked from the machine. • Tamper assembly, PL 11.16 Item 1.
Do not show the customer how to un-dock the LCSS. • 2K LCSS PWB, PL 11.26 Item 1.
Initial Actions
Enter dC330 code 11-311, actuate the rear tamper home sensor Q11-311. The display
• Figure 1. Check for damage or obstructions that would prevent the tamper assembly from
changes.
operating correctly. If necessary, install a new tamper assembly, PL 11.16 Item 1.
Y N
• Jams can be caused by removing prints from bin 1 before the machine has finished print- Go to Flag 1 and check Q11-311.
ing. If the tampers are touched while they are moving, they may stall and cause the Refer to:
machine to shutdown. The resulting shutdown can cause un-clearable jams in the finisher
• 11G-110 2K LCSS PWB Damage RAP.
and the tray 3 and tray 4 to paper path interface.
• GP 11, How to Check a Sensor.
• Jams can also be caused if the tray settings do not match the paper in the trays. Make
• P/J312, 2K LCSS PWB.
sure the tray settings are correct.
• 11D-110 2K LCSS Power Distribution RAP.
• Check the condition of the front tamper drive belt and that it is correctly tensioned. Ten-
sioning is achieved by a spring on the motor, the motor should be free to move. Repair or install new components as necessary:
• If there is a large jam of paper above bin 1 that has obstructed the tampers, this has prob- • Rear tamper home sensor, PL 11.16 Item 3.
ably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor. • 2K LCSS PWB, PL 11.26 Item 1.
Perform the following:
– Check the paper for defects that could degrade the tamping operation e.g. curl, NOTE: The away home position is used for short edge feed small paper. This saves unneces-
paper condition, buckling or paper type. Refer to IQ1 Image Quality Entry RAP. sary rear tamper travel.
– Check the operation of the paddle roll, refer to 11-024-110, 11-025-110 Paddle Roll Enter dC330, actuate the rear tamper away home sensor Q11-319. The display changes.
Failure RAP. Y N
– Check the operation of the bin 1 upper level sensor, refer to 11-030-110, 11-334-110, Go to Flag 2 and check Q11-319.
11-335-110, 11-336-110 Bin 1 Movement Failure RAP. Refer to:
– Refer to the 11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. • 11G-110 2K LCSS PWB Damage RAP.
– Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP • GP 11, How to Check a Sensor.
Switch Settings RAP. • P/J312, 2K LCSS PWB.
• 11D-110 2K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Rear tamper away home sensor, PL 11.16 Item 3.
• 2K LCSS PWB, PL 11.26 Item 1.

Perform SCP 6 Final Actions.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-281 11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-
 Rear tamper motor
MOT11-004 (located at
the front)

Rear tamper
away home
sensor
Q11-319

Rear tamper home

sensor
Q11-311

Figure 1 Component Location

Status Indicator RAPs February 2010

11-007-110, 11-008-110, 11-312-110, 11-313-110, 11- 2-282 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-283 11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-
 A
11-024-110, 11-025-110 Paddle Roll Failure RAP Enter dC330, code 11-025 and stack the code 11-326, to actuate the paddle roll position sen-
sor Q11-326. The display cycles high/low.
11-024-110 The paddle is not at the home position.
Y N
Go to Flag 1 and check Q11-326.
11-025-110 The paddle fails to rotate.
Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
NOTE: The paddle is in the home position when the sensor flag is located between the sensor
jaws. If a jam occurs in the compiler, bin 1 will not be available. • GP 11, How to Check a Sensor.
• Figure 1.
WARNING • P/J314, 2K LCSS PWB.
Take care not to topple the LCSS.
• 11D-110 2K LCSS Power Distribution RAP
The LCSS is unstable when un-docked from the machine.
Repair or install new components as necessary:
Do not show the customer how to un-dock the LCSS.
• Paddle roll position sensor, PL 11.8 Item 11.
Initial Actions • 2K LCSS PWB, PL 11.26 Item 1.
Check the following:
• That there is no paper or other obstructions in the vicinity of the paddle. Perform SCP 6 Final Actions.
• The paddle roll position sensor bracket is holding the sensor in the correct position, i.e.
the flag is in the middle of the sensor gap and the sensor does not touch any moving com- Paddle roll position
sensor
ponents.
Q11-326
• Check that paper type is set correctly. If heavyweight paper is used but not set in the UI,
the compiler capacity can be exceeded. Refer to 11J-110 Mis-Registration in Stapled Sets
and Non-stapled Sets RAP.
• Check the position of the paddles. With the paddle roll in the home position both sets of
paddles must be within the output cover, if they are not, refer to REP 11.12-110 Paddle
Wheel Shaft Assembly. If any of the paddles are out of alignment to other paddles, install
a new paddle wheel shaft assembly, PL 11.8 Item 4.
• 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Settings
RAP.

Procedure
NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.

NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, codes 11-024, paddle home position and 11-025, paddle run. The paddle
rotates correctly.
Y N
Go to Flag 2. Check the paddle motor, MOT 11-024. Paddle motor
Refer to: MOT11-024
• 11G-110 2K LCSS PWB Damage RAP.
• GP 10, How to Check a Motor.
• Figure 1.
• P/J310, 2K LCSS PWB.
• 11D-110 2K LCSS Power Distribution RAP Figure 1 Component location
Repair or install new components as necessary:
• Paddle motor, PL 11.8 Item 10.
• 2K LCSS PWB, PL 11.26 Item 1.
A
Status Indicator RAPs February 2010
11-024-110, 11-025-110 2-284 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-285 11-024-110, 11-025-110
11-030-110, 11-334-110, 11-335-110, 11-336-110 Bin 1 Procedure
Movement Failure RAP NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.
11-030-110 Bin 1 fails to move.
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.
11-334-110 Bin 1 has reached the upper limit of travel.
Remove the 2K LCSS rear cover. Enter dC330 code 11-336, bin 1 motor encoder sensor Q11-
11-335-110 Bin 1 has reached the lower limit of travel. 336, slowly rotate the encoder disk by hand. The display changes.
Y N
11-336-110 Bin 1 is not at the home position. Go to Flag 2 and check Q11-336.
Refer to:
NOTE: The home position of bin 1 is when bin 1 is actuating the bin 1 lower level sensor. See • 11G-110 2K LCSS PWB Damage RAP.
the final actions at the end of the procedure.
• GP 11 How to Check a Sensor.
Three sensors and two switches monitor the level of paper in bin 1 and the position of the tray:
• P/J304, 2K LCSS PWB.
• The bin 1 upper level sensor, the highest of two sensors that detect the top of the paper
• 11D-110 2K LCSS Power Distribution RAP.
stack in bin 1, or the empty bin 1, Figure 1.
Repair or install new components as necessary:
• The bin 1 90% full sensor detects when the tray has descended to a position where the
• Bin 1 motor encoder sensor Q11-336, PL 11.10 Item 11.
tray is 90% full, Figure 2.
• 2K LCSS PWB, PL 11.26 Item 1.
• The bin 1 lower level sensor, the lowest of two sensors that detects when paper is
removed from bin 1, Figure 1.
Enter dC330 code 11-033. Bin 1 cycles down and up.
• Bin 1 upper limit switch, S11-334, Figure 2.
Y N
• Bin 1 lower limit switch, S11-335, Figure 2. Go to Flag 1. Check the bin 1 elevator motor, MOT11-030.
Refer to:
WARNING
• 11G-110 2K LCSS PWB Damage RAP.
Take care not to topple the LCSS.
• GP 10 How to Check a Motor.
The LCSS is unstable when un-docked from the machine.
• P/J318, 2K LCSS PWB.
Do not show the customer how to un-dock the LCSS.
• 11D-110 2K LCSS Power Distribution RAP.
Initial Actions Repair or install new components as necessary:
Perform the following: • Bin 1 elevator motor MOT11-030, PL 11.10 Item 8
• Check for a physical obstruction that would prevent bin 1 from moving, such as an item of • 2K LCSS PWB, PL 11.26 Item 1.
furniture.
• Check that bin 1 is level front to back, if necessary perform ADJ 11.1-110 2K LCSS Bin 1 Figure 1, enter dC330, code 11-332. Actuate the bin 1 upper level sensor Q11-332. The dis-
Level. play changes.
• Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Y N
Switch Settings RAP. Go to Flag 4 and check Q11-332.
• Refer to the 11J-110 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. Refer to:
• If there is a large jam of paper above bin 1, this has probably been caused by poorly • 11G-110 2K LCSS PWB Damage RAP.
stacked sets failing to actuate the bin 1 upper level sensor. • GP 11 How to Check a Sensor.
Perform the relevant check: • P/J314, 2K LCSS PWB.
• If paper is overflowing the tray when it is at the lower limit, check the tray 90% full sensor. • 11D-110 2K LCSS Power Distribution RAP.
• If paper cannot be fed to bin 1 when it is at the highest position, check the bin 1 paper • REP 11.13-110 2K LCSS Un-docking.
sensor - low and bin 1 paper sensor - high. Repair or install new components as necessary:
Check the front and rear bin 1 drive belts. If necessary install new components, PL 11.10 Item • Bin 1 upper level sensor Q11-332, PL 11.12 Item 3.
1. • 2K LCSS PWB, PL 11.26 Item 1.

Figure 1, enter dC330, code 11-333. Actuate the bin 1 lower level sensor Q11-333. The dis-
play changes.

Status Indicator RAPs February 2010

11-030-110, 11-334-110, 11-335-110, 11-336-110 2-286 Xerox WorkCentre 5790 Family
 A
Y N • 11D-110, 2K LCSS Power Distribution RAP.
Go to Flag 3 and check Q11-333. Repair or install new components as necessary:
Refer to: • Bin 1 90% full sensor Q11-331, PL 11.10 Item 5.
• 11G-110 2K LCSS PWB Damage RAP. • 2K LCSS PWB, PL 11.26 Item 1.
• GP 11 How to Check a Sensor.
• P/J314, 2K LCSS PWB. As final actions, check the following sequence of operation:
• 11D-110, 2K LCSS Power Distribution RAP. • When bin 1 is empty and at the top, the bin 1 lower level sensor, Q11-333 is actuated by
• REP 11.13-110 2K LCSS Un-docking. the edge of the tray and the bin 1 upper level sensor, Q11-332 is de-actuated.
Repair or install new components as necessary: • Paper is delivered to the tray until the bin 1 upper level sensor, Q11-332 is actuated.
• Bin 1 lower level sensor Q11-333, PL 11.12 Item 3. • The motor lowers the tray until the bin 1 upper level sensor, Q11-332 is de-actuated.
• 2K LCSS PWB, PL 11.26 Item 1. • As the tray is lowered to accommodate the increase in stack height, the Bin 1 lower level
sensor, Q11-333 is held actuated by the stack rear edge.
Figure 2. Enter dC330 code 11-334. Actuate the bin 1 upper limit switch, S11-334. The dis- • When the tray is emptied, the tray returns to the home position; the bin 1 lower level sen-
play changes. sor, Q11-333 is de-actuated and the tray is elevated until both the bin 1 lower level sensor,
Y N Q11-333 and bin 1 upper level sensor, Q11-332 are made. The tray is then lowered until
Go to Flag 5 and check S11-334. the bin 1 upper level sensor, Q11-332 is just cleared. In the home position the bin one
Refer to: upper limit switch, S11-334 is also actuated.
• 11G-110 2K LCSS PWB Damage RAP.
• GP 13 How to Check a Switch.
Bin 1 lower level sensor
• P/J315, 2K LCSS PWB. Q11-333
• 11D-110 2K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Bin 1 upper limit switch, PL 11.10 Item 3. Bin 1 upper level sensor
• 2K LCSS PWB, PL 11.26 Item 1. Q11-332

Enter dC330 code 11-335, actuate the bin 1 lower limit switch, S11-335. The display
changes.
Y N
Go to Flag 6 and check S11-335.
Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
• GP 13 How to Check a Switch.
• P/J317, 2K LCSS PWB.
• 11D-110 2K LCSS Power Generation RAP.
• REP 11.13-110 2K LCSS Un-docking.
Repair or install new components as necessary:
• Bin 1 lower limit switch, PL 11.12 Item 1.
• 2K LCSS PWB, PL 11.26 Item 1.

Enter dC330 code 11-331, actuate the bin 1 90% full sensor, Q11-331. The display changes.
Y N
Go to Flag 7 and check Q11-331.
Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
• GP 11 How to Check a Sensor. Figure 1 Component location
• P/J316, 2K LCSS PWB.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-287 11-030-110, 11-334-110, 11-335-110, 11-336-110
 Bin 1 upper limit
switch, S11-334.

Bin 1 90% full sensor

Q11-331

Bin 1 motor encoder

sensor Q11-336

Bin 1 elevator motor

MOT11-030

Bin 1 lower limit switch, S11-335.

Figure 2 Component location Figure 3 Circuit diagram

Status Indicator RAPs February 2010

11-030-110, 11-334-110, 11-335-110, 11-336-110 2-288 Xerox WorkCentre 5790 Family
 Figure 4 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-289 11-030-110, 11-334-110, 11-335-110, 11-336-110
 A
11-043-110, 11-350-110 Hole Punch Operation Failure RAP • P/J307, 2K LCSS PWB.
• 11D-110 2K LCSS Power Distribution RAP.
11-043-110 The hole punch fails to perform a punch cycle.
Repair or install new components as necessary:
11-350-110 The hole punch is not at the home position. • Punch head home sensor, PL 11.6 Item 1.
• 2K LCSS PWB, PL 11.26 Item 1.
WARNING
Take care not to topple the LCSS. Enter dC330 code 11-043. The punch cycles.
Y N
The LCSS is unstable when un-docked from the machine.
Go to Flag 3. Check the hole punch motor MOT11-042.
Do not show the customer how to un-dock the LCSS.
Refer to:
Initial Actions • 11G-110 2K LCSS PWB Damage RAP.
• Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP • GP 10, How to Check a Motor.
Switch Settings RAP.
• P/J311, 2K LCSS PWB.
• Check that the hole punch is present and correctly installed.
• 11D-110 2K LCSS Power Distribution RAP.
• Check that the punch has not jammed in the down position. This can occur with transpar-
Repair or install new components as necessary:
encies and labels.
• Hole punch motor assembly, PL 11.6 Item 2.
NOTE: The home position of the punch unit is when the cut-out in the actuator is between • 2K LCSS PWB, PL 11.26 Item 1.
the punch head home sensor jaws.
NOTE: The chad bin collects the pieces of paper cut out by the hole punch. The chad bin level
Procedure sensor will not operate if the tray is incorrectly installed. Ensure the chad bin is fully inserted
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state and the lever engages in the slot.
on the UI. Make sure that the correct sensor or switch is tested.
Enter dC330, code 11-348. Figure 2, actuate the chad bin level sensor, Q11-348 using a strip
Go to Flag 5, check the link between P/J307 pins 10 and 11, 2K LCSS PWB. The link is of paper. The display changes.
good. Y N
Y N Go to Flag 4 and check Q11-340.
Repair the wiring or connector. Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
Enter dC330, code 11-351, actuate the punch head present sensor, Q11-351, Figure 1. The • GP 11 How to Check a Sensor.
display changes.
• P/J307, 2K LCSS PWB.
Y N
Go to Flag 2 and check Q11-351. • 11D-110 2K LCSS Power Distribution RAP.
Refer to: Install new components as follows.
• 11G-110 2K LCSS PWB Damage RAP. • Chad bin level sensor, PL 11.6 Item 7.
• GP 11 How to Check a Sensor. • 2K LCSS PWB, PL 11.26 Item 1.
• P/J307, 2K LCSS PWB.
Perform SCP 6 Final Actions.
• 11D-110 2K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Punch head present sensor, PL 11.6 Item 1.
• 2K LCSS PWB, PL 11.26 Item 1.

Enter dC330 code 11-350, actuate the punch head home sensor, Q11-350, Figure 1. The dis-
play changes.
Y N
Go to Flag 1 and check Q11-350.
Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
• GP 11 How to Check a Sensor.
A
Status Indicator RAPs February 2010
11-043-110, 11-350-110 2-290 Xerox WorkCentre 5790 Family
 Hole punch motor
MOT11-042

Punch head home

sensor
Q11-350 Chad bin level sensor, Q11-348
Punch head present sensor
Q11-351

Figure 1 Component location Figure 2 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-291 11-043-110, 11-350-110
 Figure 3 Circuit diagram

Status Indicator RAPs February 2010

11-043-110, 11-350-110 2-292 Xerox WorkCentre 5790 Family
 A B
11-050-110, 11-360-110 Staple Head Operation Failure RAP Go to Flag 3 and check the SU1 safety gate switch, S11-365. Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
11-050-110 The staple head fails to cycle.
• GP 13, How to Check a Switch.
11-360-110 The staple head is not at the home position. • Figure 1.
• P/J311, P/J308, 2K LCSS PWB
NOTE: The home position is with the jaws of the staple head fully open. • 11D-110 2K LCSS Power Distribution RAP.
NOTE: Staple head operation faults can be caused by offline stapling failures. The user may • Ensure that the SU1 safety gate switch is correctly actuated by the switch actuator,
be attempting to staple a set that exceeds the number of sheets/weight capacity. There may PL 11.8 Item 3.
also be an offline stapling problem, refer to 11A-110 Offline Stapling Fault RAP.
NOTE: The switch is closed and supplies +24V to the staple head when the cam is
WARNING positioned either fully counterclockwise or fully clockwise. During off line stapling
when the safety gate is partly down, the cam is in the mid position, the switch is open
Take care not to topple the LCSS.
and +24V is not supplied to the staple head.
The LCSS is unstable when un-docked from the machine.
Do not show the customer how to un-dock the LCSS. Install new components as necessary:
CAUTION • Staple head unit, PL 11.20 Item 5.
Do not run code 11-050 without two sheets of paper in the stapler jaws. Running this code with- • 2K LCSS PWB, PL 11.26 Item 1.
out the paper in position can cause damage to the machine. • SU1 safety gate switch, PL 11.8 Item 1.
Initial Actions
Perform SCP 6 Final Actions.
Switch off the machine, then switch on the machine, GP 14.

Check the following:

• Figure 1, the spring and cam are correctly located.
• Figure 1, the switch support bracket is correctly located.
• Figure 1, the safety gate switch connector is fully seated on both sides of the frame.
• The 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Set-
tings RAP.
• Figure 1, the staple head unit is correctly installed.
NOTE: Figure 1 shows the switch cam in the auto stapling position. To enable offline stapling,
the paddle motor is run in the reverse direction to lower the safety gate, this rotates the switch
cam in a counterclockwise direction, actuating the safety gate switch.

Procedure
NOTE: After repairing the fault using this RAP, switch off the machine, then switch on the
machine, GP 14, to enable operation of the staple head.

NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.

NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Place two sheets of paper in the stapler jaws. Enter dC330, code 11-050 to cycle the staple
head once, and 11-051 to reverse the staple head to the home position. The staple head
operates as expected.
Y N
Go to Flag 1 and Flag 2, check the wiring and connectors between the 2K LCSS PWB
and the staple head. The wiring is good.
Y N
Repair the wiring.
A B

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-293 11-050-110, 11-360-110
 Safety gate
switch connector

Switch support
bracket

Spring

Staple head including MOT11-

050 and staple head 1 home
sensor Q11-360
Switch cam

SU1 safety gate

switch, S11-365

Figure 1 Component location

Status Indicator RAPs February 2010

11-050-110, 11-360-110 2-294 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-295 11-050-110, 11-360-110
 A
11-053-110, 11-370-110 Staple Head Unit Movement Failure Enter dC330, code 11-370. Actuate the SU1 home sensor, Q11-370, by moving the stapler unit
to and from the home position using the green thumb-wheel. The display changes.
RAP Y N
11-053-110 The staple head unit fails to move. Go to Flag 1 and check Q11-370.
Refer to:
11-370-110 The staple head unit is not at the home position. • 11G-110 2K LCSS PWB Damage RAP.
• GP 11. How to check a sensor.
NOTE: The home position is when the staple head unit is at the corner stapling position (fully
• Figure 1.
to the front of the 2K LCSS and rotated through 45 degrees).
• P/J308, 2K LCSS PWB.
WARNING • 11D-110 2K LCSS Power Distribution RAP.
Take care not to topple the LCSS. Repair or install new components as necessary:
The LCSS is unstable when un-docked from the machine. • SU1 home sensor, PL 11.20 Item 3.
Do not show the customer how to un-dock the LCSS. • 2K LCSS PWB, PL 11.26 Item 1.
Initial Actions
Enter dC330, code 11-021 to move the ejector assembly fully to the right. Enter code 11-371.
• Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP
Actuate the SU1 front index sensor, Q11-371, by moving the stapler unit to and from the flag
Switch Settings RAP.
position (approximately 115mm (4.5 inches) from the front of the track) using the green thumb-
• Un-dock the 2K LCSS from the machine, REP 11.13-110, move the ejector assembly fully wheel. The display changes.
to the right, manually move the stapler unit along the full length of the track using the
Y N
green thumb-wheel. Check the home sensor flag and the two dual position flags for dam-
Go to Flag 2 and check Q11-371.
age, see NOTE. Check for damage or obstructions that would prevent the stapling unit Refer to:
from moving. If necessary, install a new staple head unit, PL 11.20 Item 5 or a new stapler
• 11G-110 2K LCSS PWB Damage RAP.
traverse assembly, PL 11.20 Item 1.
• GP 11 How to Check a Sensor.
NOTE: For dual position stapling, the SU1 front index sensor uses two flags. • P/J308, 2K LCSS PWB.
• Dock the 2K LCSS to the machine. • 11D-110 2K LCSS Power Distribution RAP.
Repair or install new components as necessary:
Procedure • SU1 front index sensor, PL 11.20 Item 3.
• 2K LCSS PWB, PL 11.26 Item 1.
NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.

NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state Perform SCP 6 Final Actions.
on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, code 11-021 to move the ejector assembly fully to the right. Enter code 11-055.
The stapling unit cycles back and forth along the track.
Y N
Go to Flag 3 and check MOT11-053.
Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
• GP 10, How to Check a Motor.
• Figure 1.
• P/J308, 2K LCSS PWB.
• 11D-110. 2K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Stapler traverse assembly, PL 11.20 Item 1.
• 2K LCSS PWB, PL 11.26 Item 1.

A
Status Indicator RAPs February 2010
11-053-110, 11-370-110 2-296 Xerox WorkCentre 5790 Family
 SU1 motor
MOT11-053

SU1 front index

sensor Q11-371
SU1 home sensor
Q11-370

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-297 11-053-110, 11-370-110
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

11-053-110, 11-370-110 2-298 Xerox WorkCentre 5790 Family
11-100-110 2K LCSS Paper Entry RAP
11-100-110 The leading edge of the sheet is late to the entry sensor Q11-100, Figure 1.

WARNING
Take care not to topple the LCSS.
The LCSS is unstable when un-docked from the machine.
Do not show the customer how to un-dock the LCSS.
Initial Actions
Refer to the 11H-110 Copy Damage in the 2K LCSS RAP.

Check the following:

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

Procedure Entry sensor

Q11-100
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Lower the paper entry guide assembly, PL 11.14 Item 8, to access the entry sensor. Enter
dC330, code 11-100. Actuate the entry sensor, Q11-100. The display changes.
Figure 1 Component location
Y N
Go to Flag 1 and check Q11-100.
Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
• GP 11, How to Check a Sensor.
• P/J304, 2K LCSS PWB.
• 11D-110 2K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Entry sensor, PL 11.24 Item 3.
• 2K LCSS PWB, PL 11.26 Item 1.

Perform SCP 6 Final Actions.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-299 11-100-110
 11-110-110 Sheet Late to Hole Punch RAP
11-110-110 Sheet late at the punch sensor.

WARNING
Take care not to topple the LCSS.
The LCSS is unstable when un-docked from the machine.
Do not show the customer how to un-dock the LCSS.
Initial Actions
Check the following:
• The 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Set-
tings RAP.
• Ensure the paper tray guides are set to the correct position for the size of paper in the
tray.
• For a paper jam at the entrance to the 2K LCSS. Check that there is no obstruction that
would prevent a sheet from arriving in position for punching, refer to the 11H-110 Copy
Damage in the 2K LCSS RAP.
• The punch sensor, Q11-110 for chad debris, Figure 1.

Procedure
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Figure 1. Enter dC330, code 11-110. Actuate the punch sensor, Q11-110. The display
changes.
Y N
Go to Flag 1 and check Q11-110.
Refer to:
Figure 2 Circuit diagram • 11G-110 2K LCSS PWB Damage RAP.
• GP 11, How to Check a Sensor.
• P/J307, 2K LCSS PWB.
• 11D-110 2K LCSS Power Distribution RAP
Repair or install new components as necessary:
• Punch sensor, PL 11.6 Item 7.
• 2K LCSS PWB, PL 11.26 Item 1.

Perform SCP 6 Final Actions.

Status Indicator RAPs February 2010

11-100-110, 11-110-110 2-300 Xerox WorkCentre 5790 Family
 Punch sensor Q11-110

Figure 1 Component location Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-301 11-110-110
 A
11-130-110, 11-132-110 Paper Exiting to Bin 0 RAP Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
11-130-110 The leading edge of the sheet is late to the top exit sensor.
• GP 10, How to Check a Motor.
11-132-110 The trailing edge of the sheet is late from the top exit sensor. • P/J309, 2K LCSS PWB.
• 11D-110 2K LCSS Power Distribution RAP.
WARNING Repair or install new components as necessary:
Take care not to topple the LCSS. • Transport motor 2, PL 11.22 Item 5.
The LCSS is unstable when un-docked from the machine. • 2K LCSS PWB, PL 11.26 Item 1.
Do not show the customer how to un-dock the LCSS.
Initial Actions Enter dC330, code 11-002 to energize the diverter gate solenoid, S11-002, Figure 1. The
diverter gate solenoid energizes.
Check the following:
Y N
• 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Settings Go to Flag 2 and check SOL11-002.
RAP. Refer to:
• Ensure the paper tray guides are set to the correct position for the size of paper in the • 11G-110 2K LCSS PWB Damage RAP.
tray. • GP 12, How to Check a Solenoid.
• The tensioner on the intermediate paper drive belt. Check that the tensioner is free to • P/J306, 2K LCSS PWB.
move and that the tensioner pulley is free to rotate. If necessary lubricate the tensioner
• 11D-110 2K LCSS Power Distribution RAP.
and tensioner pulley, REP 11.3-110. Refer to GP 18 Machine Lubrication.
Repair or install new components as necessary:
NOTE: The tensioner arm and the tensioner pulley require different lubricants, refer to • Diverter gate solenoid, PL 11.22 Item 12.
REP 11.3-110.
• 2K LCSS PWB, PL 11.26 Item 1.
• The drive pulleys on both transport motor 1 and 2 are secure and do not slip on the motor
shaft. Enter dC330, code 11-130, actuate the top exit sensor, Q11-130, Figure 1. The display
• All the transport drive belts are correctly fitted and are in a good condition changes.
Y N
• All he transport rolls and idler pulleys are free to rotate.
Go to Flag 1 and check Q11-130.
• The diverter gate and linkage for free movement. Refer to:
• A paper jam in the path to bin 0. • 11G-110 2K LCSS PWB Damage RAP.
• Torn paper fragments from a previous jam clearance action. • GP 11, How to Check a Sensor.
• A paper jam in the path to the top tray. If the jams occur shortly after install. Check the gap • P/J313, 2K LCSS PWB.
between the entry guide cover, PL 11.24 Item 5 and the paper guide PL 11.22 Item 10. If
• 11D-110 2K LCSS Power Distribution RAP.
the gap is less than 1 mm, adjust or install a new entry guide cover. Refer to the replace-
ment procedure in REP 11.15-110. Repair or install new components as necessary:
Refer to the 11H-110 Copy Damage in the 2K LCSS RAP and the 11J-110 Mis-Registration in • Top exit sensor, PL 11.22 Item 11.
Stapled Sets and Non-Stapled Sets RAP. • 2K LCSS PWB, PL 11.26 Item 1.

NOTE: Paper is diverted to bin 0 when the diverter gate solenoid is energized. Enter dC330, code 11-000 to energize the transport motor 1, MOT 11-000, Figure 1. The
Paper is fed to bin 1 when the diverter gate solenoid is de-energized. motor energizes.
Y N
Procedure Go to Flag 4 and check MOT 11-000.
Refer to:
NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.
• 11G-110 2K LCSS PWB Damage RAP.
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state • GP 10, How to Check a Motor.
on the UI. Make sure that the correct sensor or switch is tested. • P/J305, 2K LCSS PWB.
Enter dC330, code 11-001 to run transport motor 2, MOT11-001, Figure 1. The motor runs. • 11D-110 2K LCSS Power Distribution RAP.
Y N Repair or install new components as necessary:
Go to Flag 3 and check MOT11-001. • Transport motor 1, PL 11.14 Item 2.
A B
Status Indicator RAPs February 2010
11-130-110, 11-132-110 2-302 Xerox WorkCentre 5790 Family
B
• 2K LCSS PWB, PL 11.26 Item 1.

Perform SCP 6 Final Actions.

Top exit sensor

Q11-130

Diverter gate
solenoid
Transport motor 2 S11-002
MOT11-001

Transport motor 1
MOT 11-000

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-303 11-130-110, 11-132-110
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

11-130-110, 11-132-110 2-304 Xerox WorkCentre 5790 Family
11-140-110, 11-142-110 Sheet Late to Bin 1 RAP Procedure
11-140-110 The leading edge of the sheet is late to the 2nd to top exit sensor, Q11-140. NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors.

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

Enter dC330, code 11-000 to energize the transport motor 1, MOT 11-000. The motor ener-
gizes.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-305 11-140-110, 11-142-110
Y N
Go to Flag 2 and check MOT 11-000.
Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
• GP 10, How to Check a Motor.
• P/J305, 2K LCSS PWB.
• 11D-110 2K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Transport motor 1, PL 11.14 Item 2.
• 2K LCSS PWB, PL 11.26 Item 1.

If the fault is still present, perform 11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-319-
110 Rear Tamper Move Failure RAP.

NOTE: A software problem can cause the machine to incorrectly display the fault code 11-142-
110.

2nd to top
exit sensor
Q11-140

Diverter gate
solenoid
S11-002

Transport motor 2
MOT11-001
Transport motor 1 MOT 11-000

Figure 1 Component location

Status Indicator RAPs February 2010

11-140-110, 11-142-110 2-306 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-307 11-140-110, 11-142-110
11-300-110, 11-302-110, 11-303-110 Interlocks RAP • Enter dC330, code 11-302. Actuate the switch, if the display does not change, refer to:
– GP 13, How to Check a switch
11-300-110 The docking interlock is open during run mode.
– Figure 1.
11-302-110 The top cover interlock is open during run mode.
– P/J315, 2K LCSS PWB.
11-303-110 The front door interlock is open during run mode. • Go to Flag 3. Check the wiring between P/J315 and the switch.
WARNING • If necessary, install a new switch, PL 11.26 Item 6.
Take care not to topple the LCSS. 11-303-110 Front Door Interlock RAP
The LCSS is unstable when un-docked from the machine. Check the front door interlock switch, S11-303 as follows:
Do not show the customer how to un-dock the LCSS. • Check the switch actuator.
Initial Actions • Enter dC330, code 11-303. actuate the switch, if the display does not change, refer to:
• Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP – GP 13, How to Check a switch
Switch Settings RAP. – Figure 1.
• Check the following: – P/J302, 2K LCSS PWB.
– The 2K LCSS is docked to the machine. • Go to Flag 2. Check the wiring between P/J302 and the switch.
– The 2K LCSS front door is closed. • If necessary, install a new switch, PL 11.26 Item 5.
– The 2K LCSS top cover is closed. Perform SCP 6 Final Actions.

Procedure
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Go to Flag 1 and check for +24V on P/J302 pin 1. If the voltage is not present, refer to 11D-110
2K LCSS Power Distribution RAP.

Go to the appropriate RAP:

• 11-300-110 Docking Interlock RAP
• 11-302-110 Top Cover Interlock RAP
Docking interlock switch
• 11-303-110 Front Door Interlock RAP S11-300
11-300-110 Docking Interlock RAP
Un-dock the 2K LCSS, REP 11.13-110, Check the docking interlock switch, S11-300 as fol-
lows:
• Check the interlock actuator on the machine is not damaged or missing.

NOTE: The wiring harness passes underneath the docking interlock switch housing. If
this harness is not correctly positioned, the switch can be mis-located, giving intermittent
docking interlock problems. Top cover
interlock
• Enter dC330, code 11-300. Actuate the switch, if the display does not change, refer to: switch
– GP 13, How to Check a Switch S11-302
– Figure 1.
– P/J302, 2K LCSS PWB.
• Go to Flag 1. Check the wiring between P/J302 and the switch. Front door interlock
• If necessary, install a new switch, PL 11.4 Item 2. switch S11-303
11-302-110 Top Cover Interlock RAP
Check the top cover interlock switch, S11-302 as follows:
• Check the switch actuator. Figure 1 Component location

Status Indicator RAPs February 2010

11-300-110, 11-302-110, 11-303-110 2-308 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-309 11-300-110, 11-302-110, 11-303-110
 A
11-320-110, 11-322-110 Ejector Movement Failure RAP Repair or install new components as necessary:
• Ejector home sensor, Q11-320, PL 11.18 Item 3.
11-320-110 The ejector is not at the home position.
• 2K LCSS PWB, PL 11.26 Item 1.
11-322-110 The ejector fails to perform a cycle of operation.
Enter dC330, code 11-023 ejector cycle, check the operation of the ejector motor MOT11-020.
NOTE: A cycle of operation for the ejector is to cycle from the home position to the out position The ejector motor runs.
and back to the home position. Y N
Go to Flag 3. Check the ejector motor, MOT11-020.
WARNING Refer to:
Take care not to topple the LCSS. • 11G-110 2K LCSS PWB Damage RAP.
The LCSS is unstable when un-docked from the machine. • GP 10, How to Check a Motor.
Do not show the customer how to un-dock the LCSS. • Figure 1.
Initial Actions • P/J303, 2K LCSS PWB.
• Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP • 11D-110 2K LCSS Power Distribution RAP.
Switch Settings RAP. Repair or Install new components as necessary:
• Un-dock the 2K LCSS, REP 11.13-110, Check for any obstructions that would prevent the • Ejector assembly, PL 11.18 Item 1.
ejector from moving. Cheat the docking interlock switch. • 2K LCSS PWB, PL 11.26 Item 1.

Procedure Enter dC330, code 11-023 ejector cycle, check the ejector cycles. Stack the code 11-320 ejec-
tor sensor home, then cycle the ejector. Stack the code 11-322 ejector sensor out, then cycle
NOTE: All 2K LCSS interlocks must be made to supply +24V to the motors. the ejector. The ejector actuates the ejector home sensor and the ejector out sensor.
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state Y N
Refer to GP 7, check the following components;
on the UI. Make sure that the correct sensor or switch is tested.
• Figure 1. Pulley/drive gear, PL 11.18.
Enter dC330, code 11-322, actuate the ejector out sensor, Q11-322. The display changes. • Ejector belt, PL 11.18 Item 5.
Y N
Install new components as necessary:
Go to Flag 2. Check Q11-322.
• Pulley/drive gear, PL 11.18.
Refer to:
• Ejector belt, PL 11.18 Item 5.
• 11G-110 2K LCSS PWB Damage RAP.
• GP 11 How to Check a Sensor. The ejector cycles noisily, colliding with the end stops.
• Figure 1. Y N
• P/J304, 2K LCSS PWB. Check the stapler to ensure the staples are correctly formed. Mis-formed staples can
• 11D-110 2K LCSS Power Distribution RAP. cause the set to hang in the stapler causing ejector movement failures. The staples are
correctly formed.
Repair or install new components as necessary:
Y N
• Ejector out sensor, Q11-322, PL 11.18 Item 3. Clear the staple head of any mis-formed staples, then check the operation of the sta-
• 2K LCSS PWB, PL 11.26 Item 1. pler. If necessary, install a new staple head unit, PL 11.20 Item 5.

Enter dC330, code 11-320, actuate the ejector home sensor, Q11-320. The display changes. If the ejector is still not moving, install a new ejector assembly, PL 11.18 Item 1.
Y N Perform SCP 6 Final Actions.
Go to Flag 1. Check Q11-320.
Refer to: Go to Flag 4. +5v is available at P/J304 between pins 7 and 8.
• 11G-110 2K LCSS PWB Damage RAP. Y N
• GP 11 How to Check a Sensor. Go to the 11D-110 2K LCSS Power Distribution RAP.
• Figure 1.
Connect a service meter at P/J304 between pins 8 and 9. Slowly rotate the ejector motor
• P/J304, 2K LCSS PWB.
encoder. The voltage changes between +5V and 0V.
• 11D-110 2K LCSS Power Distribution RAP.

A
Status Indicator RAPs February 2010
11-320-110, 11-322-110 2-310 Xerox WorkCentre 5790 Family
Y N
Go to Flag 4. Check the wiring and connectors between the ejector motor encoder sensor
and the 2K LCSS PWB. If necessary repair the wiring, REP 1.2. If the wiring is good,
install a new ejector motor encoder sensor, PL 11.18 Item 3.

Perform the 11G-110 2K LCSS PWB Damage RAP, if necessary install a new 2K LCSS PWB,
PL 11.26 Item 1.

Pulley/drive gear

Ejector belt

Ejector out sensor

Q11-322

Ejector motor
MOT11-020

Ejector motor
encoder sensor
Ejector home sensor
Q11-320

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-311 11-320-110, 11-322-110
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

11-320-110, 11-322-110 2-312 Xerox WorkCentre 5790 Family
 A
11-364-110 Stapling Failure RAP NOTE: If the SH1 priming sensor does not see staples in the primed position, the staple head
cycles a number of times to prime the staple head. This occurs when the 2K LCSS interlocks
11-364-110 Staples in the stapling head are not primed.
are made.

WARNING Follow the customer instruction label inside the 2K LCSS front door to remove the staple car-
tridge, slide out the top sheet of staples from the cartridge, to expose a fresh sheet of staples
Take care not to topple the LCSS.
on the top of the stack. Ensure the forming plate is fully closed, Figure 2. Install the staple car-
The LCSS is unstable when un-docked from the machine. tridge and close the door. The stapler will now cycle a few times to feed and prime the new
Do not show the customer how to un-dock the LCSS. sheet of staples. Open the door and remove the staple cartridge. Examine the sheet of staples
Initial Actions that have been fed to the staple forming part of the stapler, by opening the forming plate, Fig-
ure 3. The first two staples have been partially formed.
• Switch off the machine, then switch on the machine, GP 14.
Y N
• Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP
Install a new staple cartridge, PL 26.10 Item 11and repeat the check. If the first two sta-
Switch Settings RAP. ples are not partially formed, install a new staple head unit, PL 11.20 Item 5. Perform SCP
• Check the following: 6 Final Actions
– The staple cartridge has staples in it and is correctly installed,
– The leading staples in the staple head have been primed, Figure 2. Install a new staple head unit, PL 11.20 Item 5. Perform SCP 6 Final Actions.
– Check that the sheets of staples in the cartridge are feeding one at a time. If staple
sheets overlap, they will jam in the cartridge. If necessary, install a new staple car-
tridge, PL 26.10 Item 11.

NOTE: The term “priming” refers to 2 staples at the front of the cartridge, that have been pre-
formed automatically by the action of the stapler, refer to Figure 2.

NOTE: The SH 1 low staples sensor, SH 1 cartridge sensor, SH 1 home sensor and the SH 1
priming sensor are all integral to the staple head unit. These sensors can be checked using
component control codes but they cannot be exchanged as components.

Procedure
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Figure 1. Enter dC330, code 11-361, actuate the SH 1 paper sensor, Q11-361. The display
changes.
Y N
Go to Flag 1 and check Q11-361.
Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
• GP 11, How to Check a Sensor.
• P/J308, 2K LCSS PWB.
• 11D-110 2K LCSS Power Distribution RAP.
Repair or install new components as necessary: SH 1 paper
sensor Q11-361
• SH 1 paper sensor, PL 11.20 Item 4.
Staple head unit
• 2K LCSS PWB, PL 11.26 Item 1.

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-313 11-364-110
 Forming plate open Primed staples Forming plate fully closed

Figure 2 Staple cartridge open Figure 3 Staple cartridge closed

Status Indicator RAPs February 2010

11-364-110 2-314 Xerox WorkCentre 5790 Family
 Figure 4 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-315 11-364-110
 A
11A-110 Offline Stapling Fault RAP Y N
Perform the 11G-110 2K LCSS PWB Damage RAP, if necessary install a new 2K
Use this RAP when offline stapling fails to operate.
LCSS PWB, PL 11.26 Item 1.
NOTE: Due to customer difficulty with the offline stapler feature, the feature is no longer pro- Check the wiring between the 2K LCSS PWB and the offline staple PWB. The wiring is
moted. The button has had the staple symbol removed. Also the label that used to be on the good.
front, showing how to put sets in for stapling has been removed. However a customer who Y N
knows about this feature may still use it. Repair the wiring.
The functionality is still present to allow the customer to lower bin 1 to remove documents.
Install a new offline staple PWB, PL 11.26 Item 3.
Initial Actions
Switch off the machine, then switch on the machine, GP 14. Enter dC330, code 11-373, actuate the offline staple switch, S11-373. The display changes.
Y N
Check the following: Go to Flag 5 and check the wiring between the 2K LCSS PWB and the offline staple
• Figure 2, the spring and cam are correctly located. PWB. The wiring is good.
• Figure 2, the switch support bracket is correctly located. Y N
Repair the wiring.
• Figure 2, the safety gate switch connector is fully seated on both sides of the frame.
• The 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Set- Refer to the 11G-110 2K LCSS PWB Damage RAP, Install new components as neces-
tings RAP. sary:
• Figure 2, the staple head unit is correctly installed. • Offline staple PWB, PL 11.26 Item 3.
• 2K LCSS PWB, PL 11.26 Item 1.
NOTE: Figure 2 shows the switch cam in the auto stapling position. To enable offline stapling,
the paddle motor is run in the reverse direction to lower the safety gate, this rotates the switch Enter dC330, code 11-367, actuate the edge registration sensor, Q11-367. The display
cam in a counterclockwise direction, actuating the safety gate switch. changes.
Y N
Operation Go to Flag 2, and Flag 3, check Q11-120. Refer to:
Offline stapling should follow the following sequence: • 11G-110 2K LCSS PWB Damage RAP.
• The offline staple button is pressed. • GP 11, How to Check a Sensor.
• Bin 1 lowers to improve access to the stapler area. NOTE: The edge registration sensor Q11-367 that detects paper in position for sta-
• The front tamper moves into position to guide the set to be stapled. pling is an infra-red device. It has two parts, the receiver is mounted on the staple
• The set to be stapled is inserted fully into the throat of the stapler. traverse assembly and the LED is mounted on the sensor support assembly PL
• The SH 1 paper sensor, Q11-361 detects the set in the throat of the stapler. The edge reg- 11.12 Item 5.
istration sensor, Q11-367 detects the set in the centre of the compiler. The set is correctly
• Figure 1.
located for stapling when both sensors are made.
• P/J308 and P/J314, 2K LCSS PWB.
• The paddle motor drives in reverse to lower the safety gate until the safety gate interlock
• 11D-110 2K LCSS Power Distribution RAP.
switch is made. This process is a safety feature.
• REP 11.13-110 2K LCSS Un-docking.
• The stapler is then cycled once to staple the set.
Repair or install new components as necessary:
Procedure
• Edge registration sensor, PL 11.20 Item 8.
WARNING • 2K LCSS PWB, PL 11.26 Item 1.
Take care not to topple the LCSS.
Enter dC330, code 11-361, actuate the SH1 paper sensor, Q11-361. The display changes.
The LCSS is unstable when un-docked from the machine.
Y N
Do not show the customer how to un-dock the LCSS. Go to Flag 6 and check Q11-361.
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state Refer to:
on the UI. Make sure that the correct sensor or switch is tested. • 11G-110 2K LCSS PWB Damage RAP.
• GP 11, How to Check a Sensor.
Enter dC330, code 11-374 to illuminate the offline staple LED. The LED is illuminated.
Y N • Figure 2.
Go to Flag 4, disconnect P/J312. +2V is available at P/J312 between pins B10 and • P/J308, 2K LCSS PWB.
B12 when the code is entered. • 11D-110 2K LCSS Power Distribution RAP.
A B
Status Indicator RAPs February 2010
11A-110 2-316 Xerox WorkCentre 5790 Family
B
Repair or install new components as necessary:
• SH 1 paper sensor, PL 11.12 Item 2. Offline staple switch S11-373
• 2K LCSS PWB, PL 11.26 Item 1. Offline staple LED
Enter dC330, code 11-365, manually actuate the SU1 safety gate switch, S11-365. The dis-
play changes.
Y N
Go to Flag 1, and check S11-365. Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
• GP 13, How to Check a Switch.
• Figure 2.
• P/J311, 2K LCSS PWB.
• 11D-110 2K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Safety gate interlock switch, PL 11.8 Item 1.
• 2K LCSS PWB, PL 11.26 Item 1.
Enter dC330, code 11-026 to run the paddle motor in reverse. The switch cam is rotated
counter clockwise to it’s end stop.
Y N
Go to 11-024-110, 11-025-110 Paddle Roll Failure RAP.
If the stapler is still inoperative, install a new staple head unit, PL 11.20 Item 5.
Perform SCP 6 Final Actions.
Safety gate switch
Edge registration connector
sensor Q11-367

Switch support
bracket
SH1 paper sen-
sor Q11-361

Stapler
traverse Staple head
assembly Spring
Edge reg-
istration
sensor
LED Offline staple PWB

SU 1 safety gate Switch cam

switch S11-365

Ejector assembly
Figure 2 Component location

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-317 11A-110
 Figure 3 Circuit diagram

Status Indicator RAPs February 2010

11A-110 2-318 Xerox WorkCentre 5790 Family
11B-110 Bin 1 Overload RAP
Use this RAP to resolve a fault on the bin 1 90% full sensor.

WARNING
Take care not to topple the LCSS.
The LCSS is unstable when un-docked from the machine.
Do not show the customer how to un-dock the LCSS.
Procedure
NOTE: In diagnostics, actuating any 2K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, code 11-331, actuate the bin 1 90% full sensor, Q11-331. The display
changes.
Y N
Go to Flag 1 and check Q11-331.
Refer to:
• 11G-110 2K LCSS PWB Damage RAP.
• GP 11, How to Check a sensor.
• Figure 1.
• P/J316 2K LCSS PWB.
• 11D-110 2K LCSS Power Generation RAP.
Repair or install new components as necessary:
• Bin 1 90% full sensor, PL 11.10 Item 5.
• 2K LCSS PWB, PL 11.26 Item 1.
Perform SCP 6 Final Actions.

Figure 2 Circuit diagram

Bin 1 90% full sensor

Q11-331

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-319 11B-110
11C-110 2K LCSS Initialization Failure RAP • Staple head not at home, refer to 11-050-110, 11-360-110 Staple Head Operation Failure
RAP.
When an initialization command is received from the machine, the units are initialized in two
• Stapling unit not at home, refer to 11-053-110, 11-370-110 Staple Head Unit Movement
stages:
Failure RAP.
• The following units are initialized sequentially:
• Ejector not at home, refer to 11-320-110, 11-322-110 Compiler Ejector Movement Failure
1. If the staple head is not at the home position, it is driven to the home position RAP.
2. If the stapling unit is not at the home position, it is driven to the home position
3. If the ejector is not at the home position, it is driven to the home position
• The following units are then initialized simultaneously:
1. If the front tamper is not at the home position, it is driven to the home position
2. If the rear tamper is not at the home position, it is driven to the home position
3. If the hole punch is not at the home position, it is driven to the home position
4. If the paddle is not at the home position, it is driven to the home position
5. If the stacker is not at the home position, it is driven to the home position
NOTE: The staple cartridge must be fully pushed home.

WARNING
Take care not to topple the LCSS.
The LCSS is unstable when un-docked from the machine.
Do not show the customer how to un-dock the LCSS.
Initial Actions Fuse
Check the fuse on the 2K LCSS PWB, If the fuse is good, continue at the procedure. If the fuse
not good, install a new 2K LCSS PWB, PL 11.26 Item 1.

Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Set-
tings RAP.
LED 1
Remove the 2K LCSS covers, REP 11.1-110, so that the units can be viewed. Cheat the front
door interlock switch and the top cover interlock switch. Check that LED 2 is illuminated, this
shows that all interlocks are made. If the LED fails to illuminate, go to 11-300-110, 11-302-110, LED 2
11-303-110 Interlocks RAP.

Procedure
Figure 1, Check that the software heartbeat is present on LED 1. The LED should flash twice Figure 1 LED location
per second if the 2K LCSS software is running. If necessary, re-load the 2K LCSS software,
refer to GP 4 Machine Software.

If the initialization sequence fails to place any unit at the home position, refer to the appropriate
RAPs:
• Front tamper not at home, refer to 11-005-110, 11-006-110, 11-310-110, 11-311-110 Front
Tamper Move Failure RAP
• Rear tamper not at home, refer to 11-007-110, 11-008-110, 11-312-110, 11-313-110, 11-
319-110 Rear Tamper Move Failure RAP.
• Paddle not at home, refer to 11-024-110, 11-025-110 Paddle Roll Failure RAP.
• Bin 1 not at home, refer to 11-030-110, 11-334-110, 11-335-110, 11-336-110 Bin 1 Move-
ment Failures RAP.
• Punch not at home, refer to 11-043-110, 11-350-110 Hole Punch Operation Failure RAP

Status Indicator RAPs February 2010

11C-110 2-320 Xerox WorkCentre 5790 Family
 A B C
11D-110 2K LCSS Power Distribution RAP WARNING
The 2K LCSS has an integral power supply providing +24V and +5V supplies to the 2K LCSS Do not install a fuse of a different type or rating. Installing the wrong type or
PWB. The AC power for the 2K LCSS power supply comes from the LVPS and base module of rating of fuse can cause overheating and a risk of fire.
the machine. Perform the following:
• Switch off the machine, GP 14.
WARNING • Go to Flag 3, disconnect all the +24V harnesses to components.
Take care not to topple the LCSS. • Check each harness for short circuits and overheating, GP 7.
The LCSS is unstable when un-docked from the machine. • Repair or install new components as necessary.
Do not show the customer how to un-dock the LCSS. • Install a new fuse F1 on the 2K LCSS PWB, switch on the machine, GP 14.
CAUTION • Monitor the voltage at the left end of the fuse and re-connect the circuits one at
Do not connect the finisher power cord directly to the AC wall outlet. The finisher cannot oper- a time. Energize the re-connected components using dC330 control codes.
ate without the machine. The machine controls the distribution of electricity to the finisher for • If the voltage drops below +22V, switch off the machine, GP 14. Re-check the
correct power on and power off sequencing. component and harness for overheating or short circuits. Repair or install new
Procedure components as necessary.

WARNING Perform the 11G-110 2K LCSS PWB Damage RAP, if necessary install a new 2K LCSS
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury. PWB, PL 11.26 Item 1.
Close or cheat all the 2K LCSS interlocks. LED 2 on the 2K LCSS PWB is illuminated.
Y N Go to Flag 2. +5V is available at P/J300 between pins 4 and 6, also between pins 7 and 8.
+24V is available at Fuse (F1) on the 2K LCSS PWB. Y N
Y N Disconnect P/J300. +5V is available at P/J300 between pins 4 and 6, also between
Go to Flag 2. +24V is available at P/J300 between pins 1 and 2, also between pins 7 and 8 on the end of the harness.
pins 5 and 3. Y N
Y N Loosen the 4 screws and lift the power supply module away from the 2K LCSS
Disconnect P/J300. +24V is available at P/J300 between pins 1 and 2, also frame. Go to Flag 1. ACL is available at CN1 between pins 1 and 3.
between pins 5 and 3 on the end of the harness. Y N
Y N Go to the 01C AC Power RAP and check the AC output voltages.
Figure 1. Loosen the 4 screws and lift the power supply module away from
the 2K LCSS frame. Go to Flag 1. ACL is available at CN1 between Check the wiring between CN2 and P/J300. The wiring is good.
pins 1 and 3. Y N
Y N Repair the wiring.
Go to the 01C AC Power RAP and check the AC output voltages.
Install a new power supply module, PL 11.26 Item 2.
Check the wiring between CN2 and P/J300. The wiring is good.
Y N Check for a short circuit or overload in the wiring or components connected to +5V on the
Repair the wiring. 2K LCSS PWB. Refer to GP 7.

Install a new power supply module, PL 11.26 Item 2. Perform the 11G-110 2K LCSS PWB Damage RAP, if necessary install a new 2K LCSS PWB,
PL 11.26 Item 1.
Check for a short circuit or an overload in the wiring or components connected
to the +24V on the 2K LCSS PWB. Refer to GP 7.

+24 V is available at PJ315 pin 5 on the 2K LCSS PWB.

Y N
Go to the 11-300-110, 11-302-110, 11-303-110 Interlocks RAP.

A B C

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-321 11D-110
 Power Supply
Module

Figure 1 Component location

Status Indicator RAPs February 2010

11D-110 2-322 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-323 11D-110
11E-110 2K LCSS to Machine Communications Interface 11F-110 2K LCSS PWB DIP Switch Settings RAP
RAP To show the correct settings for the DIP switches on the 2K LCSS PWB.
All communications between the machine and 2K LCSS are conducted through a single inter-
face cable. WARNING
Take care not to topple the LCSS.
WARNING The LCSS is unstable when un-docked from the machine.
Take care not to topple the LCSS. Do not show the customer how to un-dock the LCSS.
The LCSS is unstable when un-docked from the machine. Procedure
Do not show the customer how to un-dock the LCSS. Problems that can result from incorrect DIP switch settings are:
Procedure • False jam clearance instructions for the 2K LCSS and/or the machine exit area.
Check the 2K LCSS PWB DIP switch settings, refer to 11F-110 2K LCSS PWB DIP Switch Set- • Communication errors between the 2K LCSS and machine.
tings RAP. • Erratic behavior of the 2K LCSS.
Check the DIP switch settings, Figure 1. If necessary, switch off the machine, GP 14. Correct
Go to 03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error Rap.
the DIP switch setting, then switch on the machine, GP 14.

Figure 1 DIP switch settings

Status Indicator RAPs February 2010

11E-110, 11F-110 2-324 Xerox WorkCentre 5790 Family
11G-110 2K LCSS PWB Damage RAP
Use this RAP to determine the cause of damage to the 2K LCSS PWB, so that the cause can
be repaired before a new 2K LCSS PWB is installed.

WARNING
Take care not to topple the LCSS.
The LCSS is unstable when un-docked from the machine.
Do not show the customer how to un-dock the LCSS.
Initial Actions
Check the fuse on the 2K LCSS PWB, If the fuse is good, continue at the procedure. If the fuse
not good, install a new 2K LCSS PWB, PL 11.26 Item 1.

Procedure
The 2K LCSS PWB can be damaged by a component connected to it going short-circuit. If a
new 2K LCSS PWB is installed and power applied to the machine, the new 2K LCSS PWB will
be damaged in the same way. The cause of the damage must be found by following this proce-
dure.
Fuse
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
from the customer supply while performing tasks that do not need electricity. Electricity
can cause death or injury. Moving parts can cause injury.
Remove the 2K LCSS PWB and inspect the components shown in Figure 1 for damage. The
damage to the component may be in the form of a crack, a small crater or a burnt patch. Refer
to Table 1 to locate the component causing the damage to the 2K LCSS PWB.

Figure 1 2K LCSS PWB components

Table 1 2K LCSS PWB Drive Components

2K LCSS
PWB Driven Normal resistance Spared part and
component component measurement +/- 10% references
U10 Rear tamper PJ312 pin A1 to A3 = 29 ohms. Tamper assembly, PL 11.16
motor pin A1 to A4 = 29 ohms. pin A2 to Item 1. 11-007-110, 11-008-
A5 = 29 ohms. pin A2 to A6 = 29 110, 11-312-110, 11-313-
ohms. 110, 11-319-110 RAP
U11 Staple head PJ308 pin A8 to A10 = 20 ohms. Staple head unit, PL 11.20
motor pin A9 to A11 = 20 ohms Item 5. 11-050-110, 11-360-
110 RAP
U12 Front tamper PJ312 pin A7 to A9 = 29 ohms. Tamper assembly, PL 11.16
motor pin A7 to A10 = 29 ohms. pin A8 Item 1. 11-005-110, 11-006-
to A11 = 29 ohms. pin A8 to A12 110, 11-310-110, 11-311-110
= 29 ohms. RAP

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-325 11G-110
 Table 1 2K LCSS PWB Drive Components 11H-110 Copy Damage in the 2K LCSS RAP
2K LCSS Use this RAP to identify and correct the causes of copy damage in the 2K LCSS.
PWB Driven Normal resistance Spared part and
component component measurement +/- 10% references WARNING
U14 Transport PJ305 pin 1 to 4 = 4 ohms. pin 1 Transport motor 1, PL 11.14 Take care not to topple the LCSS.
motor 1 to 5 = 4 ohms. pin 2 to 6 = 4 Item 2. 11-130-110, 11-132-
The LCSS is unstable when un-docked from the machine.
ohms. pin 2 to 3 = 4 ohms 110 RAP
Do not show the customer how to un-dock the LCSS.
U15 Transport PJ309 pin 1 to 4 = 1.3 ohms. pin Transport motor 2, PL 11.22
motor 2 1 to 5 = 1.3 ohms. pin 2 to 6 = 1.3 Item 5. 11-130-110, 11-132- Procedure
ohms. pin 2 to 7 = 1.3 ohms. 110 RAP WARNING
U16 Hole punch PJ311 pin 1 to 2 = 6 ohms Not spared. 11-043-110, 11- Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
motor 350-110 RAP from the customer supply while performing tasks that do not need electricity. Electricity
U17 Paddle motor PJ310 pin 1 to 3 = 29 ohms. pin 1 Paddle motor assembly, PL can cause death or injury. Moving parts can cause injury.
to 4 = 29 ohms. pin 2 to 5 = 29 11.8 Item 10. 11-024-110, Check the following:
ohms. pin 2 to 6 = 29 ohms. 11-025-110 RAP
• Look for torn paper in the 2K LCSS paper path. Torn fragments can pass through the IOT
U18 SU1 motor PJ308 pin B9 to B11 = 20 ohms. Stapler traverse assembly, and 2K LCSS paper path without causing a problem until they finally wedge themselves at
(stapler index- pin B9 to B12 = 20 ohms. pin B10 PL 11.20 Item 1. 11-053-110, some point. A likely place for a piece of paper to be wedged is at the hole punch assem-
ing) to B13 = 20 ohms. pin B10 to 11-370-110 RAP bly, where the top and bottom guides form the narrowest part of the paper path.
B14 = 20 ohms.
• Ensure that the shaft diverter assembly, PL 11.22 Item 13, operates correctly and has full
U23 Ejector motor PJ303 pin 1 to 2 = 8 ohms Ejector assembly, PL 11.18 movement.
Item 1. 11-320-110, 11-322- • Ensure that the hole punches park at the fully open position. If they protrude even slightly,
110 RAP
a jam will occur in the narrow paper path of the hole punch.
Q1 Diverter gate PJ306 pin 1 to pin 2 = 74 ohms Diverter gate solenoid, PL
• Ensure that the jam clearance guide, PL 11.24 Item 6, closes and latches correctly. Check
solenoid 11.22 Item 12. 11-130-110,
that the magnet at the rear is located and functions correctly. Check the clip at the front is
11-132-110 RAP positioned correctly, Figure 1.
Q2, Q3, Q4, Bin 1 elevator PJ318 pin 1 to 2 = 7.7 ohms Bin 1 elevator motor, PL • Ensure that all idler rolls in the 2K LCSS paper path are free to rotate, particularly those
Q5 motor 11.10 Item 8. 11-030-110,
on the jam clearance guide, where the paper turns through 90 degrees.
11-334-110, 11-335-110, 11-
• Ensure that the paper path ribs of the jam clearance guide, PL 11.24 Item 6, and the entry
336-110 RAP
guide cover, PL 11.24 Item 5, are free of “scores” and “nicks”. Check also for contamina-
tion and glue from label stock.
NOTE: If difficulty is found in connecting the service meter probes to the connector headers on
the 2K LCSS PWB, refer to the RAP quoted in Table 1 and make the measurement at another
point in the harness to the driven component.

If the defective driven component is found using the table checks, disconnect the connector
closest to the driven component, then check the driven component again to identify any short
circuit in the wiring to the driven component. Repair the wiring or install new parts as neces-
sary.

If the defective driven component can not be found using the table checks, refer to GP 7, check
each driven component to ensure that it is not seized. Motors should rotate reasonably easily.
Solenoid armatures should slide easily in the coil. Also check the drive components to ensure
that they rotate easily, if necessary install new parts.

When the a new driven component has been installed or the defective drive components have
been repaired, install a new 2K LCSS PWB, PL 11.26 Item 1.

Status Indicator RAPs February 2010

11G-110, 11H-110 2-326 Xerox WorkCentre 5790 Family
 11J-110 Mis-Registration in Stapled Sets and Non-Stapled
Sets RAP
Use this RAP to identify and correct the causes of mis-registration in stapled sets, resulting in
Check that the end of the spring staples missing some sheets in the set, or poorly registered non-stapled sets.
clip is positioned on the inside of
the frame.
WARNING
Take care not to topple the LCSS.
The LCSS is unstable when un-docked from the machine.
Do not show the customer how to un-dock the LCSS.
Procedure
WARNING
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
from the customer supply while performing tasks that do not need electricity. Electricity
can cause death or injury. Moving parts can cause injury.
The most likely cause of mis-registration is paper condition and/or damage such as curl, wrin-
kle, creases, dog ears, etc.

Curl, wrinkle and creases are probably caused in the IOT, go to IQ1 Image Quality Entry RAP.

Figure 1 Position of the spring clip For other copy/print damage and dog ears, go to the 11H-110 Copy Damage in the 2K LCSS
RAP.

Check the following:

• Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL 11.2
Item 13.
• Turn over the paper stack in the tray in use.
• Use a new ream of paper in the tray in use.
• Paper type especially recycled paper can lead to registration problems. Try changing to a
different brand or type of paper.
• Ensure that the guides in the paper trays are correctly set and reported on the UI for the
paper size loaded.
• Check that paper type is set correctly. If heavyweight paper is used but not set in the UI,
the compiler capacity can be exceeded.
• Check for obstructions in the compiler.
• Ensure that the paddle roll operates correctly and that the paddles are not damaged. The
paddles should park completely inside the top section of the compiler, with the shorter
paddle in a vertical position. If all of the paddles are out of position, check the paddle roll
position sensor, PL 11.8 Item 11, the flag, PL 11.8 Item 7 and the paddle motor assembly,
PL 11.8 Item 10. If only one paddle is mis-aligned with the others, it can be re-positioned
by hand (they are not bonded to the shaft).
• Make sure the paddles are clean. If necessary, use formula A cleaning fluid, PL 26.10
Item 2 to clean the paddles.
• Ensure that the tampers operate correctly, i.e. are not stalling or losing position during the
job. Inspect the tampers for damage, if necessary install new parts. PL 11.16.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-327 11H-110, 11J-110
• Inspect the bin 1 entry nips for roll damage. The idlers should be held against the rubber 11K-110 2K LCSS Poor Stacking RAP
driving rolls and they should be free to rotate within their support springs. If necessary,
Use this RAP to find the cause of poor stacking in the 2K LCSS.
install new parts, PL 11.23.
• Inspect the four spring loaded guides on the output cover, PL 11.2 Item 7. Ensure that
they are correctly located and are free to move up and down.
Procedure
Check the following;
• Look for sets that are not dropping back fully in bin 1 and therefore not operating the bin 1
level sensors:
– Large paper sizes should not be stacked on top of small paper sizes.
– Ensure that the paper stack in each paper tray has been fanned.
– Turn over the paper stack in each paper tray.
– Ensure that all paper or other copy stock being used is within the size and weight
specifications. Refer to GP 20 Paper and Media Size Specifications.
– Try using a fresh ream of paper.
– Ensure that the edge guides of all paper trays are adjusted correctly for the paper
size and that the trays are fully closed.
– Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL
11.2 Item 13.
• Labels must not be fed to bin 1, but to bin 0 only.
• It is recommended that transparencies are fed to bin 0 whenever possible.
• Check that bin 1 is level front to back, if necessary perform ADJ 11.1-110 2K LCSS Bin 1
Level.
• Check that the bin 1 upper level sensor, Q11-332 and the bin 1 lower level sensor, Q11-
333 are working correctly. Refer to the 11-030-110, 11-334-110, 11-335-110, 11-336-110
Bin 1 Movement Failure RAP.
• Check the operation of the front and rear tampers. Refer to 11-005-110, 11-006-110, 11-
310-110, 11-311-110 Front Tamper Move Failure RAP and 11-007-110, 11-008-110, 11-
312-110, 11-313-110, 11-319-110 Rear Tamper Move Failure RAP.
• Check that the output device is not near an air conditioning or ventilation output duct. Air
flow across the output bins can cause poor stacking.
• Check if Mod. TAG F-013 LCSS bin 1 kit is installed on the finisher.
– Machine that regularly process large stacks of A4/8.5x11 inch LEF paper should
have the LCSS bin 1 W/TAG F-013 kit installed, PL 11.2 Item 16.
– Machines that regular process small stacks of A4/8.5x11 inch LEF, A3/11x17 inch
and A4/8.5x11 inch SEF paper should have the standard W/OTAG F-013 bin 1
installed, PL 11.2 Item 10.
• Check the output copies for curl, refer to IQ5.

Status Indicator RAPs February 2010

11J-110, 11K-110 2-328 Xerox WorkCentre 5790 Family
 A
11-005-120, 11-006-120, 11-310-120, 11-311-120 Front • 11C-120 1K LCSS Power Distribution RAP.
Repair or install new components as necessary:
Tamper Move Failure RAP
• Tamper assembly, PL 11.112 Item 1.
11-005-120 Front tamper fails to move to the front position.
• 1K LCSS PWB, PL 11.124 Item 1.
11-006-120 Front tamper fails to move to the rear position.
Enter dC330 code 11-310. Actuate the front tamper home sensor, Q11-310. The display
changes.
11-310-120 Front tamper not at the front home position.
Y N
11-311-120 Front tamper not at the rear home position. Go to Flag 1. Check Q11-310.
Refer to:
Initial Actions • 11F-120 1K LCSS PWB Damage RAP.
• GP 11 How to Check a Sensor.
• Figure 1. Check for damage or obstructions that would prevent the tamper assembly from
operating correctly. If necessary, install a new tamper assembly, PL 11.112 Item 1. • P/J16, 1K LCSS PWB.
• Jams can be caused by removing prints from bin 1 before the machine has finished print- • 11C-120 1K LCSS Power Distribution RAP.
ing. If the tampers are touched while they are moving, they may stall and cause the Repair or install new components as necessary:
machine to shutdown. The resulting shutdown can cause un-clearable jams in the finisher • Front tamper home sensor, PL 11.112 Item 3.
and the tray 3 and tray 4 to paper path interface. • 1K LCSS PWB, PL 11.124 Item 1.
• Jams can also be caused if the tray settings do not match the paper in the trays. Make
sure the tray settings are correct. Perform SCP 6 Final Actions.
• Check the condition and tension of the front tamper drive belt. Tensioning is achieved by a
spring on the motor, the motor should be free to move. Front tamper home
• If there is a large jam of paper above bin 1 that has obstructed the tampers, this has prob- sensor Q11-310
ably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor.
Perform the following:
– Check the paper for defects that could degrade the tamping operation e.g. curl,
paper condition, buckling or paper type. Refer to the IQ1 Image Quality Entry RAP.
– Check the operation of the paddle roll, refer to 11-024-120, 11-025-120 Paddle Roll
Failure RAP.
– Check the operation of the bin 1 upper level sensor, refer to 11-030-120, 11-334-120,
11-335-120, 11-336-120 Bin 1 Movement Failure RAP.
– Refer to the 11J-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP.
– Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP
Switch Settings RAP.

Procedure
NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors. Front tamper motor
MOT11-003 (located at the
NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state rear)
on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, codes 11-003 and 11-005 alternately. The front tamper moves between the
home and inboard positions, Figure 1.
Y N Figure 1 Component location
Go to Flag 2. Check the front tamper motor, MOT11-003.
Refer to:
• 11G-120 1K LCSS PWB Damage RAP.
• GP 10 How to Check a Motor.
• P/J9, 1K LCSS PWB.
A

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-329 11-005-120, 11-006-120, 11-310-120, 11-311-120
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

11-005-120, 11-006-120, 11-310-120, 11-311-120 2-330 Xerox WorkCentre 5790 Family
 A
11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-319-120 Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
Rear Tamper Move Failure RAP
• GP 10, How to Check a Motor.
11-007-120 Rear tamper fails to move to the front position.
• P/J9, 1K LCSS PWB.
11-008-120 Rear tamper fails to move to the rear position. • 11C-120 1K LCSS Power Distribution RAP.
Repair or install new components as necessary:
11-312-120 Rear tamper is not at the front home position. • Tamper assembly, PL 11.112 Item 1.
• 1K LCSS PWB, PL 11.124 Item 1.
11-313-120 Rear tamper is not at the rear home position.
Enter dC330 code 11-311. Actuate the rear tamper home sensor Q11-311. The display
11-319-120 Rear tamper is not at the away home position. changes.
Y N
NOTE: The away home position is with the rear tamper approximately halfway along it’s travel.
Go to Flag 1. Check Q11-311.
Initial Actions Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
• Figure 1. Check for damage or obstructions that would prevent the tamper assembly from
operating correctly. If necessary, install a new tamper assembly, PL 11.112 Item 1. • GP 11, How to Check a Sensor.
• Jams can be caused by removing prints from bin 1 before the machine has finished print- • P/J16, 1K LCSS PWB
ing. If the tampers are touched while they are moving, may stall and cause the machine to • 11C-120 1K LCSS Power Distribution RAP.
shutdown. The resulting shutdown can cause un-clearable jams in the finisher and the Repair or install new components as necessary:
tray 3 and tray 4 to paper path interface. • Rear tamper home sensor, PL 11.112 Item 3.
• Jams can also be caused if the tray settings do not match the paper in the trays. Make • 1K LCSS PWB, PL 11.124 Item 1.
sure the tray settings are correct.
• Check the condition and tension of the front tamper drive belt. Tensioning is achieved by a NOTE: The away home position is used for short edge feed small paper. This saves unneces-
spring on the motor, the motor should be free to move. sary rear tamper travel.
• If there is a large jam of paper above bin 1 that has obstructed the tampers, this has prob-
Enter dC330. Actuate the rear tamper away home sensor Q11-319. The display changes.
ably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor.
Perform the following: Y N
Go to Flag 2. Check Q11-319.
– Check the paper for defects that could degrade the tamping operation e.g. curl,
Refer to:
paper condition, buckling or paper type. Refer to the IQ1 Image Quality Entry RAP.
• 11F-120 1K LCSS PWB Damage RAP.
– Check the operation of the paddle roll, refer to 11-024-120, 11-025-120 Paddle Roll
• GP 11, How to Check a Sensor.
Failure RAP.
• P/J16, 1K LCSS PWB
– Check the operation of the bin 1 upper level sensor, refer to 11-030-120, 11-334-120,
11-335-120, 11-336-120 Bin 1 Movement Failure RAP. • 11C-120 1K LCSS Power Distribution RAP.
– Refer to the 11J-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. Repair or install new components as necessary:
– Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP • Rear tamper away home sensor, PL 11.112 Item 3.
Switch Settings RAP. • 1K LCSS PWB, PL 11.124 Item 1.

Procedure Perform SCP 6 Final Actions.

NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.

NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, codes 11-004 and 11-006 alternately. The rear tamper moves between the
home and inboard positions, Figure 1.
Y N
Go to Flag 3. Check the rear tamper motor, MOT11-004.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-331 11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-
 Rear tamper motor
MOT11-004 (located
at the front)

Rear tamper away

home sensor
Q11-319

Rear tamper home

sensor
Q11-311

Figure 1 Component Location

Status Indicator RAPs February 2010

11-007-120, 11-008-120, 11-312-120, 11-313-120, 11- 2-332 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-333 11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-
 A
11-024-120, 11-025-120 Paddle Roll Failure RAP Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
11-024-120 The paddle is not at the home position.
• GP 11, How to Check a Sensor.
11-025-120 The paddle fails to rotate. • Figure 1.
• P/J2, 1K LCSS PWB
NOTE: The home position of the paddle is when the sensor flag is located between the sensor • 11C-120 1K LCSS Power Distribution RAP
jaws. Jams will occur in the compiler and bin 1 cannot be used.
Repair or install new components as necessary:
Initial Actions • Paddle roll position sensor, PL 11.104 Item 11.
Check the following: • 1K LCSS PWB, PL 11.124 Item 1.
• That there is no paper or other obstructions in the vicinity of the paddle.
• The paddle roll position sensor bracket is holding the sensor in the correct position, i.e. Perform SCP 6 Final Actions.
the flag is in the middle of the sensor gap and the sensor does not touch any moving com-
ponents. Paddle roll position
• Check that paper type is set correctly. If heavyweight paper is used but not set in the UI, sensor
the compiler capacity can be exceeded. Refer to 11H-120 Mis-Registration in Stapled Q11-326
Sets and Non-stapled Sets RAP.
• Check the position of the paddles. With the paddle roll in the home position both sets of
paddles must be within the output cover, if they are not, refer to REP 11.10-120 Paddle
Wheel Shaft Assembly. If any of the paddles are out of alignment to other paddles, install Paddle motor
a new paddle wheel shaft assembly, PL 11.104 Item 4. MOT11-024
• 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings
RAP.

Procedure
NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.

NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, codes 11-024, paddle home position and 11-025, paddle run. The paddle
rotates correctly.
Y N
Go to Flag 2. Check the paddle motor, MOT 11-024.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
• GP 10, How to Check a Motor.
• Figure 1.
• P/J14, 1K LCSS PWB.
• 11C-120 1K LCSS Power Distribution RAP
Repair or install new components as necessary: Figure 1 Component location
• Paddle motor, PL 11.104 Item 10.
• 1K LCSS PWB, PL 11.124 Item 1.

Enter dC330, code 11-025 and stack the code 11-326, to actuate the paddle roll position sen-
sor Q11-326. The display cycles high/low.
Y N
Go to Flag 1. Check Q11-326.
A
Status Indicator RAPs February 2010
11-024-120, 11-025-120 2-334 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-335 11-024-120, 11-025-120
11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Procedure
Movement Failure RAP NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.
11-030-120 Bin 1 fails to move.
NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.
11-334-120 Bin 1 has reached the upper limit of travel.
Remove the 1K LCSS rear cover. Enter dC330 code 11-336, bin 1 motor encoder sensor Q11-
11-335-120 Bin 1 has reached the lower limit of travel. 336. Slowly rotate the encoder disk by hand. The display changes.
Y N
11-336-120 Bin 1 is not at the home position. Go to Flag 2. Check Q11-336.
Refer to:
NOTE: The home position of bin 1 is when bin 1 is actuating the bin 1 upper limit switch. See • 11F-120 1K LCSS PWB Damage RAP.
the final actions at the end of the procedure.
• GP 11 How to Check a Sensor.
Two sensors and two switches monitor the level of paper in bin 1 and the position of the tray
• P/J8, 1K LCSS PWB
• The bin 1 upper level sensor detects the top of the paper stack in bin 1, Figure 1.
• 11C-120 1K LCSS Power Distribution RAP.
• The bin 1 90% full sensor detects when the tray has descended to a position where the
Repair or install new components as necessary:
tray is 90% full, Figure 2.
• Bin 1 motor encoder sensor Q11-336, PL 11.106 Item 11.
• Bin 1 upper limit switch, S11-334, Figure 2.
• 1K LCSS PWB, PL 11.124 Item 1.
• Bin 1 lower limit switch, S11-335, Figure 2.

Initial Actions Enter dC330 code 11-033, bin 1 elevator motor, MOT11-030. Bin 1 cycles down and up.
Y N
Perform the following:
Go to Flag 1. Check MOT11-030.
• Check for a physical obstruction that would prevent bin 1 from moving, such as an item of Refer to:
furniture. • 11F-120 1K LCSS PWB Damage RAP.
• Check that bin 1 is level front to back, if necessary perform ADJ 11.1-120 1K LCSS Bin 1 • GP 10 How to Check a Motor.
Level.
• P/J12, 1K LCSS PWB
• Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP
• 11C-120 1K LCSS Power Distribution RAP.
Switch Settings RAP.
Repair or install new components as necessary:
• If the fault code is 11-030. Check that the screws to secure the motor damper and the
motor bracket are not loose. This will cause the encoder disc to move away from the • Bin 1 elevator motor, PL 11.106 Item 8.
encoder sensor. Push the motor bracket towards the encoder sensor and tighten the • 1K LCSS PWB, PL 11.124 Item 1.
screws. Refer to Figure 2.
• Refer to the 11H-120 Mis-Registration in Stapled Sets and Non-Stapled Sets RAP. Figure 1. Enter dC330, code 11-332, bin 1 upper level sensor, Q11-332. Actuate Q11-332.
The display changes.
• If there is a large jam of paper above bin 1, this has probably been caused by poorly
Y N
stacked sets failing to actuate the bin 1 upper level sensor.
Go to Flag 3. Check Q11-332.
Perform the relevant check: Refer to:
• If paper is overflowing the tray when it is at the lower limit, check the tray 90% full sensor. • 11F-120 1K LCSS PWB Damage RAP.
• If paper cannot be fed to bin 1 when it is at the highest position, check the bin 1 paper • GP 11 How to Check a Sensor.
sensor - low and bin 1 paper sensor - high.
• P/J2, 1K LCSS PWB
Check the front and rear bin 1 drive belts. If necessary install new components, PL 11.106 Item
• 11C-120 1K LCSS Power Distribution RAP.
1.
Repair or install new components as necessary:
• Bin 1 upper level sensor Q11-332, PL 11.106 Item 5.
• 1K LCSS PWB, PL 11.124 Item 1.

Figure 2. Enter dC330 code 11-334, bin 1 upper limit switch, S11-334. Actuate S11-334. The
display changes.

Status Indicator RAPs February 2010

11-030-120, 11-334-120, 11-335-120, 11-336-120 2-336 Xerox WorkCentre 5790 Family
Y N
Go to Flag 4. Check S11-334.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
• GP 13 How to Check a Switch.
• P/J5, 1K LCSS PWB
• 11C-120 1K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Bin 1 upper limit switch, PL 11.106 Item 3.
• 1K LCSS PWB, PL 11.124 Item 1.

Enter dC330 code 11-335, bin 1 lower limit switch, S11-335, actuate S11-335. The display Bin 1 upper level
changes. sensor Q11-332
Y N
Go to Flag 5. Check S11-335.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
• GP 13 How to Check a Switch.
• P/J4, 1K LCSS PWB.
• 11C-120 1K LCSS Power Distribution RAP.
• REP 11.13-110 1K LCSS Un-docking.
Repair or install new components as necessary:
• Bin 1 lower limit switch, PL 11.106 Item 11.
• 1K LCSS PWB, PL 11.124 Item 1.

Enter dC330 code 11-331, bin 1 90% full sensor, Q11-331. Actuate Q11-331. The display
changes.
Y N
Figure 1 Component location
Go to Flag 6. Check Q11-331.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
• GP 11 How to Check a Sensor.
• P/J2, 1K LCSS PWB.
• 11C-120 1K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Bin 1 90% full sensor Q11-331, PL 11.106 Item 5.
• 1K LCSS PWB, PL 11.124 Item 1.

As final actions, check the following sequence of operation:

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

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-337 11-030-120, 11-334-120, 11-335-120, 11-336-120
 Bin 1 upper limit
switch S11-334.

Bin 1 motor encoder

sensor Q11-336

Bin 1 elevator motor

MOT11-030

Bin 1 elevator motor

damper

Bin 1 lower limit switch

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

Figure 2 Component location

Figure 3 Circuit diagram

Status Indicator RAPs February 2010

11-030-120, 11-334-120, 11-335-120, 11-336-120 2-338 Xerox WorkCentre 5790 Family
 Figure 4 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-339 11-030-120, 11-334-120, 11-335-120, 11-336-120
11-050-120, 11-360-120 Staple Head Operation Failure RAP
11-050-120 The staple head fails to cycle.

11-360-120 The staple head is not at the home position.

NOTE: The home position is with the jaws of the staple head fully open.

CAUTION
Do not run code 11-050 without two sheets of paper in the stapler jaws. Running this code with-
out the paper in position can cause damage to the machine.
Initial Actions
• Switch off the machine, then switch on the machine, GP 14.
• Figure 1. Check the following:
– The 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch
Settings RAP.
– The staple head unit is correctly installed.

Procedure
NOTE: After repairing the fault using this RAP, switch off the machine, then switch on the
machine, GP 14, to enable operation of the staple head.

NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.

NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Place two sheets of paper in the stapler jaws. Enter dC330, code 11-050, staple head motor 1,
to cycle the staple head once. The staple head operates as expected.
Y N
Go to Flag 1 and Flag 2. Check the wiring and connectors between the 1K LCSS PWB
and the staple head. The wiring is good.
Y N
Repair the wiring. Staple head including MOT11-050
and staple head 1 home sensor
Q11-360
Perform the following procedures:
• 11C-120 1K LCSS Power Distribution RAP.
• 11F-120 1K LCSS PWB Damage RAP.
Install new components as necessary:
• Staple head unit, PL 11.116 Item 5.
• 1K LCSS PWB, PL 11.124 Item 1.
Figure 1 Component location

Perform SCP 6 Final Actions.

Status Indicator RAPs February 2010

11-050-120, 11-360-120 2-340 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-341 11-050-120, 11-360-120
11-100-120 1K LCSS Paper Entry RAP
11-100-110 The leading edge of the sheet is late to the entry sensor Q11-100.

Initial Actions
Refer to the 11G-120 Copy Damage in the 1K LCSS RAP.

Check the following:

• 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings
RAP.
• Ensure the paper tray guides are set to the correct position for the size of paper in the
tray.
• Check the input guide for damage or wear that could cause paper to jam.
• Paper jam in the machine to 1K LCSS paper path.
• IOT exit path and feed rolls.
• Feeding performance from a paper tray loaded with a new ream of paper.

Procedure
NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Figure 1. Lower the paper entry guide assembly, PL 11.110 Item 8, to access the entry sensor.
Enter dC330, code 11-100, entry sensor, Q11-100. Actuate Q11-100. The display changes.
Y N
Go to Flag 1. Check Q11-100.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
• GP 11 How to Check a Sensor.
• P/J8, 1K LCSS PWB
• 11C-120 1K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Entry sensor, PL 11.122 Item 3.
Entry sensor
• 1K LCSS PWB, PL 11.124 Item 1. Q11-100

Perform SCP 6 Final Actions.

Figure 1 Component location

Status Indicator RAPs February 2010

11-100-120 2-342 Xerox WorkCentre 5790 Family
 11-130-120, 11-132-120 Paper Exiting to Bin 0 RAP
11-130-120 The leading edge of the sheet is late to the top exit sensor.

11-132-120 The trailing edge of the sheet is late from the top exit sensor.

Initial Actions
Check the following:
• 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings
RAP.
• Ensure the paper tray guides are set to the correct position for the size of paper in the
tray.
• The tensioner on the intermediate paper drive belt. Check that the tensioner is free to
move and that the tensioner pulley is free to rotate. If necessary lubricate the tensioner
and tensioner pulley, REP 11.3-120. Refer to GP 18 Machine Lubrication.

NOTE: The tensioner arm and the tensioner pulley require different lubricants, refer to
REP 11.3-120.

• That the drive pulleys on both transport motor 1 and 2 are secure and do not slip on the
motor shaft.
• All the transport drive belts are correctly fitted and are in a good condition
• All the transport rolls and idler pulleys are free to rotate.
• The diverter gate and linkage for free movement.
• A paper jam in the path to bin 0.
• Paper fragments from a previous jam clearance action.
• A paper jam in the path to the top tray. If the jams occur shortly after install. Check the gap
between the entry guide cover, PL 11.122 Item 5 and the paper guide PL 11.118 Item 10.
If the gap is less than 1 mm, adjust or install a new entry guide cover. Refer to the
Figure 2 Circuit diagram replacement procedure in REP 11.13-120.
Refer to the 11G-120 Copy Damage in the 1K LCSS RAP and the 11H-120 Mis-Registration in
Stapled Sets and Non-Stapled Sets RAP.

NOTE: Paper is diverted to bin 0 when the diverter gate solenoid is energized. Paper is fed to
bin 1 when the diverter gate solenoid is de-energized.

Procedure
NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.

NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, code 11-001 transport motor 2, MOT11-001, Figure 1. MOT11-001 runs.
Y N
Go to Flag 3. Check MOT11-001.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
• GP 10, How to Check a Motor.
• P/J16, 1K LCSS PWB.
• 11C-120 1K LCSS Power Distribution RAP.
A

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-343 11-100-120, 11-130-120, 11-132-120
A
Repair or install new components as necessary:
• Transport motor 2, PL 11.120 Item 13.
• 1K LCSS PWB, PL 11.124 Item 1. Top exit sensor
Q11-130
NOTE: The diverter gate solenoid remains energized for 5 seconds.
Enter dC330, code 11-002 diverter gate solenoid, SOL11-002. SOL11-002 energizes.
Y N
Go to Flag 2. Check SOL11-002.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
Transport motor 2
• GP 12, How to Check a Solenoid.
MOT11-001
• P/J13, 1K LCSS PWB
• 11C-120 1K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Diverter gate solenoid, PL 11.118 Item 12.
Diverter gate
• 1K LCSS PWB, PL 11.124 Item 1. solenoid S11-002

Enter dC330, code 11-130, top exit sensor, Q11-130. Actuate Q11-130. The display
changes.
Y N
Go to Flag 1. Check Q11-130.
Refer to:
Transport motor 1
• 11F-120 1K LCSS PWB Damage RAP. MOT 11-000
• GP 11, How to Check a Sensor.
• P/J2, 1K LCSS PWB
• 11C-120 1K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• Top exit sensor, PL 11.118 Item 11.
• 1K LCSS PWB, PL 11.124 Item 1.

Enter dC330, code 11-000, transport motor 1, MOT11-000. MOT11-000 runs.

Y N
Go to Flag 4. Check MOT11-000.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
• GP 10, How to Check a Motor.
• P/J17, 1K LCSS PWB.
• 11C-120 1K LCSS Power Distribution RAP. Figure 1 Component location
Repair or install new components as necessary:
• Transport motor 1, PL 11.110 Item 2.
• 1K LCSS PWB, PL 11.124 Item 1.

Perform SCP 6 Final Actions.

Status Indicator RAPs February 2010

11-130-120, 11-132-120 2-344 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-345 11-130-120, 11-132-120
 A
11-140-120, 11-142-120 Sheet Late to Bin 1 RAP Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
11-140-120 The leading edge of the sheet is late to the 2nd to top exit sensor.
• GP 10, How to check a motor.
11-142-120 The trailing edge of the sheet is late to the 2nd to top exit sensor. • P/J16, 1K LCSS PWB.
• 11C-120 1K LCSS Power Distribution RAP.
Initial Actions Repair or install new components as necessary:
NOTE: Paper is diverted to bin 0 when the diverter gate solenoid is energized. Paper is fed to • Transport motor 2, PL 11.118 Item 5.
bin 1 when the diverter gate solenoid is de-energized. • 1K LCSS PWB, PL 11.124 Item 1.

Check the following:

Enter dC330, code 11-002 diverter solenoid, SOL11-002. SOL11-002 energizes.
• 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch Settings Y N
RAP. Go to Flag 4. Check SOL11-002.
• Ensure the paper tray guides are set to the correct position for the size of paper in all Refer to:
trays. • 11F-120 1K LCSS PWB Damage RAP.
For trays 3 and 4, perform the following: • GP 12, How to Check a Solenoid.
– Select the systems settings button from the tools screen. • P/J13, 1K LCSS PWB
– Select the tray management button and stock settings. • 11C-120 1K LCSS Power Distribution RAP.
– From the list, select tray 3. Select the change stock size button. Repair or install new components as necessary:
– Select the paper size loaded in the tray. Select the save button. • Diverter gate solenoid, PL 11.22 Item 12.
– Repeat for tray 4. • 1K LCSS PWB, PL 11.26 Item 1.
– Save the stock setting and exit the tools mode.
• The tensioner on the intermediate paper drive belt. Check that the tensioner is free to Enter dC330, code 11-140 2nd to top exit sensor, Q11-140. Actuate Q11-140. The display
move and that the tensioner pulley is free to rotate. If necessary re-lubricate the tensioner changes.
and tensioner pulley. Refer to ADJ 4.1. Y N
Go to Flag 1. Check Q11-140.
• That the drive pulleys on both transport motor 1 and 2 are secure and do not slip on the
motor shaft. Refer to:

• All the transport drive belts are correctly fitted and are in a good condition • 11F-120 1K LCSS PWB Damage RAP.

• All the transport rolls and idler pulleys are free to rotate. • GP 11, How to Check a sensor.

• The diverter gate and linkage for free movement. • P/J2, 1K LCSS PWB

• If the paper has dog ear on the inboard corner, install TAG 005 Rear gravity gate mylar kit. • 11C-120 1K LCSS Power Distribution RAP.

• A paper jam in the path to bin 1, to the compiler, and for poor stacking on bin 1. Repair or install new components as necessary:

• Ensure that the 1K LCSS is fully latched to the machine, refer to REP 11.11-120. • 2nd to top exit sensor, PL 11.120 Item 4.

• Torn paper fragments from a previous jam clearance action. • 1K LCSS PWB, PL 11.124 Item 1.

Refer to the 11G-120 Copy Damage in the 1K LCSS RAP and the 11H-120 Mis-Registration in
Enter dC330, code 11-000 transport motor 1, MOT11-000. MOT11-000 runs.
Stapled Sets and Non-Stapled Sets RAP.
Y N
Go to Flag 2. Check MOT11-000.
Procedure Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested. • GP 10, How to Check a Motor.
• P/J17, 1K LCSS PWB.
NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.
• 11C-120 1K LCSS Power Distribution RAP.
Figure 1. Enter dC330, code 11-001 transport motor 2, MOT11-001. MOT11-001 runs. Repair or install new components as necessary:
Y N
• Transport motor 1, PL 11.110 Item 2.
Go to Flag 3. Check MOT11-001.
• 1K LCSS PWB, PL 11.124 Item 1.

A B
Status Indicator RAPs February 2010
11-140-120, 11-142-120 2-346 Xerox WorkCentre 5790 Family
B
Perform SCP 6 Final Actions.

2nd to top exit

sensor Q11-140

Transport motor 2
MOT11-001

Diverter gate
solenoid
S11-002

Transport motor 1
MOT11-000

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-347 11-140-120, 11-142-120
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

11-140-120, 11-142-120 2-348 Xerox WorkCentre 5790 Family
11-300-120, 11-302-120, 11-303-120 Interlocks RAP • If necessary, install a new docking interlock switch, PL 11.102 Item 2.

11-300-120 The docking interlock is open during run mode. 11-302-120 Top Cover Interlock RAP
Check the top cover interlock switch, S11-302 as follows:
11-302-120 The top cover interlock is open during run mode. • Check the switch actuator.
• Enter dC330, code 11-302, top cover interlock switch, S11-302. Actuate S11-302. If the
11-303-120 The front door interlock is open during run mode. display does not change, refer to:
– GP 13, How to Check a switch
Initial Actions
– Figure 2.
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch
– P/J5, 1K LCSS PWB
Settings RAP.
• Go to Flag 3. Check the wiring between P/J5 and S11-302.
Check the following: • If necessary, install a new top cover interlock switch, PL 11.124 Item 6.
• The 1K LCSS is installed correctly, refer to REP 11.13-120. 11-303-120 Front Door Interlock RAP
• The 1K LCSS front door is closed. Check the front door interlock switch, S11-303 as follows:
• The 1K LCSS top cover is closed. • Check the switch actuator.
• Enter dC330, code 11-303, front door interlock switch, S11-303. Actuate S11-303. If the
Procedure display does not change, refer to:
– GP 13, How to Check a switch
NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested. – Figure 2.
– P/J51K LCSS PWB
Go to Flag 1. Check for +24V on P/J5 pin 1. If the voltage is not present, refer to 11C-120 1K
• Go to Flag 2. Check the wiring between P/J5 and S11-303.
LCSS Power Distribution RAP.
• If necessary, install a new front door interlock switch, PL 11.124 Item 5.
Go to the appropriate RAP: Perform SCP 6 Final Actions.
• 11-300-120 Docking Interlock RAP
• 11-302-120 Top Cover Interlock RAP
• 11-303-120 Front Door Interlock RAP
11-300-120 Docking Interlock RAP
WARNING
Take care not to topple the LCSS.
The LCSS is unstable when undocked from the machine.
Do not show the customer how to undock the LCSS.
Undock the 1K LCSS, refer to REP 11.11-120. Figure 1, check the docking interlock switch,
S11-300 as follows:
• While supporting the 1K LCSS, slide the 1K LCSS 5cm (2 inches) away from the
machine. Check the interlock actuator on the machine is not damaged or missing.

NOTE: The wiring harness passes underneath the docking interlock switch housing. If
this harness is not correctly positioned, the switch can be mis-located, giving intermittent
docking interlock problems.

• Enter dC330, code 11-300, docking interlock switch, S11-300. While supporting the 1K
LCSS, slide the 1K LCSS 5cm (2 inches) away from the machine to de-actuate S11-300.
If the display does not change, refer to:
– GP 13, How to Check a Switch
– P/J6, 1K LCSS PWB
• Go to Flag 1. Check the wiring between P/J5 and S11-300.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-349 11-300-120, 11-302-120, 11-303-120
 Top cover
interlock switch
S11-302

Front door interlock

switch S11-303

Figure 2 Component location

Docking interlock
switch S11-300

Figure 1 Component location

Status Indicator RAPs February 2010

11-300-120, 11-302-120, 11-303-120 2-350 Xerox WorkCentre 5790 Family
 Figure 3 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-351 11-300-120, 11-302-120, 11-303-120
 A
11-320-120, 11-322-120 Ejector Movement Failure RAP • 11C-120 1K LCSS Power Distribution RAP.
Repair or install new components as necessary:
11-320-120 The ejector is not at the home position.
• Ejector home sensor, Q11-320, PL 11.114 Item 3.
11-322-120 The ejector fails to perform a cycle of operation. • 1K LCSS PWB, PL 11.124 Item 1.

NOTE: A cycle of operation for the ejector is to move from the home position to the out position Enter dC330, code 11-023 to check the operation of the ejector motor, MOT11-020. MOT11-
and back to the home position. 020 runs.
Y N
Initial Actions Go to Flag 3. Check MOT11-020.
• Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Refer to:
Switch Settings RAP. • 11F-120 1K LCSS PWB Damage RAP.
• Check for any obstructions that would prevent the ejector from moving. • GP 10, How to Check a Motor.
• If the fault code is 11-322. Check that the screws to secure the motor damper and the • Figure 1.
motor bracket are not loose. This will cause the encoder disc to move away from the • P/J15, 1K LCSS PWB
encoder sensor. Push the motor bracket towards the encoder sensor and tighten the
• 11C-120 1K LCSS Power Distribution RAP.
screws. Refer to Figure 1 and REP 11.8-120.
Repair or Install new components as necessary:
Procedure • Ejector assembly, PL 11.114 Item 1.
• 1K LCSS PWB, PL 11.124 Item 1.
NOTE: All 1K LCSS interlocks must be made to supply +24V to the motors.

NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state Enter dC330, code 11-023 ejector cycle, check the ejector cycles. Stack the code 11-320 ejec-
tor sensor home, then cycle the ejector. Stack the code 11-322 ejector sensor out, then cycle
on the UI. Make sure that the correct sensor or switch is tested.
the ejector. The ejector actuates the ejector home sensor and the ejector out sensor.
NOTE: For clarity, the 1K LCSS is shown removed from the machine in Figure 1. Y N
Refer to GP 7, check the following components;
Enter dC330, code 11-322, ejector out sensor, Q11-322. Actuate Q11-322. The display
• Figure 1. Pulley/drive gear, PL 11.114.
changes.
• Ejector belt, PL 11.114 Item 5.
Y N
Go to Flag 2. Check Q11-322. Install new components as necessary:
Refer to: • Pulley/drive gear, PL 11.114.
• 11F-120 1K LCSS PWB Damage RAP. • Ejector belt, PL 11.114 Item 5.
• GP 11 How to Check a Sensor.
The ejector cycles noisily, colliding with the end stops.
• Figure 1.
Y N
• P/J8, 1K LCSS PWB
Check the stapler to ensure the staples are correctly formed, refer to the 11-364-120 Sta-
• 11C-120 1K LCSS Power Distribution RAP. pling Failure RAP. Mis-formed staples can cause the set to hang in the stapler causing
Repair or install new components as necessary: ejector movement failures. The staples are correctly formed.
• Ejector out sensor, Q11-322, PL 11.114 Item 3. Y N
Clear the staple head of any mis-formed staples, then check the operation of the sta-
• 1K LCSS PWB, PL 11.124 Item 1.
pler. If necessary, install a new staple head unit, PL 11.116 Item 5.
Enter dC330, code 11-320, ejector home sensor, Q11-320. Actuate Q11-320. The display
If the ejector is still not moving, install a new ejector assembly, PL 11.114 Item 1.
changes.
Perform SCP 6 Final Actions.
Y N
Go to Flag 1. Check Q11-320.
Go to Flag 4. +5V is available at P/J8 between pins 7 and 8.
Refer to:
Y N
• 11F-120 1K LCSS PWB Damage RAP.
Go to the 11C-120 1K LCSS Power Distribution RAP.
• GP 11 How to Check a Sensor.
• Figure 1. Connect a service meter at P/J8 between pins 8 and 9. Slowly rotate the ejector motor
• P/J8, 1K LCSS PWB encoder. The voltage changes between +5V and 0V.

A
Status Indicator RAPs February 2010
11-320-120, 11-322-120 2-352 Xerox WorkCentre 5790 Family
Y N
Go to Flag 4. Check the wiring and connectors between the ejector motor encoder sensor
and the 1K LCSS PWB. If necessary repair the wiring, REP 1.2. If the wiring is good,
install a new ejector motor encoder sensor, PL 11.114 Item 3.

Perform the 11F-120 1K LCSS PWB Damage RAP, if necessary install a new 1K LCSS PWB,
PL 11.124 Item 1.

Ejector out sensor

Q11-322

Pulley/drive gear

Ejector belt

Ejector motor
MOT11-020

Ejector motor
encoder sensor
Ejector home sensor
Q11-320
Ejector motor damper

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-353 11-320-120, 11-322-120
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

11-320-120, 11-322-120 2-354 Xerox WorkCentre 5790 Family
11-364-120 Stapling Failure RAP Y N
Install a new staple cartridge, PL 26.10 Item 11 and repeat the check. If the first two sta-
11-364-120 Staples in the stapling head are not primed.
ples are not partially formed, install a new stapler assembly, PL 11.116 Item 1. Perform
SCP 6 Final Actions
Initial Actions
Switch off the machine, then switch on the machine, GP 14. Install a new staple head unit, PL 11.116 Item 5. Perform SCP 6 Final Actions.

Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch
Settings RAP.

Check the following:

• The staple cartridge has staples in it and is correctly installed,
• The leading staples in the staple head have been primed, Figure 3.
• Check that the sheets of staples in the cartridge are feeding one at a time. If staple sheets
overlap, they will jam in the cartridge. If necessary, install a new staple cartridge, PL 26.10
Item 11.

NOTE: The term “priming” refers to 2 staples at the front of the cartridge, that have been pre-
formed automatically by the action of the stapler, refer to Figure 2.

NOTE: The SH 1 low staples sensor, SH 1 cartridge sensor, SH 1 home sensor and the SH 1
priming sensor are all integral to the staple head unit and although they can be checked using
component control they cannot be exchanged as components.

Procedure
Figure 1. Enter dC330, code 11-361, SH 1 paper sensor, Q11-361. Actuate Q11-361. The
display changes.
Y N
Go to Flag 1. Check Q11-361.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
SH 1 paper sensor
• GP 10, How to Check a Sensor.
Staple head unit Q11-361
• P/J7, 1K LCSS PWB
• 11C-120 1K LCSS Power Distribution RAP.
Repair or install new components as necessary:
• SH 1 paper sensor, PL 11.116 Item 4.
Figure 1 Component location
• 1K LCSS PWB, PL 11.124 Item 1.

NOTE: If the SH1 priming sensor does not see staples in the primed position, the staple head
cycles a number of times to prime the staple head. This occurs when the 1K LCSS interlocks
are made.

Follow the customer instruction label inside the 1K LCSS front door to remove the staple car-
tridge, slide out the top sheet of staples from the cartridge, to expose a fresh sheet of staples
on the top of the stack. Ensure the forming plate is fully closed, Figure 2. Install the staple car-
tridge and close the door. The stapler will now cycle a few times to feed and prime the new
sheet of staples. Open the door and remove the staple cartridge. Examine the sheet of staples
that have been fed to the staple forming part of the stapler, by opening the forming plate, Fig-
ure 3. The first two staples have been partially formed.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-355 11-364-120
 Primed staples
Forming plate open Forming plate fully closed

Figure 2 Staple cartridge open Figure 3 Staple cartridge closed

Status Indicator RAPs February 2010

11-364-120 2-356 Xerox WorkCentre 5790 Family
 Figure 4 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-357 11-364-120
11A-120 Bin 1 Overload RAP
Use this RAP to resolve a fault on the bin 1 90% full sensor.

Procedure
NOTE: In diagnostics, actuating any 1K LCSS sensor or switch can change the displayed state
on the UI. Make sure that the correct sensor or switch is tested.

Enter dC330, code 11-331, bin 1 90% full sensor, Q11-331. Actuate Q11-331. The display
changes.
Y N
Go to Flag 1. Check Q11-331.
Refer to:
• 11F-120 1K LCSS PWB Damage RAP.
• GP 11, How to Check a sensor.
• Figure 1.
• P/J2, 1K LCSS PWB
• 11C-120 1K LCSS Power Generation RAP.
Repair or install new components as necessary:
• Bin 1 90% full sensor, PL 11.106 Item 5.
• 1K LCSS PWB, PL 11.124 Item 1.

Perform SCP 6 Final Actions.

Figure 2 Circuit diagram

Bin 1 90% full sensor Q11-331

Figure 1 Component location

Status Indicator RAPs February 2010

11A-120 2-358 Xerox WorkCentre 5790 Family
11B-120 Initialization Failure RAP
When an initialization command is received from the machine, the units are initialized in two
stages:
• The following units are initialized sequentially:
1. If the staple head is not at the home position, it is driven to the home position
2. If the ejector is not at the home position, it is driven to the home position
• The following units are then initialized simultaneously:
1. If the front tamper is not at the home position, it is driven to the home position
2. If the rear tamper is not at the home position, it is driven to the home position
3. If the paddle is not at the home position, it is driven to the home position
4. If the stacker is not at the home position, it is driven to the home position
NOTE: The staple cartridge must be pushed fully home.

Initial Actions
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch
Settings RAP.

Remove the 1K LCSS covers, REP 11.1-120, so that the units can be viewed. Cheat the front
door interlock switch and the top cover interlock switch. Check that LED 2 is illuminated, this
shows that all interlocks are made. If the LED fails to illuminate, go to 11-300-120, 11-302-120,
11-303-120 Interlocks RAP.

Procedure
Figure 1. Check that the software heartbeat is present on LED 1. The LED should flash twice
per second if the 1K LCSS software is running. If necessary, re-load the 1K LCSS software, LED 2 LED 1
refer to GP 4 Machine Software.

If the initialization sequence fails to place any unit at the home position, refer to the appropriate Figure 1 LED location
RAPs:
• Front tamper not at home, refer to 11-005-120, 11-006-120, 11-310-120, 11-311-120 Front
Tamper Move Failure RAP
• Rear tamper not at home, refer to 11-007-120, 11-008-120, 11-312-120, 11-313-120, 11-
319-120 Rear Tamper Move Failure RAP.
• Paddle not at home, refer to 11-024-120, 11-025-120 Paddle Roll Failure RAP.
• Bin 1 not at home, refer to 11-030-120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Move-
ment Failures RAP.
• Staple head not at home, refer to 11-050-120, 11-360-120 Staple Head Operation Failure
RAP.
• Ejector not at home, refer to 11-320-120, 11-322-120 Compiler Ejector Movement Failure
RAP.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-359 11B-120
 A
11C-120 1K LCSS Power Distribution RAP • Monitor the voltage at P/J6 pin 1. Re-connect the circuits one at a time. Energize the
re-connected components using dC330 control codes.
The 1K LCSS has an integral power supply providing +24V and +5V supplies to the 1K LCSS
• If the voltage drops below +22V, switch off the machine, GP 14. Re-check the com-
PWB. The AC power for the 1K LCSS power supply comes from the LVPS and base module of
the machine. ponent and harness for overheating or short circuits. Repair or install new compo-
nents as necessary.
CAUTION
+5V is available between TP3 and TP4 on the 1K LCSS PWB.
Do not connect the finisher power cord directly to the AC wall outlet. The finisher cannot oper- Y N
ate without the machine. The machine controls the distribution of electricity to the finisher for
Go to Flag 2. +5V is available at P/J1 between pins 4 and 6, also between pins 7
correct power on and power off sequencing.
and 8.
Procedure Y N
WARNING Disconnect P/J6. +5V is available at P/J6 between pins 4 and 6, also between
pins 7 and 8 on the end of the harness.
Take care when measuring AC mains (line) voltage. Electricity can cause death or injury. Y N
Close or cheat all the 1K LCSS interlocks. LED 2 on the 1K LCSS PWB is illuminated. Go to Flag 1. Disconnect the 1K LCSS power cord from PJ22. ACL is avail-
Y N able at PJ22 between pins 1 and 3 on the LVPS and base module.
Go to Flag 2. +24V is available at P/J1 between pins 1 and 2, also between pins 5 Y N
and 3. Go to the 01C AC Power RAP.
Y N
Disconnect P/J6. +24V is available at P/J6 between pins 1 and 2, also between Remove the 1K LCSS, REP 11.12-120. Loosen the 2 screws and lift the power
pins 5 and 3 on the end of the harness. supply module away from the 1K LCSS frame. Go to Flag 1. Check the wiring
Y N between CN2 and P/J6. The wiring is good.
Go to Flag 1. Disconnect the 1K LCSS power cord from PJ22. ACL is avail- Y N
able at PJ22 between pins 1 and 3 on the LVPS and base module. Repair the wiring.
Y N
Go to the 01C AC Power RAP. Install a new power supply module, PL 11.124 Item 2.

Remove the 1K LCSS, REP 11.12-120. Loosen the 2 screws and lift the power Perform the following:
supply module away from the 1K LCSS frame. Go to Flag 1. Check the wiring
• Check for a short circuit or an overload in the wiring or components connected
between CN2 and P/J6. The wiring is good. to the +24V on the 1K LCSS PWB. Refer to GP 7.
Y N
• Perform the 11F-120 1K LCSS PWB Damage RAP. If necessary install a new
Repair the wiring.
1K LCSS PWB, PL 11.124 Item 1.
Install a new power supply module, PL 11.124 Item 2.
Perform the 11F-120 1K LCSS PWB Damage RAP. If necessary install a new 1K LCSS
PWB, PL 11.124 Item 1.
Perform the following:
• Check for a short circuit or an overload in the wiring or components connected The +24V and +5V supplies on the 1K LCSS PWB are good.
to the +24V on the 1K LCSS PWB. Refer to GP 7.
• Perform the 11F-120 1K LCSS PWB Damage RAP. If necessary install a new
1K LCSS PWB, PL 11.124 Item 1.

+24 V is available at P/J5 pin 3 on the 1K LCSS PWB.

Y N
Go to the 11-300-120, 11-302-120, 11-303-120 Interlocks RAP.

Perform the following:

• Switch off the machine, GP 14.
• Go to Flag 3. Disconnect all the +24V harnesses to components.
• Check each harness for short circuits and overheating, GP 7.
• Repair or install new components as necessary.

A
Status Indicator RAPs February 2010
11C-120 2-360 Xerox WorkCentre 5790 Family
 Power Supply
Module

Figure 1 Component location

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-361 11C-120
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

11C-120 2-362 Xerox WorkCentre 5790 Family
11D-120 1K LCSS to Machine Communications Interface 11E-120 1K LCSS PWB DIP Switch Settings RAP
RAP To show the correct settings for the DIP switches on the 1K LCSS PWB.
All communications between the machine and 1K LCSS are conducted through a single inter-
face cable. Procedure
Problems that can result from incorrect DIP switch settings are:
Procedure • False jam clearance instructions for the 1K LCSS and/or the machine exit area.
Check the 1K LCSS PWB DIP switch settings, refer to 11E-120 1K LCSS PWB DIP Switch • Communication errors between the 1K LCSS and machine.
Settings RAP. • Erratic behavior of the 1K LCSS.
Check the DIP switch settings, Figure 1. If necessary, switch off the machine, GP 14. Correct
Go to 03-360, 03-408 to 03-410, 03-418 IOT to Output Device Error Rap. the DIP switch setting, then switch on the machine, GP 14.

Figure 1 DIP switch settings

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-363 11D-120, 11E-120
11F-120 1K LCSS PWB Damage RAP
Use this RAP to determine the cause of damage to the 1K LCSS PWB, so that the cause can
Table 1 1K LCSS PWB Drive Components
be repaired before a new 1K LCSS PWB is installed.
1K LCSS
Procedure PWB Driven Normal resistance Spared part and
component component measurement +/- 10% references
The 1K LCSS PWB can be damaged by a component connected to it going short-circuit. If a
new 1K LCSS PWB is installed and power applied to the machine, the new 1K LCSS PWB will U5 Paddle motor At PJ14: Paddle motor assembly, PL
be damaged in the same way. The cause of the damage must be found by following this proce- (MOT11024) Pin 1 to 3 = 28 ohms. 11.104 Item 10.
dure. Pin 1 to 4 = 28 ohms. 11-024-120, 11-025-120
Pin 2 to 5 = 28 ohms. RAP
WARNING Pin 2 to 6 = 28 ohms.
U10 Staple head At PJ7: Staple head unit, PL 11.116
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
motor (MOT11- Pin 8 to 10 = 12.6 ohms. Item 5.
from the customer supply while performing tasks that do not need electricity. Electricity
can cause death or injury. Moving parts can cause injury. 050) Pin 9 to 11 = 12.6 ohms 11-050-120, 11-360-120
RAP
Remove the 1K LCSS PWB and inspect the components shown in Figure 1 for damage. The
U11 Bin 1 elevator At PJ12: Bin 1 elevator motor, PL
damage to the component may be in the form of a crack, a small crater or a burnt patch. Refer
motor (MOT11- Pin 1 to 2 = 6.4 ohms 11.10 Item 8.
to Table 1 to locate the component causing the damage to the 1K LCSS PWB.
030) 11-030-120, 11-334-120, 11-
335-120, 11-336-120 RAP
U12 Front tamper At PJ9: Tamper assembly, PL 11.16
motor (MOT11- Pin 1 to 3 = 20 ohms. Item 1.
003) Pin 1 to 4 = 20 ohms. 11-005-120, 11-006-120, 11-
Pin 2 to 5 = 20 ohms. 310-120, 11-311-120 RAP
Pin 2 to 6 = 20 ohms.
U13 Rear tamper At PJ9: Tamper assembly, PL 11.112
motor (MOT11- Pin 7 to 9 = 20 ohms. Item 1.
004) Pin 7 to 10 = 20 ohms. 11-007-120, 11-008-120, 11-
Pin 8 to 11 = 20 ohms. 312-120, 11-313-120, 11-
Pin 8 to 12 = 20 ohms. 319-120 RAP
U14 Transport At PJ17: Transport motor 1, PL
motor 1 Pin 1 to 3 = 2.2 ohms. 11.110 Item 2.
(MOT11-000) Pin 1 to 4 = 2.2 ohms. 11-130-120, 11-132-120
Pin 2 to 5 = 2.2 ohms. RAP
Pin 2 to 6 = 2.2 ohms.
U15 Ejector motor At PJ15: Ejector assembly, PL 11.114
(MOT11-020) Pin 1 to 2 = 6.6 ohms Item 1.
11-320-120, 11-322-120
RAP
U16 Transport At PJ16: transport motor 2, PL 11.118
motor 2 Pin 10 to 12 = 0.8 ohms. Item 5.
(MOT11-001) Pin 10 to 13 = 0.8 ohms. 11-130-120, 11-132-120
Pin 11 to 14 = 0.8 ohms. RAP
Pin 11 to 15 = 0.8 ohms.
Q1 Diverter gate At PJ13: Diverter gate solenoid, PL
solenoid (S11- Pin 1 to pin 2 = 74 ohms 11.118 Item 12.
002) 11-130-120, 11-132-120
RAP
Figure 1 1K LCSS PWB components

Status Indicator RAPs February 2010

11F-120 2-364 Xerox WorkCentre 5790 Family
NOTE: If difficulty is found in connecting the service meter probes to the connector headers on 11G-120 Copy Damage in the 1K LCSS RAP
the 1K LCSS PWB, refer to the RAP quoted in Table 1 and make the measurement at another
Use this RAP to identify and correct the causes of copy damage in the 1K LCSS.
point in the harness to the driven component.

If the defective driven component is found using the table checks, disconnect the connector Procedure
closest to the driven component, then check the driven component again to identify any short
circuit in the wiring to the driven component. Repair the wiring or install new parts as neces-
WARNING
sary. Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
from the customer supply while performing tasks that do not need electricity. Electricity
If the defective driven component can not be found using the table checks, refer to GP 7, check can cause death or injury. Moving parts can cause injury.
each driven component to ensure that it is not seized. Motors should rotate easily. Solenoid Check the following:
armatures should slide easily in the coil. Also check the drive components to ensure that they • Look for torn paper in the 1K LCSS paper path. Torn fragments can pass through the IOT
rotate easily, if necessary install new parts. and 1K LCSS paper path without causing a problem until they finally wedge themselves at
some point.
When the a new driven component has been installed or the defective drive components have
• Ensure that the shaft diverter assembly, PL 11.118 Item 13, operates correctly and has it’s
been repaired, install a new 1K LCSS PWB, PL 11.124 Item 1. full movement.
• Ensure that the jam clearance guide, PL 11.122 Item 6, closes and latches correctly.
Check that the magnet at the rear is located and functions correctly. Check the clip at the
front is positioned correctly, Figure 1.
• Ensure that all idler rolls in the 1K LCSS paper path are free to rotate, particularly those
on the jam clearance guide, where the paper turns through 90 degrees.
• Ensure that the paper path ribs of the jam clearance guide, PL 11.122 Item 6, and the
entry guide cover, PL 11.122 Item 5, are free of “scores” and “nicks”. Check also for con-
tamination and glue from label stock.

Check that the end of the spring

clip is positioned on the inside of
the frame.

Figure 1 Position of the spring clip

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-365 11F-120, 11G-120
11H-120 Mis-Registration in Stapled Sets and Non-Stapled 11J-120 1K LCSS Poor Stacking RAP
Sets RAP Use this RAP to find the cause of poor stacking in the 1K LCSS.
Use this RAP to identify and correct the causes of mis-registration in stapled sets, resulting in
staples missing some sheets in the set, or poorly registered non-stapled sets. Procedure
Check the following;
Procedure • Look for sets that are not dropping back fully in bin 1 and therefore not operating the bin 1
WARNING level sensors:
– Large paper sizes should not be stacked on top of small paper sizes.
Switch off the electricity to the machine. Refer to GP 14. Disconnect the power cord
from the customer supply while performing tasks that do not need electricity. Electricity – Ensure that the paper stack in each paper tray has been fanned.
can cause death or injury. Moving parts can cause injury. – Turn over the paper stack in each paper tray.
The most likely cause of mis-registration is paper condition and/or damage such as curl, wrin- – Ensure that all paper or other copy stock being used is within the size and weight
kle, creases, dog ears, etc. specifications. Refer to GP 20 Paper and Media Size Specifications.
– Try using a fresh ream of paper.
Curl, wrinkle and creases are probably caused in the IOT, go to the IQ1 Image Quality Entry
– Ensure that the edge guides of all paper trays are adjusted correctly for the paper
RAP.
size and that the trays are fully closed.

For other copy / print damage and dog ears, go to the 11G-120 Copy Damage in the 1K LCSS – Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL
11.100 Item 13.
RAP.
• Labels must not be fed to bin 1, but to bin 0 only.
Check the following: • It is recommended that transparencies are fed to bin 0 whenever possible.
• Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL 11.100 • Check that bin 1 is level front to back, if necessary perform ADJ 11.1-120 1K LCSS Bin 1
Item 13. Level.
• Turn over the paper stack in the tray in use. • Check that the bin 1 upper level sensor, Q11-332 is working correctly. Refer to the 11-030-
• Use a new ream of paper in the tray in use. 120, 11-334-120, 11-335-120, 11-336-120 Bin 1 Movement Failure RAP.
• Paper type, especially recycled paper, can lead to registration problems. Try changing to • Check the operation of the front and rear tampers. Refer to 11-005-120, 11-006-120, 11-
a different brand or type of paper. 310-120, 11-311-120 Front Tamper Move Failure RAP and 11-007-120, 11-008-120, 11-
312-120, 11-313-120, 11-319-120 Rear Tamper Move Failure RAP.
• Ensure that the guides in the paper trays are correctly set and reported on the UI for the
paper size loaded. • Check that the output device is not near an air conditioning or ventilation output duct. Air
• Check that paper type is set correctly. If heavyweight paper is used but not set in the UI, flow across the output bins can cause poor stacking.
the compiler capacity can be exceeded. • Check if Mod. TAG L-013 LCSS bin 1 kit is installed on the finisher.
• Check for obstructions in the compiler. – Machine that regularly process large stacks of A4/8.5x11 inch LEF paper should
have the LCSS bin 1 W/TAG L-013 kit installed, PL 11.100 Item 10.
• Ensure that the paddle roll operates correctly and that the paddles are not damaged. The
paddles should park completely inside the top section of the compiler, with the shorter – Machines that regular process small stacks of A4/8.5x11 inch LEF, A3/11x17 inch
paddle in a vertical position. If all of the paddles are out of position, check the paddle roll and A4/8.5x11 inch SEF paper should have the standard W/OTAG L-013 bin 1
position sensor, PL 11.104 Item 11, the flag, PL 11.104 Item 7 and the paddle motor installed, PL 11.100 Item 10.
assembly, PL 11.104 Item 10. If only one paddle is mis-aligned with the others, it can be • Check the output copies for curl, refer to IQ5.
re-positioned by hand (they are not bonded to the shaft).
• Make sure the paddles are clean. If necessary, use formula A cleaning fluid, PL 26.10
Item 2 to clean the paddles.
• Ensure that the tampers operate correctly, i.e. are not stalling or losing position during the
job. Inspect the tampers for damage, if necessary install new parts. PL 11.112.
• Inspect the bin 1 entry nips for roll damage. The idlers should be held against the rubber
driving rolls and they should be free to rotate within their support springs. If necessary,
install new parts, PL 11.120.
• Inspect the four spring loaded guides on the output cover, PL 11.100 Item 7. Ensure that
they are correctly located and are free to move up and down.

Status Indicator RAPs February 2010

11H-120, 11J-120 2-366 Xerox WorkCentre 5790 Family
11-024-171, 11-026-171 Paddle Roller Position RAP
11-024-171 The paddle roller has failed to return to the home position.

11-026-171 The paddle roller has failed to move from the home position.

Initial Actions Paddle roller

home sensor
WARNING Q11-326
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Pusher
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Check for damage or any obstruction that would prevent paddle movement. If necessary,
install new components.

Procedure
Figure 1 shows the location of the components.
Enter dC330, code 11-326. Manually operate the paddle roller home sensor, Q11-326, Figure
1. The display changes.
Y N
Go to Flag 1. Check the wiring and repair as necessary, REP 1.2. Check the paddle roller
home sensor, Q11-326. Refer to:
• GP 11 How to Check a Sensor. Paddle roller
motor
• P/J201, HVF Control PWB
MOT11-025
• 11A-171 HVF Power Distribution RAP.
Install new components as necessary:
• Paddle module assembly, PL 11.145 Item 2.
• HVF control PWB, PL 11.157 Item 2.

Enter dC330, code 11-025 Paddle Roll Motor Run, to check the movement of the paddle, Fig-
ure 1. The paddle turns.
Y N
Go to Flag 2. Check the wiring and repair as necessary, REP 1.2. Check the paddle roller
motor, MOT11-025. Refer to:
• GP 10 How to Check a Motor.
• P/J202, HVF Control PWB
• 11A-171 HVF Power Distribution RAP.
Install new components ad necessary:
• Paddle module assembly, PL 11.145 Item 2
Figure 1 Component location
• HVF control PWB, PL 11.157 Item 2.

Perform SCP 6 Final Actions.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-367 11-024-171, 11-026-171
 Figure 2 Circuit diagram

Status Indicator RAPs February 2010

11-024-171, 11-026-171 2-368 Xerox WorkCentre 5790 Family
11-044-171 to 11-047-171 Punch Unit Head and Position Y N
Go to Flag 4 and check the wiring from the motor to the PWB. Repair as necessary, REP
RAP 1.2. Check the punch unit motor, MOT11-045. Refer to:
11-044-171 The punch head has failed to return to the home position. • GP 10 How to Check a Motor.
• P/J502, HVF Control PWB
11-045-171 The punch head has failed to move from the home position. • 11A-171 HVF Power Distribution RAP.
Install new components as necessary:
11-046-171 The punch unit has failed to return to the home position.
• HVF hole punch assembly, PL 11.153 Item 1
11-047-171 The punch unit has failed to move from the home position. • HVF control PWB, PL 11.157 Item 2.

Initial Actions Enter dC330, code 11-044 for the punch unit home sensor and stack the code 11-045 or 11-
046 to take the punch unit motor into, and out of, the home position. Observe the condition of
WARNING the sensor on the UI. The display changes.
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the Y N
customer supply while performing tasks that do not need electricity. Electricity can Go to Flag 3 and check the wiring from the sensor to the PWB. Repair as necessary, REP
cause death or injury. Moving parts can cause injury. 1.2. Check the punch unit home sensor, Q11-044. Refer to:
Check the punch head area for any obstruction or damage that could prevent the free move- • GP 11 How to Check a Sensor.
ment of the head or the unit. If necessary, install new components. • P/J501, HVF Control PWB
• 11A-171 HVF Power Distribution RAP.
Procedure Install new components as necessary:
Figure 1 shows the location of the components. • HVF hole punch assembly, PL 11.153 Item 1
Enter dC330, code 11-043 for the punch head motor. The motor operates.
• HVF control PWB, PL 11.157 Item 2.
Y N
Go to Flag 2 and check the wiring from the motor to the PWB. Repair as necessary, REP
Perform SCP 6 Final Actions.
1.2. Check the punch head motor, MOT11-043. Refer to:
• GP 10 How to Check a Motor.
• P/J502, HVF Control PWB
• 11A-171 HVF Power Distribution RAP.
Install new components as necessary:
• HVF hole punch assembly, PL 11.153 Item 1
• HVF control PWB, PL 11.157 Item 2.

Enter dC330, code 11-350 for the punch head home sensor and stack the code 11-043 for the
punch head motor. Observe the condition of the sensor on the UI. The display changes.
Y N
Go to Flag 1 and check the wiring from the sensor to the PWB. Repair as necessary, REP
1.2. Check the punch head home sensor, Q11-350. Refer to:
• GP 11 How to Check a Sensor.
• P/J501, HVF Control PWB
• 11A-171 HVF Power Distribution RAP.
Install new components as necessary:
• HVF hole punch assembly, PL 11.153 Item 1
• HVF control PWB, PL 11.157 Item 2.

Enter dC330, code 11-045 for the motor to travel in the forward direction, or enter the code 11-
046 for the motor to travel in the reverse direction. The motor operates.

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-369 11-044-171 to 11-047-171
 Punch head motor
MOT11-043

Punch head home

sensor Q11-350

Punch unit home

sensor Q11-044

Punch unit motor

MOT11-045

Hole punch assembly

Figure 1 Component location

Status Indicator RAPs February 2010

11-044-171 to 11-047-171 2-370 Xerox WorkCentre 5790 Family
 Figure 2 Circuit diagram

February 2010 Status Indicator RAPs

Xerox WorkCentre 5790 Family 2-371 11-044-171 to 11-047-171
11-056-171, 11-057-171 Inserter Bottom Plate RAP Install new components as necessary:
• IDG Pickup sensor, PL 11.179 Item 10.
11-056-171 The inserter bottom plate has failed to return to the home position.
• HVF control PWB, PL 11.157 Item 2.
11-057-171 The inserter bottom plate has failed to lift. Perform SCP 6 Final Actions.

Initial Actions
WARNING
Switch off the electricity to the machine, GP 14. Disconnect the power cord from the
customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
Check that the bottom plate area is clear and that there is no damage or obstructions. Install
new components as necessary.
IDG Pickup Sen-
Procedure sor

Figure 1 shows the location of the components.

Enter dC330, code 11-078 for the inserter motor. The motor runs.
Y N
Go to Flag 5 and Flag 6 and check the wiring from the motor to the HVF control PWB.
Repair as necessary, REP 1.2. Check the Inserter motor, MOT-078. Refer to:
• GP 10 How to Check a Motor.
• P/J701, HVF Control PWB
• P/J4, P/J12, Inserter PWB Inserter motor
MOT11-078
• 11A-171 HVF Power Distribution RAP.
Install new components as necessary:
• Inserter Motor, MOT 11-078, PL 11.181 Item 1. Inserter bottom plate sen-
• HVF control PWB, PL 11.157 Item 2.