• Code: 311C-110
• Description: 2K LCSS 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 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.
• Remedy: Refer to. Check that the software heartbeat is present on LED 1. The LED should flash twice per second if the 2K LCSS software is running. If necessary, re-load the 2K LCSS software, refer to GP 4 Machine Software. If the initialization sequence fails to place any unit at the home position, refer to the appropriate RAPs: • Front tamper not at home, refer to the 311-005-00-110, 311-006-00-110 Front Tamper Move Failure RAP • Rear tamper not at home, refer to the 311-319-00-110 Rear Tamper Move Failure RAP. • Paddle not at home, refer to the 311-024-00-110, 311-025-00-110 Paddle Roll Failure RAP. • Bin 1 not at home, refer to the 311-030-00-110, 311-334-00-110, 311-335-00-110, 311- 336-00-110 Bin 1 Movement Failures RAP. • Punch not at home, refer to the 311-043-00-110, 311-350-00-110 Hole Punch Operation Failure RAP • Staple head not at home, refer to the 311-360-00-110 Staple Head Operation Failure RAP. • Stapling unit not at home, refer to the 311-371-00-110 Staple Head Unit Movement Failure RAP. • Ejector not at home, refer to the 311-320-00-110, 311-322-00-110 Compiler Ejector Movement Failure RAP.

• Code: 311C-120
• Description: 1K LCSS Power Distribution RAP The 1K LCSS has an integral power supply providing +24V and +5V supplies to the 1K LCSS PWB. The AC power for the 1K LCSS power supply comes from the LVPS and base module of the machine.
• Remedy: Close or cheat all the 1K LCSS interlocks. LED 2 on the 1K LCSS PWB is illuminated. Y↓N→Go to Flag 2. +24V is available at P/J1 between pins 1 and 2, also between pins 5 and 3. Y↓N→Disconnect P/J1. +24V is available at P/J1 between pins 1 and 2, also between pins 5 and 3 on the end of the harness. Y↓N→Go to Flag 1. Disconnect the 1K LCSS power cord from P/J22. ACL is available at PJ22 between pins 1 and 3 on the LVPS and base module. Y↓N→Go to the 301C AC Power RAP. Remove the 1K LCSS-120. Loosen the 2 screws and lift the power supply module away from the 1K LCSS frame. Go to Flag 1. Check the wiring between P/J22 and CN1. The wiring is good. Y↓N→Repair the wiring. Install a new power supply module, PL 11.124 Item 2. Perform the following: • Check for a short circuit or an overload in the wiring or components connected to the +24V on the 1K LCSS PWB. Refer to GP 7. • Perform the 311F-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 311-300-00-120, 311-302-00-120, 311-303-00-120 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. • Install new components as necessary. • 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. • If the voltage drops below +22V, switch off the machine, GP 14. Re-check the component and harness for overheating or short circuits. Install new components as necessary. +5V is available between TP3 and TP4 on the 1K LCSS PWB. Y↓N→Go to Flag 2. +5V is available at P/J1 between pins 4 and 6, also between pins 7 and 8. Y↓N→Disconnect P/J1. +5V is available at P/J1 between pins 4 and 6, also between pins 7 and 8 on the end of the harness. Y↓N→Go to Flag 1. Disconnect the 1K LCSS power cord from PJ22. ACL is available at PJ22 between pins 1 and 3 on the LVPS and base module. Y↓N→Go to the 301C AC Power RAP. Remove the 1K LCSS-120. Loosen the 2 screws and lift the power supply module away from the 1K LCSS frame. Go to Flag 2. Check the wiring between CN2 and P/J1. The wiring is good. Y↓N→Repair the wiring. Install a new power supply module, PL 11.124 Item 2. Perform the following: • Check for a short circuit or an overload in the wiring or components connected to the +24V on the 1K LCSS PWB. Refer to GP 7. • Perform the 311F-120 1K LCSS PWB Damage RAP. If necessary install a new 1K LCSS PWB, PL 11.124 Item 1. Perform the 311F-120 1K LCSS PWB Damage RAP. If necessary install a new 1K LCSS PWB, PL 11.124 Item 1. The +24V and +5V supplies on the 1K LCSS PWB are good.

• Code: 311C-171
• Description: HVF BM Bin 2 Failure RAP Bin 2 fails to remove the finished booklets from the exit area of the booklet maker.
• Remedy: Enter dC330 code 011-389. Actuate the BM bin 2 90% full sensor, Q11-389. The display changes. Y↓N→If a tri-folder is installed, go to Flag 4. Check the connection at PJ583 on the tri-folder. The connection are good. Y↓N→Check the connectors and harness at the tri-folder. Repair the harness as necessary. Go to Flag 1. Check Q11-389. Refer to: • GP 11, How to Check a Sensor. • P/J556, BM PWB. • 311A-171 HVF Power Distribution RAP. Install new components as necessary: • BM PWB, PL 11.166 Item 10. • BM bin 2 90% full sensor PL 11.169 Item 5. NOTE: The BM conveyor belts drive motor stops after 10 seconds. Enter dC330 code 011-402 to run the BM conveyor belts drive motor, MOT11-402. MOT11- 402 runs. Y↓N→If a tri-folder is installed, go to Flag 5. Check the connection at PJ583 on the tri-folder. The connection are good. Y↓N→Check the connectors and harness at the tri-folder. Repair the harness as necessary. Go to Flag 3 or Flag 2. Check MOT11-402. Refer to: • GP 10 How to Check a Motor. • P/J555, BM PWB. • 311A-171 HVF Power Distribution RAP. Install new components as necessary: • BM conveyor belts drive motor, PL 11.169 Item 4. • BM PWB, PL 11.166 Item 10. The fault may be intermittent, check for damaged wiring or bad connectors. If necessary install new conveyor belts, PL 11.169 Item 1.

• Code: 311E-150
• Description: LVF BM to Machine Communications Interface RAP All communications between the machine and LVF BM are conducted through a single interface cable. A UI message System Error or Finisher Comms Failure may be seen.
• Remedy: Observe the software heartbeat LED (LED 1) on the LVF PWB. LED 1 is flashing at 1Hz (0.5 seconds on, 0.5 seconds off). Y↓N→LED 1 is flashing at 0.25Hz (2 seconds on, 2 seconds off) this indicates that the finisher software is corrupt. Re-load the finisher software, GP 4. If necessary install a new LVF PWB, PL 11.90 Item 8. Observe the software heartbeat LED (LED 1) on the LVF BM PWB. LED 1 is flashing at 1Hz (0.5 seconds on, 0.5 seconds off). Y↓N→LED 1 is flashing at 0.25Hz (2 seconds on, 2 seconds off) this indicates that the booklet maker software is corrupt. Re-load the finisher software, GP 4. If necessary install a new LVF BM PWB, PL 11.90 Item 1. Go to Flag 1, check the wiring and connectors between P/J101 and P/J401. The wiring and connectors are good. Y↓N→Repair the wiring or connectors. Go to Flag 2, check the wiring and connectors between P/J301and P/J11. The wiring and connectors are good. Y↓N→Repair the wiring or connectors. The finisher checks are good. Switch off the machine, then switch on the machine, GP 14. If the fault remains, perform the Forced Altboot Software Loading Procedure, GP 4.

• Code: 311E-171
• Description: Copy Damage in the HVF BM RAP Use this RAP to identify and correct the causes of copy damage in the HVF BM.
• Remedy: Check the following: • Check the alignment between the IOT and the HVF BM, ADJ 11.1-171. • Look for paper fragments in the HVF BM paper path. Paper fragments can move through the IOT and HVF BM paper path without causing a problem until they finally wedge themselves at some point. A likely place for a fragment of paper to be wedged is at the hole punch assembly, where the top and bottom guides form the narrowest part of the paper path. • Ensure that the exit diverter gate solenoid, PL 11.150 Item 4, operates correctly and has it’s full movement. • Ensure that the hole punches park at the fully open position. If they protrude, even slightly, a jam will occur in the narrow paper path of the hole punch. Refer to the 311-044- 00-171 to 311-047-00-171 Punch Head Position RAP. • Check that all the idler rolls in the HVF BM paper path are free to rotate, particularly those on the jam clearance guides. Refer to ADJ 40.1 Machine Lubrication. • Make sure that the jam clearance guides 5a, 5b and 5c close and latch correctly. • Check that the paper path ribs of the jam clearance guide 5b, PL 11.161 Item 7 and the exit path PL 11.168 are free of scores and nicks. Check also for contamination and glue from label stock. • Make sure that the compiler carriage tampers move to the correct paper size. • Check that the paper size reported on the user interface corresponds to the actual paper size loaded in the trays, refer to the 371B Tray 1 and 2 Wrong Size Paper RAP. • Make sure that the BM tampers move to the correct paper size, refer to the 311-066-00- 171, 311-384-00-171 HVF BM Tamper Failure RAP. • Ensure that the BM paper guide, PL 11.161 Item 7, closes and latches correctly. • If the top sheet of paper is being been torn from booklets, check that the components in the lower crease roll gear and clutch assembly are correctly installed. Refer to the replacement procedure-171 BM Crease Rolls, Gears and Bearings. • If heavy-weight paper is used, the paper can stop in the vertical transport and cause a 10- 126 fault. The fault is caused when the vertical transport motor is over loaded. Check the position of the jam clearance guides 5a, 5b and 5c. Check the vertical transport rolls and bearings for contamination. If necessary remove and clean the drive shaft and the bearings. If the problem continues then install a new transport motor,.

• Code: 311F-171
• Description: Mis-Registration in Stapled and Unstapled Sets RAP 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.
• Remedy: A probable cause of mis-registration is the condition of the paper and/or damage such as, curl, wrinkle, creases, dog ears, etc. • Curl, wrinkle and creases are probably caused in the IOT, go to the IQ1 Image Quality Entry RAP. • For other copy / print damage and dog ears, go to the 311E-171 Copy Damage in the HVF BM RAP. Check the following: • Check the alignment between the IOT and the HVF BM, ADJ 11.1-171. • 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, refer to the 371B Tray 1 and 2 Wrong Size Paper RAP. • 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 the paddle roll mechanism in the eject housing operating correctly, refer to the 311-024-00-171, 311-026-00-171 Paddle Roll Position RAP. • Make sure that the compiler carriage tampers move to the correct paper size. • Make sure that the BM tampers move to the correct paper size, refer to 311-066-00-171, 311-384-00-171 HVF BM Tamper Failure RAP. • Check if the HVF module has had the W/TAG V-006 modifications installed. If necessary perform ADJ 11.13-171 HVF Performance Improvement (W/TAG V-006).

• Code: 311G-120
• Description: Copy Damage in the 1K LCSS RAP Use this RAP to identify and correct the causes of copy damage in the 1K LCSS.
• Remedy: Check the following: • Look for torn paper in the 1K LCSS paper path. Torn fragments can pass through the IOT and 1K LCSS paper path without causing a problem until they finally wedge themselves at some point. • Ensure that the shaft diverter assembly, PL 11.118 Item 13, operates correctly and has it’s 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. • 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 contamination and glue from label stock.

• Code: 311G-150
• Description: LVF BM 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 staples missing some sheets in the set, or poorly registered non-stapled sets.
• Remedy: The most likely cause of mis-registration is paper condition and/or damage such as curl, wrinkle, creases, dog ears, etc. Curl, wrinkle and creases are probably caused in the IOT, go to IQ1 Image Quality Entry RAP. For other copy/print damage and dog ears, go to the 311H-150 Copy Damage in the LVF BM RAP. Check the following: • Check that bin 1 is seated correctly and the bin 1 alignment clip is in position, PL 11.50 Item 12. • 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 home sensor, PL 11.56 Item 4, the flag, PL 11.56 Item 7 and the paddle motor assembly, PL 11.56 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). If necessary install new paddles, PL 11.56 Item 3. • 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 11.64. • 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 11.72. • Inspect the four spring loaded guides on the output cover, PL 11.56 Item 9. Ensure that they are correctly located and are free to move up and down.