• The following guide provides possible solutions to operating problems that may arise. It is not intended to provide a complete solution to all the possible problems shown, but should be used in conjunction with advice on curative action from your local service team. For a description of all error codes, see the 'Advanced Troubleshooting Guide'.

    To assist in identification of modules referred to, see the 'Module Identification Guide'.

  • Note

    If persistent operating problems are occurring clean all sensors before taking further action (see Vertical Stacker).

  • PROBLEM POSSIBLE SOLUTION / ACTION
    Envelopes and Insert Area

    1. Poor pick-up of envelopes. a) Side guides too tight - set to 1mm free play each side.

    b) Separator shield set too far back (to adjust, see items Separator Wear and Gap Adjust of Fine tuning of settings).

    c) Clean envelope pick-up rollers.
    2. Flaps not opening. a) Ensure envelope stack is angled back in hopper, not upright.

    b) Separator is set slightly too tight.

    c) Clean envelope opener conveyor belts.

    d) Clean envelope pickup rollers.

    e) Ensure conveyor cover is fully closed.
    3. Fingers not inserting properly. a) Angle of fingers may need adjusting - slacken lock screw to adjust.

    b) Check outer fingers are narrower than envelope by 9 - 10mm each side but must be wider than insert - reduce side clearance if necessary.
    4. Envelope skewed at insert. a) Check side guide clearance - should be 1mm free play each side.

    b) Check software for correct envelope size (see the section "Selecting the envelope" of Defining the mailset).
    5. Inserts not arriving at insert area. a) Side guides too tight - set to 1mm free play each side.

    b) Increase envelope depth in software (see Creating an Envelope).
    6. Inserts coming out of envelope when leaving insert area. a) Metal tape underneath kicker needs angling downwards - contact Service Department.
    7. Filled envelopes crashing at turnover eject (underneath turnover). a) Check turnover belts are not misplaced.

    b) Check looped plastic tapes at eject area are not broken.
    8. Filled envelope failing to leave insert area. a) Wetter roller not fully lowered.

    b) Carrier on wetter conveyor not fully seated.
    Hi-Cap or Std-Cap Feeder

    1. Paper not picking up or not feeding properly. a) Side guides too tight - set to 1mm free play each side (check from top to bottom - note guides are also adjustable for angularity.

    b) Check paper stack is pushed fully forward.

    c) Feed rollers dirty, especially pickup rollers.

    d) Separator is set too tight (to adjust, see items Separator Wear and Gap Adjust of Fine tuning of settings).

    e) Sensors in feed area blocked or dirty.

    f) Ensure stationery is correctly loaded on printer prior to use, ie. prime side must be printed.
    2. Doubles or stream-feeding occurring. a) Check correct document information is being used in Documents and Configuration.

    b) Separator gap too large. c) Feed rollers dirty, especially pickup rollers.

    d) Check side guides and paper stack (see a) & b) in problem 1).

    e) Let stationery settle for 24 hours near to  machine before use.

    f) Check relative humidity - should be 30 - 80%.
    3. Feed overrun. a) Pivoting feed roller carrier left in raised position - lower it.

    b) Paper stack support tray is lopsided - contact Service Department.
    4. “Hi-cap overrun” error message appearing on screen. a) Uneven paper stack (one side higher than the other) - may be caused by uneven ink/toner laydown. Reduce stack to 250 sheets.

    b) Paper tray tilted due to stretched chains - contact Service Department.
    Collator

    1. Paper not arriving at OMR/Barcode  area. a) Hi/Lo-Cap feeder separator gap too tight - fine-adjust from Run screen.

    b) Sensors obscured - clean on both Hi/Lo-Cap and collator.

    c) Roller carrier plate at Hi/Lo-Cap feed area not properly latched down.

    d) Black conveyor belt carriers under reader head are raised - fully lower them.
    2. Paper not arriving at collator holdpoints. a) Improper location of 2 spring-loaded shafts with white nylon rollers - also check drive pins are present.

    b) Main collator conveyors not fully latched down.

    c) Side guides on lower conveyor incorrectly set - adjust using green knob on RH side.
    3. Paper crashing at entry to collate pocket (under lower conveyor). a) Collate pocket incorrectly set for paper size (eg. Letter setting but A4 paper) - check document setup.

    b) Collate pocket side guides incorrectly set - adjust using green knob on RH side.
    4. Paper crashing at exit from collate pocket. a) Collator not fully latched to main machine.

    b) Document trapped between collator exit and main machine - unlatch and withdraw to check.

    c) Paper excessively curled - restack and check printer (may be running too hot).
    5."Collate pocket exit jam" or "Form not arrived at collate exit" error message on screen. a) Paper not central in collate pocket - adjust side guides so that trailing edge gives 1 - 2mm clearance each side. Open collate conveyor to adjust.

    b) Feed in one sheet, open collate conveyor and measure clearance.

    c) Steel balls restricting entry - contact Service Department to remove one or more symmetrically.
    Folder  
    1. Paper not folding correctly. a) Dirty fold rollers - clean with damp cloth

    b) Fold plates incorrectly set - check settings in Document and Configuration screens.

    c) Change standard fold type (eg. C instead of Z) or use custom fold.

    d) Check fold plates are fully latched.
    2. Paper not exiting from folder correctly. a) Paper caught behind shuttle bed - raise shuttle to reveal. Clean four exit rollers at far edge of shuttle bed.

    b) Loose ribbon cable connector at front of shuttle.

    c) Metal output tapes on folder exit are incorrectly set.

    d) Insert track overguide incorrectly set (located above track cassette).
    Insert Track

    1. Shuttle stalling. a) Loose ribbon cable connector at front of shuttle.

    b) Metal tapes underneath shuttle incorrectly set.

    c) Shuttle pawls need resetting - manually pull round a few centimetres.
    2. Paper crashing on insert track. a) Insert track overguide incorrectly set (located above track cassette).

    b) Folded document wrong size for track - check settings in Document screen, particularly if custom fold.

    c) Dirty sensors in insert track or shuttle area - clean. d) Manually check that insert track pawls can be moved.
    3. Insert track stall (reported on screen). a) Remove all documents from track, upstream and downstream, and press Process one cycle button (see The Run Screen displayed).

    b) Check shuttle bed underneath shuttle is fully lowered.
    Feeder  
    1. Feeder not picking up. a) Side guides too tight - set to 1mm free play each side.

    b) Ensure envelope stack is angled back in hopper, not upright.

    c) Dirty or glazed feed rollers - clean.

    d) Separator is set slightly too tight - fine adjust from Run screen.

    e) Check separator shield setting (if feed is slow, increase shield) - adjust in document inserter from Run screen (see items Separator Wear and Gap Adjust of Fine tuning of settings).

    f) Dirty sensors on feeder - clean.

    g) Run with inserts opposite way round or inverted.

    h) Check springloaded shaft with pickup rollers is properly located. Also check pivoting roller plate in front of this is fully latched.
    2. Doubles being fed, or stream feeding. a) Check correct document information is set in Configuration and Job screens.

    b) Separator is set slightly too wide - fine adjust from Run screen.

    c) Dirty separator rollers - clean.

    d) Separator needs recalibrating - perform this in document inserter from Run screen (see items Separator Wear and Gap Adjust of Fine tuning of settings).
    3. Inserts crashing on exit of feeder. a) Paper caught behind shuttle bed - raise shuttle to reveal. Clean conveyor belts on feeder interface.

    b) Loose ribbon cable connector at front of shuttle.

    c) Run with inserts opposite way round or inverted.

    d) Feeder output tapes (at far end of shuttle) incorrectly set.
Date created:
03/05/2018 08:56:34
Last updated:
03/07/2018 07:43:41
Product(range):
DS-1200 G4i
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