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Xerox 5915, Service Manual

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Xerox 5915 Service Manual Download Page 118

6-8

Section 6  General

6.5  Installation/ Removal

6.5.2   Removal

Removal as described in this Manual applies to
field clearance activity only

Perform the removal procedure in the reverse order
of installation.
Customer Service Engineers should check the final
destination of the machine prior to field clearance.

For  removal, the following are required:
1. Category Check List
2. Sticker indicating M/C destination
3. Installation Procedure
4. Packaging Tapes and Clothes
5. Plastic Bag (Drum Cover)

Removal Procedure

1. Check if any consumable or wear parts require

 replacement by referring to the service record
 card. (See the “Trim” section of the Manual.)

Note

:  If any parts are installed wrongly, correct,

           before removal.
2. If any adjustment has been made based on

 the customers desire, put it back to the original
 status.

3. Perform Trim operation and clean inside of the

 machine.

4. Turn on the power, make copies, and check

 copy quality, paper feed and copy count.

5. Switch off the machine and unplug the power

 cord.

6. Remove paper from the Paper Tray.
7. Remove the Copy Output Tray.
8. Remove the Tray Module and unplug the

 connector from the Main Processor.

9. Clean the machine surroundings.
10. Enter relevant data in the service record card

 and store it along with the Category Check
 List.

11. Affix the return delivery sticker on the Top

Cover.

12. Place the Drum Cover for consumables on

 the Platen Cover.

13. Log in the Service Report.

Summary of Contents for 5915

Page 1: ...XEROX 5915 SERVICE MANUAL Issued by Overseas Technical Group Xerox of Shanghai Limited 7th July 200 ...

Page 2: ... a replacement page containing changes modifications burn it or take the necessary action including cutting by a shredder Be careful of handing the manual to avoid missing or damaging it Issued JUNE 2000 Revision and Modification Information When design changes or revisions relating to this service manual occur overseas technical information or overseas service bulletins may be issued as supplemen...

Page 3: ...iring connectors list Wiring connectors positions PWBS reference materials Section 8 Information of Related Products Not to be issued as the 5915 is unique Section 9 Block Schematic Diagrams BSD This section contains the following Block Schematic Diagrams BSD of Chains 1 to 9 and other wiring information on the XEROX 5915 Chain 1 STANDBY POWER Chain 2 MODE SELECTION MACHINE RUN CONTROL START PRINT...

Page 4: ...Section 1 Service Procedure ...

Page 5: ...1 2 Other precautions 1 2 1 2 Work Process When Making Calls 1 2 1 3 Detailed Explanation of Work When Making Calls 1 3 1 3 1 What to do first 1 3 1 3 2 Check for repeatability of the problem 1 3 1 3 3 Check the image quality 1 3 1 3 4 Feed Counter Check 1 3 1 3 5 Paper Jam Status Check 1 4 1 3 6 TRIM 1 4 ...

Page 6: ...1 2 Section 1 Service Procedure 1 1 Precautions Intentional bank page ...

Page 7: ...cy Service Items H F S I requiring attention 8 Verify and classify the fault Use the information obtained in the previous steps to determine the cause of the fault If the previous steps do not determine the fault fully exercise the copier utilising all options until the fault is determined 9 Plan the call Using the information noted in previous steps structure the call Check all H F S I required a...

Page 8: ... the overall M C operation before work Check on paper feeding copy quality abnormal noise etc 2 Clean Platen Glass top bottom surfaces Platen Cushion and Mirrors Clean Platen Glass top bottom surfaces with silicon cloth and lens cleaning liquid Clean Platen Cushion with wet cloth Clean Mirrors 1 4 and Lamp Reflector with optics cleaning cloth 3 Clean Transfer Detach Pre transfer Corotrons Clean Wi...

Page 9: ...Section 2 Troubleshooting ...

Page 10: ...Mode 2 4 2 2 2 Entries of Chain Codes Function Codes Set Values 2 4 2 2 3 How to Exit Diagnostic C E Mode 2 4 2 2 4 Diagnostic Functions and Operating Procedures 2 4 2 3 Level 1 Troubleshooting 2 3 1 Level 1 FIP 2 12 2 3 2 Chart of Jam Status Codes 2 13 2 3 3 A List of Status Codes 2 15 2 4 Level 2 Troubleshooting 2 4 1 General FIPs 2 16 2 4 2 U Code F I P s 2 19 2 4 3 Misfeed Jams 2 25 ...

Page 11: ...XX appears when the machine discovers a problem This XX is called Status Code Actuate Mechanically press or release the Switch Actuator or the linking Mechanical Linkage Block Place a document or a sheet of paper against the Photo Sensor to make the Sensor detect one Check Visually Check parts such as the Relay or Mechanical Linkage for its proper operation or check to see if parts are defective E...

Page 12: ...2 3 Section 2 Troubleshooting Intentional blank page ...

Page 13: ... press the Stop Clear button once during the check the Function Code Entry awaiting status is initiated while you press it twice the Chain Code Entry awaiting status is initiated A D Input Check Function This displays the input voltage level from the Sensor with a digital value Procedure 1 Enter Diagnostic C E Mode 2 Enter the Chain Code for a part to be checked and press the Start button 3 Enter ...

Page 14: ...k Switch H L 5 2 1 Console Button 1 2 3 10 Option Set H L 2 11 Option Start H L 2 12 Option Stop H L 2 6 1 Lens Sensor H L 3 2 Optical Regi Sensor H L 3 8 Exposure Monitor Signal A D 3 17 Fuser Thermistor A D 7 18 Fuser Thermistor Open Circuit A D 7 7 1 Tray 1 Size Sensor H L 5 6 Tray 1 No Paper Sensor H L 5 10 MSI No Paper Sensor H L 5 8 8 Regi Gate Sensor H L 5 9 Fuser Exit Switch H L 7 10 MSI S...

Page 15: ...rt button The designated part starts operating 4 When you operate parts simultaneously enter the Function Codes for the parts you will operate successively Press the Start button 5 When you stop operating a part simultaneously press the Stop Clear button When parts are operating stop them simultaneously The following parts stop automatically after respective specified periods of time All Solenoids...

Page 16: ...rase Lamp 2 7 6 3 Lamp Carriage Motor Scan 1sec 3 4 Lamp Carriage Motor Return 1sec 3 7 Exposure Lamp Erase Lamp 30sec 2 3 7 8 1 Main Motor Erase Lamp 2 7 2 Tray 1 Feed Solenoid 5 6 Regi Gate Solenoid 5 7 MSI Feed Clutch 5 9 1 Main Motor Erase Lamp 2 7 2 DEVE Bias 7 3 ISIL 7 10 1 Optical Cooling Fan Motor 3 4 Fuser fan Motor 7 ...

Page 17: ...lue has been changed to the new one 5 When you press the Stop Clear button once the Function Code Entry awaiting status is initiated while you press it twice the Chain Code Entry awaiting status is initiated NVM Initialization 20 96 Function This initializes all NVM contents Procedure 1 Enter Diagnostic C E Mode 2 Enter Chain Code 20 and Function Code 96 Press the Start button The Quantity is disp...

Page 18: ...27mm 32 64 8 27mm 0 2584mm 11 Registration Adjustment MSI 16 4 13mm 32 64 4 13mm 0 2564mm 14 Selection of Exposure Photoreceptor Sensitivity Correction 0 OFF 1 ON 1 ON 16 Bias Curve Selection 1 0 4 8 17 Bias Curve Selection 2 0 slot 1 Flat 1 Flat 20 Exposure Lamp Adj 0 50 99 5 1 4 23 Drum Photoreceptor Sensitivity Correction Constant 0 0 11 1 1 40 4 0 0 1 30 Fuser Temperature Adjustment Stand by 0...

Page 19: ...tion This counts Original Paper Jams and display their counts for every component where they occur Procedure 1 Enter Diagnostic C E Mode 2 Enter Chain Code 40 and press the Start button 3 Enter the Function Code for the counter to be checked Press the Start button The counter value is displayed on the Quantity Display 5 To exit this mode press the Stop Clear button twice NOTE Counter Value is coun...

Page 20: ...enter Diagnostic C E Mode 2 Enter Chain Code 50 and press the Start button 3 Enter Function Code 21 and press the Start button The Quantity Display displays Ed indicating the clearance is complete 4 Close the Front Interlock 5 Set the power to OFF ON CHAIN CODE FUNCTION CODE SETUP ITEM SET VALUE CONTENT EXPLANATION 0 inhibit 50 1 Toner Touch Up Function 1 execute Only when the new Drum unit is ins...

Page 21: ...2 12 Section 2 Troubleshooting 2 3 Level1 Troubleshooting 2 3 Level 1 Troubleshooting 2 3 1 Level 1 F I P ...

Page 22: ...ooting Section 2 Troubleshooting 2 3 2 Chart of JAM Status Codes Machine E1 1 E1 2 C1 3 C1 2 E3 3 E3 6 E1 6 C9 3 OFF CHECK JAM OFF CHECK JAM STATIC JAM STATIC JAM MSI MISS FEED JAM ON CHECK JAM TRAY 1 REGI GATE SNR FUSER EXIT SW ...

Page 23: ...ens i e Lens starts moving Refer to the U Code F I P 3 U4 1 FUSER THERMISTOR OPEN FAIL Open or defective circuit of Fuser Thermistor Refer to the U Code F I P 5 U4 2 FUSER WARM UP FAIL Fuser Ready is not initiated within 1 min After the power is on or Front interlock Switch is turned OFF ON Refer to the U Code F I P 5 U4 3 FUSER OVER HEAT FAIL 1 Heater Rod has been on for 10 sec or more after Fuse...

Page 24: ...end condition Supply toner Check the Toner Empty Sensor circuit 5 J1 2 TONER LIFE END The counter value of toner unit reaches the default value 7700 Replace the Toner Cartridge 5 J3 1 DRUM UNIT SET FAIL Drum unit is not set or is set incorrectly to the machine Ensure to install the Drum Unit to the machine properly 5 J3 2 Toner Cartridge SET FAIL Toner unit is not set or is set incorrectly to the ...

Page 25: ...e the Sensor Check to see if the document detecting position on Platen Glass is contaminated If not replace the PWB Check outer light check the sensor for its installation and signal chattering If no problem exists replace the PWB Permeable Sensor F I P SENSOR H OTHER SENSORs with 3 Wiring Preparation Remove any remaining paper if there is any Procedure Enter Diag Make Actuator turn ON OFF manuall...

Page 26: ...s replace the Switch Check the Panel etc for end play or recheck Switch Leads 1 2 If no problem exists replace PWB Solenoid Clutch Motor F I P 1 Solenoid or Clutch doesn t energize Motor doesn t rotate Procedure Enter Diag NOTE All you have to do here is enter Diag Don t start Is the voltage from Pin 3 of PWB to COM 24VDC Y N Is the voltage from Pin 1 of Solenoid Clutch Motor to GND 24VDC Y N Is t...

Page 27: ...Switch Check the Panel etc for end play or recheck Switch Leads 1 2 If no problem exists replace PWB Solenoid Clutch Motor F I P 1 Solenoid or Clutch doesn t energize Motor doesn t rotate Procedure Enter Diag NOTE All you have to do here is enter Diag Don t start Is the voltage from Pin 3 of PWB to COM 24VDC Y N Is the voltage from Pin 1 of Solenoid Clutch Motor to GND 24VDC Y N Is the voltage fro...

Page 28: ...necessary Fuser Assy PL8 4 Regi Roller Gear PL2 7 Slide out the Drum Unit and restart the Main Motor Do abnormal noises occur or does the Main Motor rotate irregularly Y N Check the Drum Unit for its drive mechanics If any load or abnormal noise exists replace the Drum Unit WARNING Power off the machine and disconnect the power cord Check the mechanics Gear Bearing etc of the following and replace...

Page 29: ...d press the start button Does the Lamp Carriage return Y N Replace the Main PWB Using the Permeable Sensor F I P General F I P and the wiring diagram perform the diagnosis of Optical Regi Sensor If no problem exists replace the Main PWB U3 1 LENS POSITION FAIL Ref BSD 3 Preparation Ensure that the following connectors are securely connected P J405 of Main PWB Relay Connector P J604 of Lens Motor R...

Page 30: ...r off the machine and disconnect the power cord WARNING Fuser surfaces are hot allow the fuser to cool down before attempting service procedure Fuser lubricant can cause discomfort to eyes Do not allow fuser lubricant to touch eyes Remove the Fuser Cover Is there continuity between the Fuser Thermostat leads Y N Press the Manual Reset button of the Fuser Thermostat Is there continuity between the ...

Page 31: ...f Fuser Does the level between P J410 12 to COM remain low L Y N WARNING Power off the machine and disconnect the power cord WARNING Fuser surfaces are hot allow the fuser to cool down before attempting service procedure Fuser lubricant can cause discomfort to eyes Do not allow fuser lubricant to touch eyes Disconnect P J14 Check the circuit continuity from T111 to T110 AC DRIVER Y N Check the fol...

Page 32: ...requencies around the installation site Ensure that no high voltage wires such as the Corotron have burnt out or have leakage Procedure Power OFF ON Has the display of Status Code disappeared Y N Enter Diag C E Mode Enter 20 96 and press the Start button Power OFF ON Has the display of Status Code disappeared Y N Replace the Main PWB Make copies Confirm that the machine operates properly and monit...

Page 33: ...he start signal of the INTLK Power Relay Is the level from P J410 11 to com 0v Y N Replace the Main PWB Check the wire from P J430 4 of AC DRIVER to P J410 11 of Main PWB for an open circuit short circuit or improper connection If no problem exists replace the Main PWB Replace the Main PWB U8 4 EXPOSURE VOLTAGE OVER FAIL Ref BSD 3 Problem Area Light Quantity Voltage Control Optics Procedure check ...

Page 34: ...nch Roller Check them for the deterioration Y N Did the lead edge of paper reach the Regi Gate Y N Replace the Feed Roller Clean the paper path Check the Regi Gate sensor Enter 8 8 check the level from P J407 8 to com does it go high H and go low L If no change is the voltage from P J600 1 to P J600 3 5VDC Y N Check the 5VDC circuit Replace the Regi Gate Sensor Replace the Feed Roller Clean the pa...

Page 35: ...Section 4 Disassembly Assembly Adjustment ...

Page 36: ...acement 4 22 5 Xerographic 5 1 1 Drum Unit Replacement 4 23 5 1 2 Drum Finger Replacement 4 23 5 1 3 Charge Corotron Wire Replacement 4 24 5 1 4 Basic Copy Quality Adjustment 4 24 5 1 5 ISIL Assembly Replacement 4 26 5 1 6 ISIL Copy Edge Erase Amount Adjustment 4 26 6 Development 6 2 1 Deve Unit Removal Installation 4 27 6 2 2 Mag Roll Blade Replacement 4 27 6 2 3 Toner Empty Sensor Replacement 4 ...

Page 37: ...4 2 Section 4 Disassembly Assembly Adjustment Intentional blank page ...

Page 38: ...urpose To adjust the position of the Cassette Tray to align the document image transferred onto the Drum with paper in the Drum axis direction Reference The Tray positions in front rear directions are each adjustable by 2mm 4mm in total Adjustment 1 Slide out the Cassette Tray from the machine 2 Fig 1 Perform the Side Registration Adjustment as follows NOTE The Right Left Stoppers should be moved ...

Page 39: ...ove Screw Remove MSI Feeder Assembly Fig 2 Installation 1 Perform the installation in the reverse order of removal 2 2 2 MSI Retard Pad Replacement NOTE You should replace the Retard Pad the Feed Roller 2 3 2 You should clear the Feed Counter in Diag Mode 30 4 Removal 1 WARNING Power off the machine and disconnect the power cord 2 Remove the MSI Feeder Assembly 2 2 1 3 Fig 1 Remove the Tie Plate A...

Page 40: ...oval 1 WARNING Power off the machine and disconnect the power cord 2 Remove the MSI Feeder Assembly 2 2 1 3 Fig 1 Remove the MSI Size Sensor Disconnect P J110 Remove Size Sensor Remove Size Sensor Actuator Fig 1 Installation 1 Perform the installation in the reverse order of removal 2 Perform an Input Check of the MSI Size Sensor in Diag Mode 8 10 2 3 4 MSI No Paper Sensor Replacement Removal 1 WA...

Page 41: ...nsport Cover Remove Screw Push Transport Cover to rear side Remove Transport Cover by sliding away Pin on its front side Fig 1 4 Fig 2 Remove the Chute Remove Chute from Pins by pulling its rear side Slide Chute to rear and remove it Fig 2 5 Fig 3 Remove the Feeder Assy Disconnect P J610 Tray 1 and the Ground wire Remove Screws 2 Wire Guard disengages together Lift No Paper Sensor Actuator manuall...

Page 42: ...llation 1 Perform the installation in the reverse order of removal NOTE Fig 7 Install the Feeder Assy to the machine with the Feed Roller half moon shaped facing upwards Fig 7 When installing the Feeder Assembly to the machine take great care not to damage the No Paper Sensor Actuator Fig 8 Install the Feeder Assy to the machine with the Assy cutouts hooked on the machine pins Fig 8 Reconfirm that...

Page 43: ... 2 Open the Transport Cover 3 Remove the Transport Cover Remove Screw Push Transport Cover to rear side Remove Transport Cover by sliding away Pin on its front side Fig 1 4 Fig 2 Remove Transport Cover INTLK Switch Push up the hook that fixes INTLK Switch Slide out INTLK switch then disconnect Fig 2 Installation 1 Perform the installation in the reverse order of removal 2 1 1 2 ...

Page 44: ...allation 1 Perform the installation in the reverse order of the removal 2 5 6 TRAY 1 Switch Adjustment Purpose To prevent the Tray from hitting the Tray Switch as deformation of the Switch Actuator will lead to poor contact 1 WARNING Power off the machine and disconnect the power cord 2 Remove the Rear Lower Cover 3 Remover the LVPS 9 1 3 4 Fig 1 Loosen two fixing screws of Tray 1 Switch Bracket F...

Page 45: ... Chute Assy Fig 1 8 Fig 2 Remove the Registration Assy Disconnect P J116 for Regi Sensor P J214 for Regi Gate Solenoid Remove Screws 2 Remove Registration Assy Fig 2 Installation 1 Reinstall the Registration Assy by reversing Step 8 Removal 2 Restore the machine to its original state in the reverse order of the removal 2 7 2 Registration Gate Solenoid Replacement 2 7 3 Regi Gate Sensor Replacement...

Page 46: ...he lead edge of paper Check 1 In 100 Mode align Test Chart 499T247 or 248 with Regi Guide and make a copy 2 Fig 1 Check that there is 10 1 6mm from the copy s lead edge to the reference line Fig 1 Adjustment Fast Paper Feed The distance is more than 10 1 6mm from the copy s lead edge to the reference line 1 Key in Diag 20 1 2 Increase data NOTE Changing the data by 1 will change the distance by 0 ...

Page 47: ...ew Remove Main Switch Cover Fig 1 7 Fig 2 Remove AC DRIVE PWB Remove Screw Remove AC Drive PWB Cover Disconnect the plug and remove AC Drive PWB Fig 2 8 Fig 3 Remove the Vacuum Transport Assembly Remove Screw Remove Vacuum Transport Assy NOTE Pushing the rear pin with a screw driver as shown in Fig 3 makes it easier to remove Fig 3 9 Fig 4 Remove the Transport Belt Remove E Clip and then Bearing S...

Page 48: ...1 Perform the installation in the reverse order of removal 4 1 2 Optical Cooling Fan Replacement Removal 1 Power off the machine and disconnect the Power Plug 2 Remove the Left Upper Rear Upper Covers 3 Fig 1 Remove the Optical Cooling Fan Disconnect P J408 Remove Screws 2 Remove Optical Cooling Fan Fig 1 Installation 1 Perform the installation in the reverse order of removal Reference This Fan co...

Page 49: ...e Regi Sensor Disconnect P J100 Fig 2 Installation 1 Perform the installation in the reverse order of removal NOTE While pushing the Regi Sensor toward the lower right to eliminate end play tighten the Screw 4 2 2 Lamp Carriage Motor Replacement Removal 1 Power off the machine and disconnect the Power Plug 2 Remove Rear Upper Covers 3 Fig 1 Remove Lamp Carriage Motor Disconnect P J605 Remove Screw...

Page 50: ...arriage NOTE When replacing the Rear Cable remove the Optical Cooling Fan 4 1 2 Fig 2 8 Fig 3 To make the rest of this procedure easier gently move the Full Rate Carriage up to the frame cutout NOTE Move the Carriage by holding at the rear keeping it perpendicular to the frame because its front is not fixed to the Cable Fig 3 9 Fig 4 Remove the Cable from the spring and then the whole Cable from t...

Page 51: ...y Check that the copy exhibits no optical skew etc 4 3 1 Full Rate Half Rate Carriages Parallel Adjustment Purpose To set the Carriages parallel so that the Front Rear Light Paths are the same in length NOTE This adjustment should be performed when the following problem occurs or after the work is complete 1 Optical Skew Skewed image 2 Carriage Cable Removal Installation 4 2 3 Check 1 Power off th...

Page 52: ...pstan Pulley Adjust by rotating Capstan Pulley or Shaft NOTE Do not remove Screw for Rear Capstan Pulley Tighten Screws 2 Reference The standard tightening Torque is 0 5N m 5kgf cm Fig 4 2 Fig 5 Remove the end play in the Drive Shaft axis direction and tighten the screws for the Capstan Pulley Insert 0 5mm Thickness Gauge between Capstan Pulley and Bearing Push Capstan Pulley to front and Shaft to...

Page 53: ...k that the Lamp is on 3 Perform the Basic Copy Quality Adjustment 5 1 4 4 3 3 Optical Skew Adjustment Purpose To correct the optical image skew in the Drum axis and paper feed directions NOTE Ensure that the following are functioning correctly 1 Paper is fed properly a There is no difference in skew level between Trays b There is no difference in skew level between continuously made copies 2 The R...

Page 54: ...e Platen Glass 4 1 1 3 Remove the Right Upper Cover 4 Fig 3 Move the Half Rate Carriage holding it at its front NOTE Do not move the Carriage right and left more than 2mm otherwise there could occur problems such as poor resolution and the Carriage slamming on the frame Loosen Front Capstan Pulley screws 2 Fig 3 To adjust move the Half Rate Carriage by rotating the Capstan Pulley NOTE Do not remov...

Page 55: ...ment Removal 1 Select 100 Magnification After the Lens stops power off the machine and disconnect the Power Plug 2 Open the Platen Cover and remove the Platen Glass 4 1 1 3 Fig 1 Remove the Optical Shield Loosen Screws 2 Raise the rear side of Mirror Carriage and remove Optical Shield Fig 1 4 Fig 2 Remove the Lens Carriage Shield Remove Screw Remove Lens Carriage Shield NOTE Take care not to break...

Page 56: ...e form its ball to the Pulley then hook it on the Lens Carriage with the spring Fig 7 5 Remove the tape fixing the Lens Carriage and route the Cable to the Pulley A 6 Power on the machine Check that the Lens Carriage timing hole aligns with the Rail timing hole Step 5 Removal when the Lens is set to 100 If the holes don t align with each other check the installation procedure again Check in partic...

Page 57: ...1 9 Fig 2 Disconnect Connector P J604 from the Lens Motor Fig 2 10 Remove the Motor wire from each Cable clamp 11 Fig 3 To fix the Mirror Carriage position at 100 insert the Phillips Screwdriver through the Worm Wheel timing hole to the frame timing hole The screwdriver goes through the frame hole Fig 3 12 Fig 4 Remove the Gear Remove E Clip Remove Gear Fig 4 13 Fig 5 Remove the Lens Motor Remove ...

Page 58: ... 50 000 c Drum Cartridge Unit Replacement Display Remaining Copy Output Qty Drum Cartridge Replacement Display Status Code Copy 5 000 ON Possible 500 Flash Possible 0 Flash continuously J7 1 Not possible When the cartridge reaches the end of its service life the Replace copy cartridge lamp flashes and the Copy Quantity display shows J7 d Remaining Copy Output Qty The remaining copy output quantity...

Page 59: ...riginal NOTE Copy Quality Adjustment should be performed when copy quality problems occur or the following are replaced Drum Unit Replacement 5 1 1 Exposure Lamp Replacement 4 3 2 Main PWB Replacement 9 1 2 NOTE Perform TRIM before making the Copy Quality Adjustment Adjustment Flow 5 1 4 A Exposure Light Quantity Setup Purpose To adjust light quantities applicable to each magnification and store t...

Page 60: ...on 6 to decrease the Exposure b Button 9 to increase the Exposure 4 While making the copies adjust the exposure so that the 20 gray lines are reproduced clearly and the 10 gray lines disappear 5 When the correct setting has been achieved press the Start button and make three straight copies 6 Repeat Steps 3 4 5 until the results satisfy the spec in Step 5 Check 7 When the reproduced copies meet th...

Page 61: ...hird copy 2 Fig 1 Check the erase amount 4mm along lead trail edges 4mm or less at rear NOTE Front Side Edge Amount is set up by moving the Front Shield Cover of the Charge Corotron Fig 1 Adjustment Lead Edge 1 Enter Diag Mode and key in 20 4 2 The current set value appears 3 Key in a new set value and press the Start button Increase the value The erase amount decreases Decrease the value The eras...

Page 62: ...Mag Roll Blade otherwise a large quantity of toner will be spilled Remove Screws 5 Remove Upper Cover Remove Screws 2 Remove Mag Roll Blade Fig 1 Installation 1 Perform the installation in the reverse order of removal Pay attention to the following NOTE Ensure that the Blade and the Mag Roll have no foreign objects on their surfaces Install the Blade flat Fig 2 After the assembly ensure that there...

Page 63: ...achine 3 Remove the Drum Unit and place a black cover over it 5 1 1 4 Remove the Left Upper Cover 5 Fig 1 Remove the Main Switch Cover Remove Screw Remove Main Switch Cover Fig 1 6 Fig 2 Remove the Fuser Cover Loosen Screw Remove Fuser Cover Fig 2 Replacement Procedure for Thermostat only 7 Fig 3 Remove the Thermostat Remove Wire going to Thermostat Loosen Screws 2 and remove Sensor Bracket Remove...

Page 64: ... Front Cover and then the machine 3 Remove the Drum Unit and place a black bag over it 5 1 1 4 Remove the Left Rear Upper Covers 5 Fig 1 Remove the Main Switch Cover Remove Screw Remove Main Switch Cover Fig 1 6 Disconnect P J s 12 13 from the Heater Rod 7 Fig 2 Remove the Front Rear Heater Rod Covers each Loosen Screw Remove Front Rear Heater Rod Covers Fig 2 8 Fig 3 Remove the Heater Rod Loosen ...

Page 65: ...t Rear Upper Covers 5 Fig 1 Remove the Main Switch Cover Remove Screw Remove Main Switch Cover Fig 1 6 Fig 2 Disconnect P J117 for Fuser Exit Switch at rear Remove the Fuser Cover and the Finger Assy Disconnect P J117 Loosen Screw and Remove Fuser Cover Loosen Screw and Remove Finger Assy Fig 2 7 Fig 3 Remove the Sensor Bracket Loosen Screws 2 Remove Sensor Bracket Fig 3 8 Remove the Heater Rod 8 ...

Page 66: ...ser to cool down before attempting service procedure Fuser lubricant can cause discomfort to eyes Do not allow fuser lubricant to touch eyes 2 Open the Front Cover and then the machine 3 Remove the Heat Roller 8 2 2 4 Fig 1 Remove the Pressure Roller Finger Assy Remove Screw 2 Remove the Pressure Roller Finger Assy Fig 1 5 Fig 2 Remove the Pressure Roller Remove the Pressure Roller Finger Assy Fig...

Page 67: ...wn 4 Hold the measurement paper so that it copy reaches the Heat Roll the Pressure Roll 5 Take out the measurement paper after closing the machine for approx 8 10 seconds 6 Fig 2 Open the measurement paper gently Take measurements at the positions 75 mm from the both sides of the paper respectively at two positions on the fold made when the paper is folded into quarters with its lead edge aligning...

Page 68: ... Finger Assy Disconnect P J117 Loosen Screw and remove Fuser Cover Loosen Screw and remove Finger Assy Fig 2 Replacement Procedure for Heat Roller Fingers only 5 Fig 3 Remove the Heat Roller Fingers Remove Screws 4 Remove KL Clips 2 Remove Heat Roller Fingers along with their shafts Fig 3 Installation 1 Perform the installation in the reverse order of removal NOTE Fig 4 When installing the Shaft t...

Page 69: ...r Assy Loosen Screws enough Remove Screw Fig 1 8 Fig 2 Remove the Fuser Fan Motor Assy Disconnect P J409 from Main PWB Remove Fuser Fan Motor Assy Fig 2 Installation 1 Perform the installation in the reverse order of removal CAUTION Put the shock absorber of the Fan Motor Assy against the Ozone Filter securely 8 5 2 Ozone Filter Fuser Fan Replacement Removal 1 WARNING Power off the machine and dis...

Page 70: ...the Rear Upper Cover 6 Disconnect all connectors from the Main PWB 7 Fig 1 Remove the Main PWB Fig 1 Installation 1 Install the Main PWB 2 Fig 2 Perform the Dip Switch SW2 Setup 3 Enter Diag Mode and key in 20 96 Perform the initialization NOTE The initialization is required because the new Main PWB s NVM values are unstable Items to be Initialized Set the initial value in each item of Reference C...

Page 71: ... Paper Loop Amount Adjustment 0 8 27mm 32 64 8 27mm 0 2584mm 11 MSI Registration Adjustment 16 4 13mm 32 48 4 13mm 0 2584mm 14 Selection of Exposure Photoreceptor Sensitivity Correction 0 OFF 1 ON 1 ON 16 Bias Curve Selection 1 0 4 8 17 Bias Curve Selection 2 0 slot 1 Flat 1 Flat 20 Light Quantity Adj 0 50 99 5 1 4 A 23 Drum Photoreceptor Sensitivity Correction Constant 0 0 11 1 1 40 4 0 0 1 30 Fu...

Page 72: ...2 Nation Configuration Setup 2 AP This supplements a lack of the exposure light quantity by the Deve Bias when it doesn t reach its target value 0 execute 1 execute 2 execute 4 Black Band Creation Function 3 inhibit Create a black band of Toner on the Drum to prevent Talc Deletion 0 No 6 Related Products L6 Detection 1 Yes This temporarily inhibits the detection of L6 when changes are made to spec...

Page 73: ...rews 2 Remove LVPS Fig 1 Installation 1 Perform the installation in the reverse order of removal 9 1 4 AC Drive PWB Replacement Removal 1 WARNING Power off the machine and disconnect the power cord 2 Remove the Rear Upper Covers 3 Fig 1 Remove AC Drive PWB Remove Screws 2 Remove AC Drive PWB Cover Disconnect all connectors from AC Drive PWB and Remove it Fig 1 Installation 1 Perform the installati...

Page 74: ...4 Installation 1 Perform the installation in the reverse order of removal 10 1 2 Rear Gas Spring Replacement Removal 1 Power off the machine and disconnect the Power Plug 2 Open the Front Cover and then machine 3 Fig 1 Set the Stopper under the Front Gas Spring Fig 1 4 Remove the Left Rear Upper Covers 5 Disconnect P J14 for Heater Rod P J117 for Fuser Exit Switch and P J118 for Fuser Thermistor f...

Page 75: ... Cover Removal Installation Removal 1 WARNING Power off the machine and disconnect the power cord 2 Remove the Platen Cover 3 Remove the Platen Glass 4 1 1 4 Remove the Console Assy 10 2 1 5 Remove the Drum Unit and place a black bag over it 5 1 1 6 Remove the Deve Unit 6 2 1 7 Disconnect P J200 from ISIL 8 Fig 1 Remove the Top Cover Remove Screws 4 Disconnect the following P J209 T64 T65 for Fron...

Page 76: ...Section 5 Parts List ...

Page 77: ...embly 5 13 4 2 Optical Drive 5 14 4 3 Full Rate Half Rate Carriage 5 15 4 4 Mirror Carriage 5 16 4 5 Lens Carriage 5 17 PL 5 XEROGRAPHIC 5 1 XERO Module Assembly 5 18 5 2 TC DTC Corotron 5 19 PL 6 DEVELOPMENT 6 1 Deve Mechanism 5 20 6 2 Deve Assembly 5 21 PL 8 FUSER 8 1 Inlet Chute Temperature Control 5 22 8 2 Heat Roller 5 23 8 3 Paper Exit 5 24 8 4 Upper Frame Receiving Tray 5 25 8 5 Fuser Fan M...

Page 78: ...XT 7 20E 21721 PULEY CAPSTAN 8 20E 22063 PULLEY CAPSTAN OUT 9 12E 93390 CABLE SCAN OUT 10 130E 80970 SENSOR REGI OPT 11 20K 94411 PULLEY IDLER METAL 12 FULL RATE ADJUST BLOCK REF ONLY 13 HALF RATE ADJUST BLOCK REF ONLY 14 6K 82301 SHAFT ASSY DRIVE 15 68S 50270 MOT SCAN ASSY WITH 16 18 16 127S 50222 MOT SCAN 17 68S 50269 BRKT MOT SCAN 18 7E 94981 GEAR 5 1 3 Symbols and Marks Symbols Marks With 2 10...

Page 79: ...210 DRUM GEAR 3 7E 35200 MAIN MOTOR GEAR 4 7E 27680 GEAR HELICAL T36 T41 5 SHAFT REF ONLY 6 BRACKET REF ONLY 7 7E 41270 GEAR T18 34 8 7E 41280 GEAR T22 9 9E 76500 SPRING EXTENSION 10 12E 97580 LINK ASSY 11 121E 84454 MSI SOLENOID ASSY 12 SADDLE REF ONLY 13 BRACKET 14 7E 27970 GEAR SPUR T35 28 15 7E 32890 GEAR T40 16 7E 28000 GEAR T21 ...

Page 80: ... T27 8 7E 22910 GEAR T37 23 9 WASHER REF ONLY 10 7E 33020 GEAR SPUR T25 11 GEAR BRACKET REF ONLY 12 7E 32450 GEAR T28 13 22E 83690 ROLLER 14 7E 32970 GEAR T18 32 15 7E 32951 GEAR HELICAL T19R 16 7E 33010 GEAR HELICAL T25 17 SUPPORT BRACKET REF ONLY 18 13E 92520 BEARING DRUM 19 EARTH PLATE REF ONLY 20 SCREW M3 8 REF ONLY 21 EARTH PLATE REF ONLY 22 SCREW REF ONLY 23 7E 32990 GEAR T23 24 7E 33000 GEA...

Page 81: ...IDE 6 49P 50212 PLATE BOTTOM 7 9P 50222 SPRING N F 8 9P 50221 SPRING N F 9 3P 63172 STOPPER 10 19P 50217 SNUBBER F 11 SPRING REF ONLY 12 12E 93400 LINK 13 TAPPING SCREW REF ONLY 14 50P 50237 CASSETTE 15 INSTRUCTION LABEL 16 38P 50217 GUIDE END 17 3E 30040 STOPPER CASSETTE 18 68K 85602 BRKT ASSY 19 9P 50213 SPRING Q C L C J Q 15 17 18 14 13 12 11 9 10 8 7 5 19 3 4 5 6 5 1 2 16 W I T H 2 19 I T E M7...

Page 82: ...mbly ITEM PART NO DESCRIPTION 1 22S 50256 MSI FEEDER ASSY WITH 2 5 SEE PL2 3 2 54E 09243 CHUTE MSI AP 220V 3 19S 50212 PAD ASSY RETARD 4 9E 78271 SPRING 5 19E 42170 FILM CHUTE 6 9E 78782 SPRING N F MSI 7 50S 50238 TRAY ASSY MSI 8 7E 32871 GEAR T29 28 9 7E 27521 GEAR SKEW T22 10 SUPPORT REF ONLY ...

Page 83: ...5620 GEAR PICK UP 2 13E 84520 BEARING 3 120E 13150 MSI ACTUATOR 4 107E 06650 MSI SIZE SENSOR 5 13E 84490 BEARING 6 22E 84350 ROLL CORE 7 120E 09921 ACTUATOR N P 8 107E 06650 SENSOR 9 FRONT BRACKET ASSY REF ONLY 10 REAR BRACKET ASSY REF ONLY 11 8E 93751 CAM PICK UP 12 6S 50220 SHAFT ASSY PICK UP 13 802E 05051 COVER ROLL ...

Page 84: ...ON 1 121E 83330 MAGNET CATCH 2 63P 50206 TAPE STOPPER 3 SCREW REF ONLY 4 54E 82040 CHUTE FEED 5 110P 50202 SWITCH SPOT MINIATURE 6 PLATE COVER REF ONLY 7 121E 83312 MAGNET CATCH 8 48P 50237 COVER R H 9 PLATE COVER REF ONLY 10 9P 50214 SPRING FRONT 11 9P 50215 SPRING BACK 12 22E 81851 ROLLER PINCH 13 22E 81861 ROLLER PINCH ...

Page 85: ...ROLL ASSY FEED 5 WASHER REF ONLY 6 7E 41593 GEAR PICK UP FEED 7 9E 76810 SPRING PICK UP 8 7E 41571 GEAR T28 9 3E 35531 STOPPER 10 13E 84490 BEARING 11 6P 50236 SHAFT FEED ROLL 12 9E 65960 SPRING 13 12E 97890 LINK SOL 14 121K 16860 SOLENOID ASSY 15 107E 06650 PHOTO INTERRUPT 16 120E 99400 ACTUATOR SNR 17 COVER REF ONLY 18 FRAME ASSY REF ONLY 19 7K 83521 DRIVE ASSY 20 7E 34950 GEAR IDLER T17 21 22P ...

Page 86: ... 08210 UPPER CHUTE ASSEMBLY WITH 2 12 2 TORSION SPRING 3 TORSION SPRING 4 13E 80030 BEARING 5 13E 93670 BEARING 6 HOOK REF ONLY 7 22K 49970 ROLL ASSY REGI PINCH 8 22K 47662 ROLL ASSY PRE REGI PINCH 9 32E 99342 CHUTE GUIDE 10 PINCH SUPPORT REF ONLY 11 CHUTE UP REF ONLY 12 FILM CHUTE REF ONLY 13 9E 65760 SPRING WITH 2 12 8 ...

Page 87: ... 2 15 2 7E 32360 GEAR T27 3 7E 32940 GEAR T18 4 13E 80030 BEARING 5 7E 32930 GEAR 18 6 13E 84520 BEARING 7 12K 93160 LINK STUD 8 9E 65810 SPRING 9 54E 08345 CHUTE LOW REGI 10 22K 47222 ROLL ASSY PRE REGI 11 50K 28751 GATE ASSY REGI 12 130K 56130 SENSOR REGI 13 22K 47211 ROLL ASSY REGI 14 121K 22340 SOLENOID ASSY 15 9E 65800 SPRING GATE 16 13E 84490 BEARING WITH 2 15 ...

Page 88: ... O ITEM 1 8 TUBE P O ITEM 1 9 20E 21860 WHEEL METAL 10 TUBE P O ITEM 1 11 WHEEL SUPPORT P O ITEM 1 12 SPACER P O ITEM 1 13 103K 80361 REGISTOR ASSY 14 1S 50286 FRAME ASSY TRANSPORT WITH15 21 15 22E 19430 ROLL IDLER 16 SHAFT P O ITEM 14 17 13E 84490 BEARING 18 VACUUM TRANSPORT ASSEMBLY P O ITEM 14 19 23E 12250 VACUUM TRANSPORT BELT 20 SHAFT P O ITEM 14 21 7E 32421 GEAR 24T 2 3 4 3 11 12 13 15 19 18...

Page 89: ...PART NO DESCRIPTION 1 90S 50209 GLASS ASSY PLATEN 2 15P 50249 PLATE GLASS 3 SCREW REF ONLY 4 57K 90521 SEAL GLASS 5 127S 50224 FAN ASSY OPT 6 55K 20881 SHIELD ASSY OPTIC 7 53E 91530 FILTER RIGHT 8 14P 61844 PLATEN SPACER 9 48E 17460 COVER GLASS SEAL 1 5 6 7 3 2 8 9 4 8 H A Q A Q ...

Page 90: ... 6 9P 20224 SPRING EXT 7 20E 21721 PULEY CAPSTAN 8 20E 22063 PULLEY CAPSTAN OUT 9 12E 93390 CABLE SCAN OUT 10 130E 80970 SENSOR REGI OPT 11 20K 94411 PULLEY IDLER METAL 12 FULL RATE ADJUST BLOCK REF ONLY 13 HALF RATE ADJUST BLOCK REF ONLY 14 6K 82301 SHAFT ASSY DRIVE 15 68S 50270 MOT SCAN ASSY WITH 16 18 16 127S 50222 MOT SCAN 17 68S 50269 BRKT MOT SCAN 18 7E 94981 GEAR 4 4 14 5 5 6 6 7 16 11 18 1...

Page 91: ...48E 20972 COVER CONTACT IN 3 108K 90710 FUSE ASSY EXP 4 9E 65820 SPRING FUSE 5 162K 12611 CABLE ASSY 6 122P 50201 LAMP HALOGEN 7 62E 93400 MIRROR 1 8 41S 50210 HALF RATE CARRIAGE ASSY WITH 2 7 9 HALF RATE CARRIAGE P O ITEM 8 10 20K 94441 CARRIAGE CABLE PULLEY 11 113E 16410 CORD PULLEY 12 MIRROR SPRING P O ITEM 8 13 62E 93420 NO 2 3 MIRROR WITH 2 7 WITH 9 13 ...

Page 92: ...N 1 NO 4 MIRROR ASSY REF ONLY 2 35E 30190 SEAL 3 9E 65650 SPRING NO 4 HSG 4 SHAFT REF ONLY 5 9E 65360 SPRING EXTENSION 6 ANGLE PLATE REF ONLY 7 9E 65610 SPRING 8 6E 57190 SHAFT CAM 9 20E 24480 WORM WHEEL 10 9E 65600 SPRING NO 4 SHAFT 11 15K 87900 WORM GEAR 11 10 10 8 7 5 4 2 3 1 6 9 AQ AQ R CH CH ...

Page 93: ... LENS MOTOR ASSY 3 SENSOR BRACKET REF ONLY 4 107E 06650 LENS SENSOR 5 LENS CARRIAGE SHIELD REF ONLY 6 9E 65630 SPRING EXTENSION 7 41K 93880 LENS CARRIAGE ASSY 8 9E 65460 SPRING EXTENSION 9 12E 93370 LENS CABLE 10 7E 32820 CABLE GEAR PULLEY 11 7E 32830 GEAR 24 50T 12 7E 32840 GEAR 24 32T 13 7E 32850 GEAR 48T 14 20E 21710 PULLEY IDLER ...

Page 94: ...0 FRONT INSULATOR BLOCK 8 55E 27391 FRONT ARC SHIELD 9 15K 34621 PLATE CRU ASSY 10 122S 50203 ISIL LAMP ASSY 11 9P 50220 SPRING COMPRESSION 12 9E 65710 SPRING 13 XERO MODULE 14 TAPPING SCREW REF ONLY 15 91E 71050 LABEL VOLTAGE REF ONLY 16 TONER SEAL REF ONLY 17 SPRING REF ONLY 18 19K 92822 FINGER ASSY 19 SPRING REF ONLY 20 19E 93200 DRUM FINGER 21 COOLING DUCT ERASELAMP SEE PL8 5 22 ID ASSY 19 20 ...

Page 95: ...0 13 14 2 55E 27650 REAR ARC SHIELD 3 55E 29550 FRONT ARC SHIELD 4 VOLTAGE LABEL 5 32E 05740 DTC GUIDE 6 9E 65900 WIRE SPRING 7 117K 19220 COROTRON WIRE 8 118K 91591 REAR INSULATOR BLOCK 9 118E 98610 FRONT INSULATOR BLOCK 10 TC TDC SHIELD P O ITEM 1 11 9E 65722 REAR TC DTC SPRING 12 9E 65732 FRONT TC DTC SPRING 13 55S 50204 EARTH SPRING 14 SCREW REF ONLY ...

Page 96: ...anism ITEM PART NO DESCRIPTION 1 1K 49781 DEVE RAIL ASSY WITH 2 5 2 1K 51861 RAIL ASSY 3 PLATE FRONT REF ONLY 4 PLATE REAR REF ONLY 5 9E 65630 SPRING 6 68K 11652 BRACKET SUPPORT ASSY 7 ROLL P O ITEM 6 8 STUD ROLL P O ITEM 6 9 48S 50267 DEVE ASSY SEE PL 6 2 10 TONER CARTRIDGE ...

Page 97: ...7 PLATE P O ITEM 1 8 33K 91570 MAG ROLLER BLADE P O ITEM 1 9 COVER PLATE 10 49E 37860 COUPLING PLATE 11 7K 82601 GEAR 27T WITH 10 12 12 9E 65850 SPRING 13 7E 32480 IDLER GEAR 40T 14 7E 41250 GEAR 22 31T 15 7E 41240 GEAR 27T 16 7E 34880 IDLER GEAR 32 21T P O ITEM 1 17 ROLLER ASSY MAG P O ITEM 1 18 7E 88070 GEAR 24 20T 19 130E 80990 TONER EMPTY SENSOR 20 48E 62480 COVER 21 121K 86670 MAG ROLLER 6 5 ...

Page 98: ...N LABEL 3 130K 85732 FUSER SENSOR ASSY WITH 4 6 10 4 SENSOR BRACKET REF ONLY 5 HARNESS REF ONLY 6 130P 08241 FUSER THERMOSTAT 7 54E 11970 INLET CHUTE 8 21E 93630 REAR HEATER ROD COVER 9 21K 91341 FRONT HEATER ROD COVER 10 HARNESS REF ONLY 11 130K 85790 FUSER THERMISTOR 2 5 8 6 10 7 9 AQ T AQ AQ AQ AQ AQ ü À 2 ü À 4 6 10 1 4 11 3 WITH 4 6 10 WITH 2 ...

Page 99: ...R ROD SUPPORT 10 7E 34921 IDLER GEAR 22T 11 7K 82230 IDLER GEAR 22T 12 7K 82220 IDLER GEAR 23T 13 7E 32431 IDLER GEAR 24T 14 7E 32441 IDLER GEAR 31T 15 ROLLER REF ONLY 16 12E 90560 LINK 17 9E 65930 SPRING 18 126K 97451 HEATER ROD 220V 19 REAR LEVER REF ONLY 20 WAVE WASHER 21 10E 91872 SLIDE 22 9E 76490 SPRING LEVER 23 49E 63961 FRONT SLIDE BRACKET 24 49E 63971 REAR SLIDE BRACKET 25 FRONT LEVER REF...

Page 100: ... FINGER 19E 92740 HEAT ROLLER FINGER ALT 4 SHAFT REF ONLY 5 110K 91880 EXIT SWITCH ASSY 6 22K 39321 EXIT PINCH ROLLER ASSY 7 59K 09000 FUSER EXIT ROLLER ASSY 8 54K 09470 CHUTE ASSEMBLY WITH 9 12 9 19E 22130 PERSSURE ROLLER FINGER P O ITEM 8 10 9E 65950 TORSION SPRING P O ITEM 8 11 26E 56030 STUD P O ITEM 8 12 CHUTE P O ITEM 8 13 7E 34931 GEAR 25T 14 13E 84490 BEARING ...

Page 101: ...5 25 PL 8 FUSER Section 5 Parts List PL 8 FUSER 8 4 Upper Frame Receiving Tray ITEM PART NO DESCRIPTION 1 126S 50225 FUSER ASSEMBLY 2 50P 50247 EXIT TRAY ASSY 2 1 A Q ...

Page 102: ... Section 5 Parts List PL 8 FUSER PL 8 FUSER 8 5 Fuser Fan Motor Ozone Filter ITEM PART NO DESCRIPTION 1 127K 84431 FUSER FAN MOTOR 2 53E 91510 OZONE FILTER 3 54E 08552 DUCT REF ONLY 4 122K 92080 ERASE LAMP ...

Page 103: ... Parts List PL 9 ELECTRICAL 9 1 Rear Side 1 ITEM PART NO DESCRIPTION 1 PWB SUPPORT 2 140S 50182 MAIN PWB 3 140S 50191 AC DRIVE PWB 4 48P 50261 AC DRIVE PWB COVER 5 110P 50203 TRAY 1 SWITCH 6 105S 50209 LVPS 7 SCREW 8 POWER CORD 220V ...

Page 104: ... PL 9 Electrical PL 9 ELECTRICAL 9 2 Rear Side 2 ITEM PART NO DESCRIPTION 1 113S 50217 CHARGE COROTRON HOLDER 2 113S 50218 TC TDC COROTRON HOLDER 3 105S 50210 HVPS 4 48P 50273 HVPS COVER 5 26P 62407 SCREW 2 1 4 5 A Q A Q A Q 3 ...

Page 105: ... GAS SPRING KIT WITH 2 2 STOPPER P O ITEM 1 3 9P 50209 FRONT GAS SPRING KIT 4 26E 82620 TAPPING SCREW 5 1P 50264 RIGHT FRAME 6 TAPPING SCREW REF ONLY 7 1P 50263 LEFT FRAME 8 49E 37471 LATCH 9 6E 47133 SHAFT 10 9E 65670 SPRING 11 3P 50208 LATCH LEVER 6 6 2 8 8 9 7 10 11 5 4 4 2 A S A S C Q I I C O C O C S A X W I TH 2 1 W I TH 2 3 ...

Page 106: ... 36K 90941 COUNTER BALANCE P O ITEM 1 3 26E 46630 TAPPING SCREW 4 4K 92320 PLATEN CUSHION 5 26P 50221 SCREW 6 302P 50329 RIGHT BLIND COVER 7 302P 50330 LEFT BLIND COVER 8 26E 93961 SCREW M4 8 9 48S 50281 CONSOLE ASSEMBLY 10 48P 50236 TOP COVER 11 110P 50202 FRONT INTERLOCK SWITCH 12 121E 83330 MAGNET CATCH 10 9 A T 6 4 8 3 2 7 12 3 12 5 11 W I TH 2 3 1 ...

Page 107: ...P 50294 FRONT COVER 2 63E 93100 STOPPER TAPE 3 112W 27659 SCREW DEL M3 8 4 26E 46630 TAPPING SCREW 5 3E 35414 HINGE 6 110P 50208 MAIN POWER SWITCH 7 96P 50345 LEBEL DEVE 8 48P 01440 LEFT LOWER COVER 9 2E 60560 MAIN POWER SWITCH COVER 10 SCREW 11 48P 50232 LEFT COVER 12 LABEL NVM 8 AQ 6 11 7 9 5 5 1 12 2 3 4 4 10 ...

Page 108: ...ver ITEM PART NO DESCRIPTION 1 48P 50238 REAR LOWER COVER 2 302P 50322 REAR CONNECTER COVER 3 DATE PLATE REF ONLY 4 26E 93961 SCREW DEL M4 8 5 26E 14060 TAPPING SCREW 6 48P 50251 REAR UPPER COVER 7 53P 50204 FILTER 8 48P 50268 FILTER HOUSING 9 48P 50231 RIGHT COVER 8 9 7 6 4 4 1 4 2 5 3 ...

Page 109: ...SCREW DEL AU 158W 28255 SCREW DELTITE AV 158W 28655 SCREW AW 158W 35655 SCREW M4 6 AX 158W 35855 SCREW DEL AY 158W 36255 SCREW DELTITE T AZ 180W 65850 SCREW WING BA 201W 21251 NUT PART NO DESCRIPTION BB 220W 21250 NUT FLANGE BC 220W 24350 NUT BD 232W 26250 NUT CLINCHING BE 236W 21250 NUT SPEED BF 251W 21251 WASHER BG 251W 24251 WASHER BH 251W 24451 WASHER BI 252W 24250 WASHER NYLON BJ 252W 24350 W...

Page 110: ...Section 6 GENERAL ...

Page 111: ...e loss 6 4 6 1 18 Copy capacity 6 4 6 1 19 Warm up time 6 4 6 1 20 Copy quality 6 5 6 2 Tools and consumables for servicing 6 2 1 Tools 6 6 6 2 2 Consumables for servicing 6 6 6 3 Consumables 6 6 6 4 Modification 6 4 1 Symbology 6 6 6 4 2 Relevant area 6 6 6 4 3 Modification list 6 6 6 5 Installation Removal 6 5 1 Installation 6 7 6 5 2 Installation Removal 6 7 6 6 Program Setting 6 6 1 Entering t...

Page 112: ...ecifications 6 1 1 Product Code Model M C No Product Code 5915 220V SEA TRANSPORT 350100001X G3L 5915 220V AIR TRANSPORT 350500001X G4L X Check Digit 6 1 2 Dimensions XEROX 5915 Unit mm Width mm Depth mm Height mm Weight kg 5915 570 653 395 41 395 570 653 385 ...

Page 113: ...consumption kWh Conditions XEROX 5915 A4 LEF No optional No Stand by mode Run length Monthly average C V 2 000 sheets V Power ON OFF 1 day N Workdays monthly 21 days D Workhours day 8 hours T Warm up time 23 C 30 0 SEC Calculation for power consumption Wh Mo 7 29ND 176 49 TD 1 3600x 3 81V 30 0ND 1 2 1 18V 3 1 At warm up 2 At standby 3 In operation 6 1 6 Calorific power Power consumption x 0 86kcal...

Page 114: ... of g m 2 x 0 86 coefficient e g L paper 64g m2 x 0 86 55 kg The following paper is applicable Trays 1 SEF A3 B4 A4 B5 LEF A4 B5 Bypass Tray A3 A6 SEF Tray capacity Trays 1 250 sheets L Bypass Tray 100 sheets L 6 1 16 Compatibility Platen Mode Alignment to the 95 copies Tolerance at 1 1 copies Tolerance at reduction enlargement Feeding direction Lead Edge Registration 1 6mm or less 2 7mm or less 4...

Page 115: ...d Over 0 46 Below 0 40 Blue Reproducibility Uniformity 100 499T247 0 2 Blue Over 0 17 Over 0 57 Below 0 40 Solid Reproducibility Uniformity 100 499T247 1 0 solid Over 1 2 Below 0 3 Low contrast Light image Reproducibility Uniformity Reproducibility 100 499T247 0 2 gray 0 1 gray Not confirmed Over 0 57 Below 0 40 B G D Background 100 499T247 Below 1 2 Resolution 100 70 141 499T247 A3 Resolution tar...

Page 116: ...ervicing arises requiring a particular consumable unique to this model the case will be handled separately 6 3 Consumables The consumables available with this model are Name Prod Code Capacity Ref Life Drum Unit 673S50211 50K Toner Cartridge black 6R01020 500g 6K 6 Area coverage is assumed on A4 size documents 6 4 Modification 6 4 1 Symbology When there are differences by modification in the Manua...

Page 117: ...ur areas of the machine 4 Close the machine 5 Peel off the tapes from the optical area air ship only 6 Load the toner Cartridge 1 Open the Front Cover 2 Spread a sheet of paper to protect the back of the cover from toner spillage 3 Remove the dummy Cartridge tube toward the front side Put the it in the empty box for disposal 4 Shake the Toner Cartridge more than 10 times 5 Fit the claw of the new ...

Page 118: ...rd See the Trim section of the Manual Note If any parts are installed wrongly correct before removal 2 If any adjustment has been made based on the customers desire put it back to the original status 3 Perform Trim operation and clean inside of the machine 4 Turn on the power make copies and check copy quality paper feed and copy count 5 Switch off the machine and unplug the power cord 6 Remove pa...

Page 119: ...Exit the Program Mode 6 6 5 Operation procedure to display the number of copies made Note This applies only to the Program Number 8I 83 84 1 Enter the Program Mode 2 Enter Program Number 81 and press the Start button LCD shows the copy volume made by the Drum cartridge 3 Enter Program Number 83 and press the Start button LCD shows the copy volume made by the Customer 4 Enter Program Number 84 and ...

Page 120: ...s 0 No password mode The machine will enter directly the ready to copy state when it is turned on 1 Single password mode The information presenting state Id will be displayed when the machine is turned on and a password has to be entered before copies can be made 5 When the selected value is displayed in the Quantity display press Start for the setting to be memorized There is no display in the Co...

Page 121: ...e entered value is correct 5 Press Custom Presets to make the machine exit the customizing state and return to the normal copy state 6 Press or turn off the machine and turn it on again to make it enter the information presenting state Id 7 Enter a 4 digit password using number keys the initial one being 1111 For security each number is displayed in the Quantity display as I I I I If you want to r...

Page 122: ...sing number keys and the machine enters the waiting state 3 Press Custom Presets and the machine enters the customizing state 4 Press the number key 0 and then the Start button There is I I I I displayed on the panel and the lamp in the Quantity display will keep flashing Re enter a 4 digit password and the lamp in the Quantity display will stop flashing Re press Start There is no display on the p...

Page 123: ...Section 7 Wiring Data ...

Page 124: ...7 1 Contents Section 7 Wiring Data Section 7 Wiring Data Plug Jack List 7 2 Connector Configuration 7 5 ...

Page 125: ...y match with the number of wires Destination Indicates to which component or module the plug jack is connected P J No Fig No Number Of pins Destination 1 2 3 LVPS 12 BSD7 1 HEATER ROD FRONT 13 BSD7 1 HEATER ROD REAR 14 9 4 3 FUSER THERMOSTAT AC DRIVE PWB 15 2 2 EXPOSURE LAMP AC DRIVE PWB 16 2 2 EXPOSURE LAMP 40 2 8 LVPS 100 5 8 3 OPTICAL REGI SENSOR 105 8 3 LENS SENSOR 110 9 14 3 MSI SIZE SENSOR 1...

Page 126: ... 2 16 MAIN PWB 407 2 18 MAIN PWB 408 2 2 MAIN PWB 409 2 4 MAIN PWB 410 2 14 MAIN PWB 413 2 4 MAIN PWB 417 8 16 CONTRAL CONSOLE P J NO Fig No Number of Pins Destination 418 8 12 CONTROL CONSOLE 430 2 4 10 AC DRIVE PWB 431 4 3 AC DRIVE PWB 437 2 AC DRIVE PWB 500 9 8 HVPS 600 9 3 MAIN PWB REGI GATE SENSOR 604 2 6 LENS MOTER 605 6 LAMP CARRIAGE PWB 610 1 6 MAIN PWB TRAY1 NO PAPER TRAY1 FEED SOLENOLD 6...

Page 127: ...umber of Pins Destination T59 3 2 BSD2 BSD6 TRAY1 SWITCH T60 UP CHUTE ASSY GROUND WIRE T61 UP CHUTE ASSY GROUND WIRE T62 3 6 BSD6 RIGHT COVER SWITCH T63 3 6 BSD3 BSD6 RIGHT COVER SWITCH T64 BSD1 BSD2 FRONT COVER INTLK SWITCH T65 BSD1 FRONT COVER INTLK SWITCH ...

Page 128: ...7 5 Connector Configuration Section 7 WIRING DATA TOP VIEW Fig 1 TOP VIEW Fig 2 REAR VIEW Fig 3 MAIN MOTOR MAIN PWB ...

Page 129: ...7 6 Section 7 Wiring Data Connector Configuration TOP VIEW Fig 4 A A Details MAIN SW Terminal No Wire Color Wire Color Terminal No T13 BRN 2 5 BLU T14 T11 BRN 1 4 BLU T12 FRONT VIEW Fig 5 ...

Page 130: ...7 7 Connector Configuration Section 7 WIRING DATA R H VIEW A A DETAILS TOP VIEW Fig 6 Fig 7 ...

Page 131: ...7 8 Section 7 Wiring Data Connector Configuration TOP VIEW Fig 8 BASE FRAME TOP VIEW Fig 9 ...

Page 132: ...Section 9 BSD Block Schematic Diagram ...

Page 133: ... COPY TRANSPORTATION AND FUSING 9 11 How to use the BSD Refer to this chapter containing 9 BSDs during troubleshooting which is normally begun from the Level 1 FIP or status code list Function parts are indicated on each BSD is being Supplemented by text data notes Troubleshooting using the BSD is carried out using a combination of the necessary text data and diagnostic modes Adjustment ADJ No and...

Page 134: ...of the I O signal 9 1 2 Signal nomenclature Output signal REGI GATE SOL ON L 24VDC Voltage level when the signal is high H Signal name Voltage level necessary to activate the electrical part For certain signals the activating voltage level is high Input signal REGI SENSOR SENSED L 25VDC Voltage level when the signal is high H Signal name Voltage level when the switch or sensor is activated or ener...

Page 135: ...9 3 1 1 STANDBY POWER Section 9 BSD Block Schematic Diagram ...

Page 136: ...9 4 Section 9 BSD Block Schematic Diagram 1 1 STANDBY POWER ...

Page 137: ...9 5 1 1 STANDBY POWER Section 9 BSD Block Schematic Diagram ...

Page 138: ...9 6 Section 9 BSD Block Schematic Diagram 2 MODE SELECTION MACHINE RUN CONTROL START PRINT POWER ...

Page 139: ...9 7 3 1 OPTICS Section 9 BSD Block Schematic Diagram ...

Page 140: ...ter lens initialization was initiated start of movement U8 1 EXPOSURE CONTROL FAIL Control mode is not set within 0 5 sec after exposure lamp turned on U8 4 EXPOSURE VOLTAGE OVER FAIL Voltage level of exposure signal intensity level already exceeds 2 9 V when exposure lamp turns on U8 5 EXPOSURE VOLTAGE UNDER FAIL Voltage level of exposure signal intensity level is already below 0 5 V when exposur...

Page 141: ...9 9 4 PAPER SUPPLYING AND TRANSPORTATION Section 9 BSD Block Schematic Diagram ...

Page 142: ...te sensor remains on at power on or standby Remaining paper E6 1 R H UPPER INTLK OPEN FAIL Right upper cover is open or right upper interlock switch is faulty MSI size detection The MSI paper size is detected for the following purposes a Lamp scan control b Fuser temperature control c Detection of FUSER EXIT JAM E3 3 1 Width is detected by the MSI size sensor by measuring time from start of 1st pa...

Page 143: ...9 11 5 XEROGRAPHICS COPY TRANSPORTATION AND FUSING Section 9 BSD Block Schematic Diagram ...

Page 144: ...emaining J1 1 TONER EMPTY FAIL Number of copies reaches 100 after toner empty sensor sensed toner end condition J1 2 TONER UNIT LIFE END The counter value of toner unit reaches the default value 7700 J3 1 DRUM UNIT SET FAIL Drum unit is not set or is set incorrectly to the machine J3 2 TONER UNIT SET FAIL Toner unit is not set or is set incorrectly to the machine J3 3 TOTAL COUNTER SET FAIL Total ...

Page 145: ...o mode during standby and start a copy cycle ON 0V OFF 13VDC 14VDC Auto and variable modes 4 CC TC ON L 24VDC J407 13 COM Start a copy cycle in normal mode ON 0V OFF 13VDC 14VDC 5 DEVE BIAS ON L 5VDC J407 16 COM Enter diag code 9 2 and start a copy cycle ON 0V OFF 13VDC 14VDC 6 DTC DEVE BIAS ON L 24VDC J407 15 COM Start a copy cycle in normal mode ON 0V OFF 13VDC 14VDC 7 FUSER THERMISTOR SENSED SI...

Page 146: ... a replacement page containing changes modifications burn it or take the necessary action including cutting by a shredder Be careful of handing the manual to avoid missing or damaging it Issued JUNE 2000 Revision and Modification Information When design changes or revisions relating to this service manual occur overseas technical information or overseas service bulletins may be issued as supplemen...

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