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Xerox WorkCentre 5790 Series, Service Manual

The Xerox WorkCentre 5790 Series is a high-performance multifunction printer designed to meet the demands of busy offices. For easy troubleshooting and maintenance, users can access the comprehensive Service Manual. Download this manual for free from our website manualshive.com and optimize the functionality of your WorkCentre 5790 Series effortlessly.

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May 2013

xiv

Xerox® WorkCentre® 5790 Family

Translation of Warnings

Introduction

AVVERTENZA: Procedere con cautela durante la misurazione della tensione CA della 
rete. L'elettricità può causare infortuni o morte. 

VORSICHT: Bei der Netzspannungsprüfung stets vorsichtig vorgehen 

AVISO: Tenga cuidado al medir la tensión de la línea de alimentación de corriente 
alterna. La electricidad puede causar lesiones e incluso la muerte. 

WARNING

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.

DANGER : Ne pas réparer de fusible F1 ou en installer un nouveau sur la carte d'alimen-
tation de la machine. Il existe un risque de surchauffe voire d'incendie.

AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non riparare o instal-
lare un nuovo fusibile F1 sul PWB IOT.

VORSICHT: Die Sicherung F1 auf dem IOT-PWB nicht reparieren oder neu installieren - 
Überhitzungs- und Brandgefahr. 

AVISO: No repare un fusible F1 ni instale uno nuevo en la PWB de la IOT. Un fusible rep-
arado o nuevo puede producir sobrecalentamiento y el riesgo de incendio. 

WARNING

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.

DANGER : Ne pas réparer de fusible F1 ou en installer un nouveau sur la carte de distri-
bution électrique. Il existe un risque de surchauffe voire d'incendie.

AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non riparare o instal-
lare un nuovo fusibile F1 sul PWB distribuzione di alimentazione 

VORSICHT: Die Sicherung F1 auf dem Stromverteilungs-PWB nicht reparieren oder neu 
installieren - Überhitzungs- und Brandgefahr. 

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 
riesgo de incendio. 

WARNING

Do not repair or install a new fuse F1 on the main drive PWB. Repairing or installing a 
new fuse can cause overheating and a risk of fire.

DANGER : Ne pas réparer de fusible F1 ou en installer un nouveau sur la carte 
d'entraînement principal. Il existe un risque de surchauffe voire d'incendie.

AVVERTENZA: per evitare rischi di surriscaldamento o d'incendio, non riparare o instal-
lare un nuovo fusibile F1 sul PWB azionamento principale.

VORSICHT: Die Sicherung F1 auf dem Hauptantriebs-PWB nicht reparieren oder neu 
installieren - Überhitzungs- und Brandgefahr. 

AVISO: No repare un fusible F1 ni instale uno nuevo en la PWB de impulso principal. Un 
fusible reparado o nuevo puede producir sobrecalentamiento y el riesgo de incendio. 

WARNING

Avoid exposure to laser beam. Invisible laser radiation.

DANGER : Eviter toute exposition au faisceau laser. Radiation laser invisible.

AVVERTENZA: Evitare l'esposizione al fascio laser. Radiazioni laser invisibili.

VORSICHT: Nicht in den Laserstrahl blicken. Verletzungsgefahr durch unsichtbare 
Laserstrahlung. 

AVISO: Evite la exposición al rayo láser. Radiación de láser invisible. 

WARNING

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

DANGER : Exécuter cette procédure avec précaution. Les moteurs peuvent devenir très 
chauds en fonctionnement normal.

AVVERTENZA: procedere con cautela durante questa procedura. I motori si riscaldano 
molto durante il funzionamento.

VORSICHT: Bei diesem Vorgang vorsichtig vorgehen, da Motoren im Normalbetrieb heiß 
werden können.

AVISO: Tenga cuidado al efectuar este procedimiento. Los motores alcanzan altas tem-
peraturas durante su funcionamiento normal.

WARNING

Do not touch the fuser while it is hot.

DANGER : Ne pas toucher au four pendant qu'il est encore chaud.

AVVERTENZA: Non toccare il fonditore quando è caldo.

VORSICHT: Fixierbereich erst berühren, wenn dieser abgekühlt ist.

AVISO: No toque el fusor mientras está caliente. 

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.

DANGER: Attention à ne pas faire tomber la trieuse/agrafeuse petite capacité. Elle n'est 
pas stable lorsqu'elle est détachée de la machine. Ne pas montrer au client comment 
détacher la trieuse/agrafeuse.

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 
cliente come sganciarlo 

VORSICHT: Stapler nicht umstoßen. Nach Trennung des Staplers vom Document Centre 
ist dieser sehr instabil 

AVISO: Tenga cuidado de que no se caiga el apilador/grapadora de baja capacidad. 
Cuando no está acoplada a la máquina es inestable. No le muestre al cliente como desa-
coplar el apilador/grapadora de baja capacidad.

WARNING

Keep away from the crease blade mechanism when working in close proximity to the 
booklet maker while the machine is powered on. The crease blade mechanism activates 
quickly and with great force.

DANGER: Ne pas s'approcher du méchanisme de la lame de pliage lors d'une activité à 
proximité de la plieuse/brocheuse pendant que la machine est sous tension. Ce mécan-
isme s'active rapidement et avec force.

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 
piegatura si attiva con velocità e forza notevoli. 

VORSICHT: Wenn bei eingeschaltetem Gerät nahe am Booklet Maker gearbeitet wird, 
von der Schneidevorrichtung fernhalten. Die Schneidevorrichtung wird schnell und mit 
viel Druck ausgelöst. 

Summary of Contents for WorkCentre 5790 Series

Page 1: ...Xerox WorkCentre 5790 Family Service Manual 708P90298 May 2013 ...

Page 2: ...t 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...

Page 3: ...duction Introduction About This Manual iii How To Use This Manual iii Change History iv Mod Tag Identification viii Voltages Resistances and Tolerances ix Safety Information xi Health and Safety Incident reporting xii Translation of Warnings xiii ...

Page 4: ...May 2013 ii Xerox WorkCentre 5790 Family Introduction ...

Page 5: ...s 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 ...

Page 6: ... Tray 3 and Tray 4 Transport Roll W TAG 151 REP 8 48 Tray 3 Stack Height Sensor W TAG 151 REP 8 49 Tray 3 Empty Sensor W TAG 151 REP 8 50 Tray 4 Feed Sensor W TAG 151 REP 8 51 Tray 4 Stack Height Sensor W TAG 151 REP 8 52 Tray 4 Empty Sensor W TAG 151 RAP 07 355 Tray 3 Elevator Lift Failure RAP W O Tag 151 Mod Tag 151 Introduction of the FAR Feeder HCF The following procedures are updated Generic ...

Page 7: ...sembly 2 of 4 PL 10 25 Short Paper Path PL 11 12 2K LCSS Bin 1 Control PL 11 20 2K LCSS Staple Head Unit Traverse Assembly PL 11 135 HVF Stacker PL 11 150 HVF Main Drives PL 31 11 Maintenance Installation removal Kits 2 of 5 PL Common Hardware GP 3 Service Information GP 5 Portable Work Station and Tools GP 4 Machine Software GP 5 Portable Work Station and Tools GP 15 How to Set the Machine Config...

Page 8: ...99 Incompatible Xerographic Module RAP 09C Photoreceptor Fan RAP 10 101A 102A 103A Lead Edge Late to Fuser Exit Switch 35 55 ppm RAP 10 101B 102B 103B Lead Edge Late to Fuser Exit Switch 65 90 ppm RAP 10 315 10 320 10 321 10 323 10 340 10 350 10 360 10 365 10 380 Fuser Over Temperature RAP 11 364 110 Stapling Failure RAP 11F 110 2K LCSS PWB DIP Switch Settings RAP 11 024 171 11 026 171 Paddle Roll...

Page 9: ...8 115A 08 117A Tray 5 Misfeed 35 55 ppm RAP 08 115B 08 117B Tray 5 Misfeed 65 90 ppm RAP 08 132 Tray 3 Paper Feed Jam W TAG 151 RAP 08 150A 151A Registration Jam 35 55 ppm RAP 08 150B 151B Registration Jam 65 90 ppm RAP 08 190 Post Jam Clearance Initialization RAP 09 060 HVPS Fault RAP 09 310 09 390 Low Toner Sensor Failure RAP 09 341 09 342 Scorotron Cleaning Failure RAP 09 360 09 361 09 362 09 3...

Page 10: ...GP 27 Fuser Xerographic Module End of Life Extension dC131a NVM Tables Chain 1 to 10 dC604 Registration Setup Procedure TAGs PJ Locations Table 1 PJ Locations Table 2 Wiring Diagram 8 Wiring Diagram 9 Wiring Diagram 34 The following procedures are new REP 7 29 Tray 5 Elevator Tray Guides ADJ 7 6 Tray 5 Stack Height Sensor and Retard Shield Mod Tag 158 Mod Tag F 012 Mod Tag L 012 Mod Tag P 011 Mod ...

Page 11: ...ithin a RAP GP 11 How to Check a Sensor NOTE This links to General Procedures information Figure 1 IOT PWB NOTE The P J links to the connector location on the PWB in a circuit diagram NOTE The PWB links the connector to the pin layout on the PWB referenced in the Wir 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...

Page 12: ...May 2013 x Xerox WorkCentre 5790 Family Voltages Resistances and Tolerances Introduction Figure 2 Symbols used in circuit diagrams ...

Page 13: ...he power cord is connected Ozone 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 ...

Page 14: ...ehs xerox com 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 ehs europe xerox com 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 ...

Page 15: ...es de mantenimiento la radiación de láser invisible puede causar daños en los ojos si se mira directamente a ella WARNING 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 DANGER Ne pas installer de fusible de type ou de calibre différent Il existe un risque de surchauffe voire d incendie AVVERTENZA per evitare ...

Page 16: ...e to laser beam Invisible laser radiation DANGER Eviter toute exposition au faisceau laser Radiation laser invisible AVVERTENZA Evitare l esposizione al fascio laser Radiazioni laser invisibili VORSICHT Nicht in den Laserstrahl blicken Verletzungsgefahr durch unsichtbare Laserstrahlung AVISO Evite la exposición al rayo láser Radiación de láser invisible WARNING Take care during this procedure Moto...

Page 17: ...e senti oggetti con bordi taglienti pericolosi VORSICHT Bei diesem Vorgang vorsichtig vorgehen damit keine Verletzungen durch die scharfen Kanten entstehen AVISO Tenga cuidado al efectuar este procedimiento Puede haber bordes afilados que podrían producir lesiones WARNING Take care when measuring AC mains line voltage Electricity can cause death or injury DANGER Prendre des précautions lors du rel...

Page 18: ...cristal roto puede ocasionar daños 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 Reinigungsm...

Page 19: ... AVVERTENZA Non utilizzare la copertura destra W TAG 148 con un dispositivo di uscita tranne il complessivo del trasporto OCT Se questa copertura non viene utilizzata in modo corretto si potrebbero esporre parti meccaniche in movimento con rischio di infortuni ACHTUNG Rechtsseitige Abdeckung W TAG 148 NUR mit Ausgabegeräten vom Typ OCT Transporteinheit verwenden Bei unsachgemäßer Verwendung bietet...

Page 20: ...May 2013 xviii Xerox WorkCentre 5790 Family Translation of Warnings Introduction ...

Page 21: ... Service Call Procedures 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 ...

Page 22: ...May 2013 1 2 Xerox WorkCentre 5790 Family Service Call Procedures ...

Page 23: ...efer 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 l...

Page 24: ...tions Use the Normal Call Actions to find the reason for the service call Initial Actions 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 Procedure NOTE If an error message appears go to the RAP for the error message If necessary refer to OF4 Status Codes and Messages RAP Perform the steps that follow 1 Review the cop...

Page 25: ...and Status Codes If the machine has the problems that follow go to the 19 401 19 402 19 403 Out of Memory Resources RAP A message that there is not enough memory to complete the job The machine does not print a complex job The customer reports that the print speed is slow If a status code or message is displayed but not a fault code go to OF4 Status Code and Messages RAP If a fault code is display...

Page 26: ...ks RAP 11A 171 HVF BM Power Distribution RAP 11B 171 HVF BM to Machine Communications Interface and BM Present RAP 11C 171 HVF BM Bin 2 Failure RAP 11D 171 Booklet Quality RAP 11E 171 Copy Damage in the HVF BM RAP 11F 171 Mis Registration in Stapled and Unstapled Sets RAP 11G 171 HVF BM Poor Stacking RAP 11H 171 Pause To Unload PTU RAP 11J 171 Inserter Paper Sensing and 5V Supply RAP 11K 171 HVF I...

Page 27: ...n of New Parts HFSI Lubrication How to Clean the Machine Installation of New Parts The design life of the major components is shown in Table 1 NOTE If a range of machine speeds are specified within Table 1 the life expectancy for the part will be specific for that machine If the speed has not been specified the life expectancy for the part applies to all machines within the product family Table 1 ...

Page 28: ...400k feeds PL 8 32 Item 11 Tray 4 feed W O TAG 151 Feed rolls All sheets fed from tray 4 after last HFSI reset 1 500k feeds PL 8 31 Item 2 Tray 4 feed W TAG 151 Feed rolls All sheets fed from tray 4 after last HFSI reset 400k feeds PL 8 33 Item 9 Tray 1 trans Transport roll The total feeds from tray 1 2 3 4 after last HFSI reset 2 000k feeds PL 8 25 Item 8 Tray 2 trans Transport roll The total fee...

Page 29: ...f necessary provide the customer with training 14 At the completion of the service call report the three billing counters in order billing counter C13 billing counter C1 and billing counter C2 SCP 7 Machine Features Configuration Options 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...

Page 30: ...striking of TAG 150 August 2010 Introduction of the copier only 5790F device in the USSG region only Refer to GP 30 for details on the identification and unique service procedures for the copier only configured machines July 2011 Introduction of the Fully Active Retard Roll FAR Feeder HCF module The FAR Feeder HCF module with proven tray 3 and tray 4 FAR feeder robustness is expected to produce si...

Page 31: ...5790 Family SCP 7 Service Call Procedures 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 ...

Page 32: ...May 2013 1 12 Xerox WorkCentre 5790 Family SCP 7 Service Call Procedures ...

Page 33: ...5 03 401 03 403 Fax Not Detected RAP 2 97 03 412 Foreign Device PWB Fault RAP 2 97 03 415 Tray 5 Module Not Detected Confirmed RAP 2 99 03 417 Incompatible Fax Software RAP 2 101 03 419 03 420 Incompatible Software RAP 2 101 03 423 424 433 434 821 822 831 832 Print Command Late RAP 2 102 03 480 IOT 24V Supply Failure RAP 2 102 03 700 03 780 03 785 03 790 Power On Power Off Event Fault RAP 2 103 03...

Page 34: ...on Jam RAP 65 90 ppm 2 238 08 155 08 156 Bypass Tray Registration Jam Entry RAP 2 240 08 155A 08 156A Bypass Tray Registration Jam RAP 35 55 ppm 2 240 08 155B 08 156B Bypass Tray Registration Jam RAP 65 90 ppm 2 243 08 160 08 161 Duplex Paper Path Jam Entry RAP 2 245 08 160A 08 161A Duplex Paper Path Jam RAP 35 55 ppm 2 246 08 160B 08 161B Duplex Paper Path Jam RAP 65 90 ppm 2 249 08 171 Unexpecte...

Page 35: ...11 132 171 HVF Top Exit Sensor RAP 2 419 11 140 171 11 142 171 HVF 2nd to Top Exit Sensor RAP 2 421 11 157 171 11 161 171 HVF Buffer Position Sensor RAP 2 423 11 158 171 11 160 171 162 171 163 171 HVF BM Entry RAP 2 425 11 164 171 11 165 171 HVF Buffer Path RAP 2 428 11 172 171 HVF BM Compiler Exit Jam RAP 2 431 11 173 171 to 11 177 171 HVF Offset Unit RAP 2 434 11 180 171 11 182 171 HVF BM Exit J...

Page 36: ... Overwrite Error RAP W TAG X 001 2 572 20A Fax Entry RAP 2 572 20B Unable To Send A Fax RAP 2 573 20C Unable To Send A Fax To Some Machines RAP 2 575 20D Unable To Receive A Fax RAP 2 576 20E Fax Will Not Print RAP 2 577 20F Fax Tab Not Available RAP 2 577 20G Embedded Fax Checkout 2 578 20H Embedded Fax PWB Voltage Checkout W O TAG X 001 2 579 20J Fax Problems on Digital Networks RAP 2 580 Chain ...

Page 37: ...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 S01 300 and associated wiring Refer to GP 13 How to Check a Switch P J17 LVPS and base module REP 1 2 Wiring Harness Repa...

Page 38: ...May 2013 2 6 Xerox WorkCentre 5790 Family 01 300 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 39: ...de 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 If necessary install a new left hand door interlock PL 7 30 Item 3 Check that the left hand door closes correctly If not check t...

Page 40: ...ause a failed or poor electrical contact Refer to REP 1 2 for information concerning wiring harness repairs 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 ...

Page 41: ... 2 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 Figure 2 Corotron shield ground Main frame ground connection Auxiliary output ground connection Main input ground connection ...

Page 42: ...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 con tinuity check that the hardware is tight and the harness crimping is good If necessary discon nect the terminals clean the contact faces and re assemble to improve continuity Figure 4 DADH ground connection Corotron shield ground return wire v...

Page 43: ...e 35 55 ppm duplex transport is shown in Figure 6 The 65 90 ppm duplex trans port has a duplex duct installed PL 8 20 Item 12 Duplex Paper Path Refer to Figure 6 Check the duplex paper path ground contact spring and ground wire termi nal If necessary remove and clean the spring shafts and bearings then re assemble to improve continuity Figure 6 Duplex path ground contact spring Registration Transp...

Page 44: ...hafts and bearings then re assemble to improve continuity NOTE The two bearings in contact with the registration ground contact spring are manufac tured from conductive plastic It is not possible to measure the resistance of these bearings with the standard multi meter Figure 8 Registration ground contact spring Registration roll shaft Grounding screw Pre registration drive roll shaft Registration...

Page 45: ... continuity Also check and clean if necessary the part of the machine frame where the ground contact spring makes contact Figure 9 Bypass tray guide Refer to Figure 10 Check for continuity of less than 2k ohms between the ground contact spring Figure 9 and the feed shaft Check for continuity of less than 2k ohms between the feed shaft and the main frame ground connection when the left hand door is...

Page 46: ... tray 3 REP 7 2 Refer to 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 assem ble to improve continuity Refer to Figure 12 Remove then 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...

Page 47: ...heck for continuity of less than 1 ohm between the tray 3 metal side wall and the main frame ground connection To improve continuity remove clean and re assemble the grounding spring to improve continuity Also clean the contact area on the metal side wall Figure 14 Tray 3 grounding spring Tray 3 ground contact spring Tray 3 grounding spring ...

Page 48: ...ing spring Tray 3 and 4 W TAG 151 Refer to Figure 16 Figure 19 and Figure 20 Remove the tray 3 front cover PL 7 26 Item 5 4 screws With tray 3 closed check for continuity of less than 10k ohms between the following points and the main frame ground connection Tray 3 takeaway roll shaft PL 8 36 Item 2 Tray 3 and 4 transport roll shaft PL 8 32 Item 4 Tray 3 lift plate and paper tray guide Tray 4 lift...

Page 49: ...ig ure 18 clean the bearings and shaft Then install the removed components Figure 18 Component cleaning 4 Empty tray 3 of paper Refer to Figure 19 disconnect and clean the tray 3 ground harness connectors Then install the removed components Figure 19 Tray 3 grounding Clean the bearing areas of the tray 3 takeaway roll shaft Clean inside and outside of the conductive plastic bearings Conductive pla...

Page 50: ... 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...

Page 51: ...installed Figure 22 Embedded FAX PWB ground connection Tray 5 Refer to Figure 23 Check the ground connection on the frame the elevator motor and on the base of the paper tray Ensure that the in line connectors are connected Figure 23 Tray 5 ground connections Grounding strip Ground connection Ground connection under the paper tray In line ground connector ...

Page 52: ...ponent in the list that follows that has the suspect 0V supply Check the wiring GP 7 ROS PL 6 10 Item 4 Flag 1 P J18 P J120 Bypass tray width sensor PL 7 30 Item 1 and bypass tray empty sensor PL 7 30 Item 7 Flag 5 IOT PWB P J10 Flag 4 IOT PWB 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...

Page 53: ...May 2013 2 21 Xerox WorkCentre 5790 Family 01B Status Indicator RAPs Figure 1 3 3V Return ...

Page 54: ...May 2013 2 22 Xerox WorkCentre 5790 Family 01B Status Indicator RAPs Figure 2 3 3V Return ...

Page 55: ...tem 2 Flag 20 P J272 P J63 Flag 55 P J394 Flag 19 P J9 P J271 Flag 15 P J27 HCF control PWB W TAG 151 PL 7 21 Item 2 Flag 20 P J272 P J63 Flag 56 P J7 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 Ite...

Page 56: ...May 2013 2 24 Xerox WorkCentre 5790 Family 01B Status Indicator RAPs Figure 3 5V Return ...

Page 57: ...May 2013 2 25 Xerox WorkCentre 5790 Family 01B Status Indicator RAPs Figure 4 5V Return ...

Page 58: ...130 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 J15...

Page 59: ...May 2013 2 27 Xerox WorkCentre 5790 Family 01B Status Indicator RAPs Figure 5 12V Return ...

Page 60: ...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...

Page 61: ...May 2013 2 29 Xerox WorkCentre 5790 Family 01B Status Indicator RAPs Figure 6 24V Return ...

Page 62: ...May 2013 2 30 Xerox WorkCentre 5790 Family 01B Status Indicator RAPs Figure 7 24V Return ...

Page 63: ...May 2013 2 31 Xerox WorkCentre 5790 Family 01B Status Indicator RAPs Figure 8 24V Return ...

Page 64: ... 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 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 read...

Page 65: ...Family 01C Status Indicator RAPs Figure 2 Supply to the fuser module Figure 3 Fuser module Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 P J100 PJ24 Pin 5 Pin 6 Pin 4 Pin 3 Pin 10 Pin 9 Pin 8 Pin 7 Pin 2 Pin 1 CRUM P J 100 ...

Page 66: ...May 2013 2 34 Xerox WorkCentre 5790 Family 01C Status Indicator RAPs Figure 4 AC circuit diagram ...

Page 67: ...dth 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 ...

Page 68: ...May 2013 2 36 Xerox WorkCentre 5790 Family 01D Status Indicator RAPs Figure 1 3 3V distribution circuit diagram ...

Page 69: ...May 2013 2 37 Xerox WorkCentre 5790 Family 01D Status Indicator RAPs Figure 2 3 3V distribution circuit diagram ...

Page 70: ...em 6 registration sensor PL 8 17 Item 3 Flag 2 P J7 Flag 1 P J27 Xerographic CRUM part of the xerographic module 35 ppm PL 9 22 Item 2 or 40 90 ppm PL 9 20 Item 2 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 W O ...

Page 71: ...May 2013 2 39 Xerox WorkCentre 5790 Family 01E Status Indicator RAPs Figure 1 5V distribution circuit diagram ...

Page 72: ...May 2013 2 40 Xerox WorkCentre 5790 Family 01E Status Indicator RAPs Figure 2 5V distribution circuit diagram ...

Page 73: ...rol 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 J26 Xerographic CRUM part ...

Page 74: ...May 2013 2 42 Xerox WorkCentre 5790 Family 01F Status Indicator RAPs Figure 1 12V distribution circuit diagram ...

Page 75: ...May 2013 2 43 Xerox WorkCentre 5790 Family 01F Status Indicator RAPs Figure 2 12V distribution circuit diagram ...

Page 76: ...fuse F1 being blown and all 24V interlocked outputs not available Be aware that a high resistance short circuit on any of the outputs will damage but not blow fuse F1 resulting in measurements of 24V at the top cap input of fuse F1 and less than 24V but not 0V on the bottom cap of fuse F1 Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do no...

Page 77: ...d at the top cap of fuse F1 is the same as the voltage measured on the bottom cap of fuse F1 Y N A high resistance short circuit has damaged the fuse F1 Identify and repair the cause of the high resistance short circuit refer to Figure 2 Figure 3 and the Component list Refer also to the 01H Short Circuit and Overload RAP When the cause of the high resistance short circuit has been repaired install...

Page 78: ...Flag 7 P J6 Flag 5 P J27 Bypass tray feed solenoid PL 7 30 Item 4 Flag 8 P J10 Flag 5 P J27 OCT Module PL 12 10 Flag 9 P J11 Flag 5 P J27 HVPS PL 1 10 Item 5 Flag 10 P J14 P J55 Flag 5 P J27 Photoreceptor drive motor part of the main drive module 35 55 PL 4 15 Item 17 65 90 ppm PL 4 10 Item 17 Flag 12 P J151 Flag 11 P J147 P J16 Ozone fan PL 9 25 Item 1 Flag 13 P J153 Flag 12 P J151 Flag 11 P J147...

Page 79: ...May 2013 2 47 Xerox WorkCentre 5790 Family 01G Status Indicator RAPs Figure 2 24V distribution circuit diagram ...

Page 80: ...May 2013 2 48 Xerox WorkCentre 5790 Family 01G Status Indicator RAPs Figure 3 24V distribution circuit diagram ...

Page 81: ...May 2013 2 49 Xerox WorkCentre 5790 Family 01G Status Indicator RAPs Figure 4 24V distribution circuit diagram ...

Page 82: ...May 2013 2 50 Xerox WorkCentre 5790 Family 01G Status Indicator RAPs Figure 5 24V distribution circuit diagram ...

Page 83: ...control assembly to the left NOTE Refer to Figure 3 for the low voltage distribution This is an overview of all the low volt age harnesses within the machine NOTE Refer to GP 7 at every harness check and if necessary perform REP 1 2 To check the output voltages of the LVPS disconnect the following Figure 2 PJ16 PJ17 PJ18 PJ19 and PJ25 Figure 1 All the PJ connectors on the IOT PWB except PJ26 Flag ...

Page 84: ...2 and CR13 are on check the harness Flag 20 from PJ10 on the IOT PWB to the bypass tray PL 7 30 WD 10 5 Disconnect PJ11 Flag 21 If the LEDs CR12 and CR13 are on check the harness Flag 21 from PJ11 on the IOT PWB to the output devices WD 5 6 Disconnect PJ7 Flag 19 If the LEDs CR12 and CR13 are on check the harness Flag 19 from PJ7 to the components that follow a Developer temperature sensor 35 ppm ...

Page 85: ...drive PWB WD 6 b Disconnect PJ4 on the IOT PWB If the measurement remains below 1 Ohm this cir cuit is good move to the next step If the measurement changes to open circuit 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 If the measurement remains below 1 Ohm this cir cuit is good ...

Page 86: ...May 2013 2 54 Xerox WorkCentre 5790 Family 01H Status Indicator RAPs Figure 3 Low voltage distribution ...

Page 87: ...May 2013 2 55 Xerox WorkCentre 5790 Family 01H Status Indicator RAPs Figure 4 12V interlock circuit diagram ...

Page 88: ...rting this RAP Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 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 t...

Page 89: ...May 2013 2 57 Xerox WorkCentre 5790 Family 01J Status Indicator RAPs Figure 2 Power ON circuit and dependencies ...

Page 90: ...rough the single board con troller PWB to the IOT This causes the IOT to generate the PS ON signal to the LVPS 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 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 P...

Page 91: ...e wiring as necessary REP 1 2 Install new parts as necessary User interface harness PL 2 10 Item 3 User interface control PWB PL 2 10 Item 11 User interface touch screen PWB PL 2 10 Item 6 User interface touch screen PL 2 10 Item 5 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 Install anew LVPS and base module PL 1 1...

Page 92: ...r the wiring as necessary REP 1 2 Install new parts as necessary Fax PWB PL 20 10 Item 4 Riser PWB PL 3 22 Item 3 Single board controller PWB PL 3 24 Item 3 Go to Flag 2 Measure the voltage at P J1 pin 5 on the IOT PWB Arrange for a Fax to be sent from another machine to this machine The voltage measured changes from 3 3V to 0V when the Fax arrives at the machine Y N Check the wiring and connector...

Page 93: ...NOTE Any voltage change will be small Less than 1V The voltage changes when the UI screen is touched or a UI button is pressed Y N Go to Flag 6 3 3V is available at P J130 on the User interface PWB between pins 1 and 2 Y N Go to Flag 6 3 3V is available at P J133 on the Power distribution PWB between pins 3 and 4 Y N Go to Flag 5 and Flag 7 12V is available at P J131 on the Power distribu tion PWB...

Page 94: ...rd Controller PWB Repair the wiring REP 1 2 as necessary Go to Flag 4 Measure the voltage at P J26 pin 7 on the IOT PWB The voltage changes from 3 3V to 0V when the UI screen is touched or a UI button is pressed Y N Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed PL 1 10 Item 2 Install a new LVPS and base module PL 1 10 Item 3 Figure 1 Component location Energy saver button ...

Page 95: ...May 2013 2 63 Xerox WorkCentre 5790 Family 01K Status Indicator RAPs Figure 2 Circuit diagram ...

Page 96: ...May 2013 2 64 Xerox WorkCentre 5790 Family 01K Status Indicator RAPs ...

Page 97: ...and CR15 on the IOT PWB refer to the OF7 IOT PWB Diag nostics RAP 4 Enter dC305 UI test Perform the Communications Self Test 5 Check the harness connections between the user interface PL 2 10 and the single board controller PWB PL 3 24 Item 3 6 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 02 320 02 380 UI Commu...

Page 98: ...Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 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 1 Switch off the machine then switch on the machine GP...

Page 99: ...ile performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 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 ...

Page 100: ...May 2013 2 68 Xerox WorkCentre 5790 Family 02 705 02 707 02 709 02 712 02 715 Status Indicator RAPs ...

Page 101: ... 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 randomly the cause may be due to electrical noise Go to OF10 intermittent Failure RAP If an 03 300 fault occurs with 03 320 03 330 and 03 340 fault codes together with a...

Page 102: ...May 2013 2 70 Xerox WorkCentre 5790 Family 03 300 306 461 482 805 870 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 103: ...switch on the machine GP 14 Check the fault history file for other 03 XXX fault codes If the 03 XXX fault codes occur randomly 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...

Page 104: ... 20 Single board controller PWB PL 3 24 Item 3 03 320 to 03 324 Single Board Controller PWB to DADH Error RAP 03 320 Communications between the single board controller PWB and the DADH have failed 03 321 Communications between the single board controller PWB and the DADH are out of sequence 03 322 The DADH has detected a read write error 03 323 The DADH has detected a software error 03 324 The DAD...

Page 105: ...May 2013 2 73 Xerox WorkCentre 5790 Family 03 320 to 03 324 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 106: ...o 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 randomly the cause may be due to electrical noise Go to OF10 intermittent Failure RAP If an 03 330 fault occurs with 03 300 03 320 and 03 34...

Page 107: ...May 2013 2 75 Xerox WorkCentre 5790 Family 03 330A 03 462A Status Indicator RAPs Figure 1 Circuit diagram ...

Page 108: ...May 2013 2 76 Xerox WorkCentre 5790 Family 03 330A 03 462A Status Indicator RAPs Figure 2 Circuit diagram ...

Page 109: ...er unavailable message go to the 03D Software Module 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 15 Item 4 CCD PWB PL 14 15 Item 19 Scanner daughter PWB PL 3 24 Item 20 NOTE To gain access to the scanner PWB remove the document glass ass...

Page 110: ...May 2013 2 78 Xerox WorkCentre 5790 Family 03 330B 03 462B Status Indicator RAPs Figure 1 Circuit diagram ...

Page 111: ...to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord 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 fo...

Page 112: ...ailed 03 416 The network controller software version supplied at power on is not compatible with the single board controller PWB software Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Switch off the mac...

Page 113: ... 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 randomly the cause may be due to electrical noise Go to OF10 intermittent Failure RAP Procedure 1 Switch off the machine GP 14 Ensure P J9 and P J271 are correctly and securely con nected 2 Go to Flag 1 Check the harness Repair as...

Page 114: ...e cause may be due to electrical noise Go to OF10 intermittent Failure RAP Procedure 1 Ensure the P Js on the tray 1 and 2 control PWB PL 7 10 Item 2 and the W O TAG 151 HCF PWB PL 7 20 Item 2 or W TAG 151 HCF PWB PL 7 21 Item 2 are correctly and securely connected 2 Go to Flag 1 Check the harness Repair as necessary GP 7 3 Go to Flag 1 Check the power supply lines Refer to 01G 24V Distribution RA...

Page 115: ...May 2013 2 83 Xerox WorkCentre 5790 Family 03 359 03 407 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 116: ...ower 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 4 OCT Only If the problem persist...

Page 117: ...May 2013 2 85 Xerox WorkCentre 5790 Family 03 360 03 408 to 03 410 03 418 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 118: ...OT 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 R...

Page 119: ...can cause death or injury Moving parts can cause injury 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 Procedure 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 Diagno...

Page 120: ...May 2013 2 88 Xerox WorkCentre 5790 Family 03 366 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 121: ... 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 Swit...

Page 122: ...ule 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 ...

Page 123: ...May 2013 2 91 Xerox WorkCentre 5790 Family 03 371 03 372 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 124: ...gnals 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 se...

Page 125: ...May 2013 2 93 Xerox WorkCentre 5790 Family 03 374 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 126: ...ely con nected 2 03 395 Only This fault can be caused by the following a 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 b A paper guide in a paper tray being set to the wrong paper size Check the paper guide settings in the paper trays c An HVPS fault perform the 09 060 HVPS Fault RAP 3 Perform the OF7 IOT PWB Di...

Page 127: ... 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...

Page 128: ...May 2013 2 96 Xerox WorkCentre 5790 Family 03 397 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 129: ...emporary shorting link Do not leave a shorting link installed Switch off the machine then switch on the machine GP 14 Ensure the foreign interface PWB PL 3 22 Item 4 is securely connected to the single board controller PWB PL 3 24 Item 3 NOTE Do not attach a foreign interface vend adaptor with this configuration of foreign inter face PWB Procedure Go to Flag 1 Check the harness The harness is good...

Page 130: ...May 2013 2 98 Xerox WorkCentre 5790 Family 03 412 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 131: ...edure 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...

Page 132: ...May 2013 2 100 Xerox WorkCentre 5790 Family 03 415 Status Indicator RAPs Figure 1 Circuit diagram ...

Page 133: ...mpatible Software RAP 03 419 The IOT DADH or user interface software version supplied at power on is not compati ble with the image processing software 03 420 The tray 5 module software version supplied at power on is not compatible with the image processing software Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Ref...

Page 134: ...ages out of order caused by confused software Procedure NOTE These codes record events in the fault history file but may not prevent the machine operating normally These faults will also result in a blank sheet being delivered to the output tray 1 Delete the job Switch off then switch on the machine GP 14 2 Reload the software GP 4 3 Install new components as necessary ROS PL 6 10 Item 4 Single bo...

Page 135: ...on the machine They can therefore be used as an aid to identifying the root cause of faults 03 720 ODIO Time out Error RAP 03 720 The image processing software has not detected on ODIO On Demand Image Over write completion response within 45 minutes This indicates that a memory module may be hung up or may have crashed while overwriting an image Initial Actions WARNING Ensure that the electricity ...

Page 136: ...t need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 1 Check with the customer that the AC mains line input power supply is not experiencing 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 switc...

Page 137: ...L 3 24 Item 2 Single board controller PWB PL 3 24 Item 3 Figure 1 Circuit diagram 03B Mark Service Unavailable RAP Before performing this RAP any relevant status code RAP must have been performed Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death ...

Page 138: ... The machine may intermittently display the following re occurring messages Scanner fault but no scanner fault code in fault history Re order but do not replace the fuser module but no fuser fault code in fault history Local interface problem detected Network controller unavailable Network controller unavailable together with many of one or more of 03 300 03 320 03 330 and 03 340 fault codes in fa...

Page 139: ...r does not turn go to the 04A Main Drive Motor Checkout 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 1...

Page 140: ...May 2013 2 108 Xerox WorkCentre 5790 Family 04A Status Indicator RAPs Figure 2 Circuit diagram ...

Page 141: ...erface 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 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 ...

Page 142: ...maged 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 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 G...

Page 143: ...May 2013 2 111 Xerox WorkCentre 5790 Family 05 305 Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Actuator DADH top cover interlock switch S05 305 ...

Page 144: ...documents are longer than 110mm go to the procedures that follow 05 330 05 331 DADH Feed Sensor Failure Entry RAP 05 335 DADH Takeaway Sensor Failure RAP 05 350 05 352 DADH CVT Sensor Failure RAP 05 340 DADH Registration Sensor Failure RAP 05 330 05 331 DADH Feed Sensor Failure Entry RAP 05 330 The DADH feed sensor does not detect the lead edge of the document within the cor rect time after the fe...

Page 145: ...rocedure 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 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 01D 3 3V Distribution RAP The 3 3V return in the 01B 0V Distribution RAP Install new components a...

Page 146: ...mponent location Figure 2 Component location DADH feed roll assembly DADH feed sensor Q05 330 DADH feed motor MOT05 020 DADH feed clutch CL05 025 P J201 Top cover interlock switch DADH feed solenoid SOL 05 010 CVT motor MOT 05 030 Clip Feed yoke shaft Feed yoke and spring Feed gates Feed gates ...

Page 147: ...l 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 ...

Page 148: ...n 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 b...

Page 149: ...May 2013 2 117 Xerox WorkCentre 5790 Family 05 330B 05 331B Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram Clip Feed yoke shaft Feed yoke and spring Feed gates Feed gates ...

Page 150: ...sor 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 t...

Page 151: ... RAPs Figure 1 Component location Figure 2 Circuit diagram DADH takeaway sensor Q05 335 Takeaway roll Takeaway roll idlers Feed motor tension spring Feed motor drive belt P J191 DADH feed motor MOT05 020 Top cover interlock switch DADH feed roll assembly Feed assembly ...

Page 152: ...ry 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 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 ...

Page 153: ...y 05 340 Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram DADH registration sensor Q05 340 CVT motor MOT05 030 CVT roll CVT motor tension spring CVT motor drive belt Top cover interlock switch DADH feed motor MOT05 020 ...

Page 154: ...AP 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 Check the CVT motor drive belt tension 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 NOTE The exit roll idlers remain lowered for 30 seconds Enter dC330 code 05 050 to energize the DADH duplex solenoid ...

Page 155: ...t 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 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 r...

Page 156: ...ion Figure 3 Component location CVT motor MOT05 030 Duplex solenoid SOL05 050 CVT roll CVT motor tension spring CVT roll pulley and drive belt Top cover interlock switch Feed Rolls Feed clutch Feed motor MOT05 020 Exit roll Feed motor tension spring Feed motor drive belt Exit roll pulley Exit roll idlers ...

Page 157: ... 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 ...

Page 158: ...nto 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...

Page 159: ...May 2013 2 127 Xerox WorkCentre 5790 Family 05 350 05 352 Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram Exit roll idlers ...

Page 160: ...c eliminator PL 5 17 Item 14 Static eliminator PL 5 15 Item 14 3 Use a service meter to verify that the wires to the static eliminators are well grounded giv ing a resistance reading of less than 3 ohms to ground if necessary the resistance read ing may be improved by removing cleaning and re installing the ground wires 05B DADH Document Present Sensor Failure Entry RAP Use this RAP when the DADH ...

Page 161: ...he 05K DADH Document Size Sensor Failure RAP 40 90 ppm 05D DADH Motor Failure RAP Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Go to the correct procedure DADH Feed Motor Failure DADH CVT Motor Failure NOTE ...

Page 162: ...May 2013 2 130 Xerox WorkCentre 5790 Family 05D Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Feed motor MOT05 020 CVT motor MOT05 030 ...

Page 163: ... the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 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 I...

Page 164: ...p 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 Check the CVT r...

Page 165: ...e 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 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 References GP 11 How to Check a Sensor P J184 DADH PWB 01D 3 3V Distribution RAP 01B 0V Distribution ...

Page 166: ...ent 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 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 References GP 11 How to Check a Sensor P J184 DADH PWB 01E 5V...

Page 167: ... 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 01D 3 3V Distribution RAP 01B 0V Distribution RAP refer to the 3 3V return Install n...

Page 168: ...05J Status Indicator RAPs Figure 1 Component location Figure 2 Component location DADH length sensor 1 Q05 315 DADH length sensor 2 Q05 320 DADH feed sensor Q05 330 DADH registration sensor Q05 340 DADH width guides DADH width sensor Q05 325 Arm ...

Page 169: ...May 2013 2 137 Xerox WorkCentre 5790 Family 05J Status Indicator RAPs Figure 3 Circuit diagram ...

Page 170: ...efer 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 01D 3 3V Distribution RAP 01B 0V Distribution RAP refer to the 3 3V ret...

Page 171: ...05K Status Indicator RAPs Figure 1 Component location Figure 2 Component location DADH length sensor 1 Q05 315 DADH length sensor 2 Q05 320 DADH feed sensor Q05 330 DADH registration sensor Q05 340 DADH width guides DADH width sensor Q05 325 Arm ...

Page 172: ...May 2013 2 140 Xerox WorkCentre 5790 Family 05K Status Indicator RAPs Figure 3 Circuit diagram ...

Page 173: ...fer to the 3 3V return and 24V return 01D 3 3V Distribution RAP 01G 24V Distribution RAP Enter the dC330 output code 06 020 to run the ROS motor Go to Flag 2 0V is avail able at P J2 pin 1 on the IOT PWB Y N Go to Flag 3 0V is available at P J2 pin 6 on the IOT PWB Y N Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed PL 1 10 Item 2 NOTE The ROS must be removed from the machine...

Page 174: ...May 2013 2 142 Xerox WorkCentre 5790 Family 06 020 Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram P J2 harness P J18 harness ROS P J120 P J121 ...

Page 175: ... 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 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 marked with the correct PJ numbers P J122 can be identified as a four way power ...

Page 176: ...May 2013 2 144 Xerox WorkCentre 5790 Family 06 340 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 177: ...6 350 Status Indicator RAPs 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 ...

Page 178: ...May 2013 2 146 Xerox WorkCentre 5790 Family 06 350 Status Indicator RAPs ...

Page 179: ...h 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 Perform the following Check the paper size leaf spring is mounted corr...

Page 180: ...ay 2013 2 148 Xerox WorkCentre 5790 Family 07 301 Status Indicator RAPs Figure 2 Tray 1 home switch test point Figure 3 Tray 1 circuit diagram Check the voltage at the switch terminal Tray 1 home switch ...

Page 181: ...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 Perform the following Check the paper size leaf spring is mounted...

Page 182: ...May 2013 2 150 Xerox WorkCentre 5790 Family 07 302 Status Indicator RAPs Figure 2 Home switch test point Figure 3 Tray 2 circuit diagram Check the voltage at the switch terminal Tray 2 home switch ...

Page 183: ...h 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 07 303 Tray 3 Open During Run Entry RAP 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 cha...

Page 184: ...May 2013 2 152 Xerox WorkCentre 5790 Family 07 303A Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Tray 3 home switch S07 303 Switch actuator ...

Page 185: ...ns behind the tray Ensure that the tray is pushed fully home Check the sensor flag Figure 1 Procedure Enter dC330 code 07 303 tray 3 home sensor Q07 303 Press Start Open and fully close the tray The display changes Y N Go to Flag 1 Check Q07 303 Refer to GP 11 How to Check a Sensor P J1 HCF control PWB 01E 5V Distribution RAP 01B 0V Distribution RAP Install new components as necessary Tray 3 home ...

Page 186: ...n 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 07 304 Tray 4 Open During Run Entry RAP 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...

Page 187: ...May 2013 2 155 Xerox WorkCentre 5790 Family 07 304A Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Tray 4 home switch S07 304 Switch actuator ...

Page 188: ...r obstructions behind the tray Ensure that the tray is pushed fully home Check the sensor flag Figure 1 Procedure Enter dC330 code 07 304 tray 4 home sensor Q07 304 Press Start Open and fully close the tray The display changes Y N Go to Flag 1 Check Q07 304 Refer to GP 11 How to Check a Sensor P J1 HCF control PWB 01B 0V Distribution RAP Install new components as necessary Tray 4 home sensor PL 7 ...

Page 189: ...at 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...

Page 190: ...ter 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 T...

Page 191: ... Status Indicator RAPs 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 Empty RAP Figure 1 Component location Figure 2 Circuit diagram Drive gears Stack height mechanism actuator ...

Page 192: ...hanges 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 01B 0V Distribution RAP 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 CAUTION To prevent damage to the elevator and paper feed mechanism the paper tray must be pulled out before MOT07 020 is run in...

Page 193: ... 3 stack height sensor does 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 Procedure Go to the relevant procedure W O TAG 151 go to the 07 355A Tray 3 Elevator Lift Failure RAP W O TAG 151 W TAG 151 go to the 07 355B Tray 3 Elevator Lift Failure RAP W TAG 151 ...

Page 194: ...s 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 Disconnect P J396 on the HCF control PWB Flag 3 Connect a service meter between pin 1 and pin 3 on the wiring side of the connector Continuity is mea...

Page 195: ...55A Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Tray 3 elevator MOT07 030 Tray 3 home switch S07 303 HCF control PWB Tray 3 feed assembly Tray 3 feed sensor Q08 103 Stack limit switch S07 393 Stack height sensor Q07 383 ...

Page 196: ... 11 How to Check a Sensor P J1 HCF control PWB 01E 5V Distribution RAP 01B 0V Distribution RAP Install new components as necessary Tray 3 stack height sensor PL 8 32 Item 7 HCF control PWB PL 7 21 Item 2 Disconnect P J10 on the HCF control PWB Flag 3 Connect a service meter between pin 1 and pin 2 on the wiring side of the connector Continuity is measured when the stack limit switch is deactuated ...

Page 197: ...B Status Indicator RAPs Figure 1 Component location Figure 2 Component location Tray 3 feed assembly Tray 3 over elevate switch Tray 3 stack height sensor Q07 383 HCF control PWB Tray 3 home sensor Q07 303 Tray 3 elevator MOT07 030 Tray 3 feed assembly ...

Page 198: ...ray 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 Procedure Go to the relevant procedure W O TAG 151 go to the 07 360A Tray 4 Elevator Lift Failure RAP W O TAG 151 W TAG 151 go to the 07 360B Tray 4 Elevator Lift Failure RAP W TAG 151 ...

Page 199: ...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...

Page 200: ...ly 07 360A Status Indicator RAPs Figure 1 Component location Figure 2 Tray 4 Circuit diagram Tray 4 elevator motor MOT07 040 Tray 4 feed assembly Tray 4 home switch S07 304 HCF control PWB Stack height sensor Q07 384 Stack limit switch S07 394 ...

Page 201: ... 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 J3 HCF control PWB 01E 5V Distribution RAP 01B 0V Distribution RAP Install new components as necessary Tray 4 stack height sensor PL 8 33 Item 6 HCF control PWB PL 7 21 Item 2 Disconnect P J12 on the HCF control PWB Flag 3 Connect...

Page 202: ...atus Indicator RAPs Figure 1 Component location Figure 2 Component location Tray 4 feed assembly Stack height sensor Q07 384 Tray 4 over elevate switch S07 394 Tray 4 feed assembly HCF control PWB Tray 4 home sensor Q07 304 Tray 4 elevator motor MOT07 040 ...

Page 203: ...se injury 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 n...

Page 204: ...orkCentre 5790 Family 07 372 Status Indicator RAPs Figure 1 Component location Figure 2 Component location Figure 3 Tray 1 circuit diagram Tray 5 docking switch S07 372 Tray 5 docking location pin Docking latch Rail assembly ...

Page 205: ... 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...

Page 206: ...re 1 Component location Figure 2 Component location Tray 5 elevator MOT07 373 Tray 5 control PWB Tray 5 elevator motor encoder Q07 406 Stack height sensor Q07 402 Tray upper limit switch S07 412 Cable holder Tray upper limit switch actuator S07 412 Door interlock switch S07 306 ...

Page 207: ...May 2013 2 175 Xerox WorkCentre 5790 Family 07 373 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 208: ...405 Figure 1 Press Start Man ually activate the stack down sensor actuator The display changes Y N Go to Flag 2 Check Q07 405 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 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 Ma...

Page 209: ...nt location Figure 2 Component location Tray 5 elevator motor MOT07 373 Tray 5 control PWB Tray 5 elevator motor encoder sensor Q07 406 Stack down sensor Q07 405 Cable holder Tray down limit switch S07 415 Located in the paper tray press the plate under the paper tray to actuate the switch ...

Page 210: ...May 2013 2 178 Xerox WorkCentre 5790 Family 07 374 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 211: ...sor 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 2 P J275 Tray 1 and 2 control PWB 01E 5 V Distribution RAP 01B 0V Distributi...

Page 212: ...aken 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...

Page 213: ...f paper 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 the tray 3 level encoder Q07 338 Tray 4 Go to Flag 2 Check the tray 4 level encoder Q07 339 Refer to GP 11 How to Check a Sensor NOTE In this check place a piece of paper between the sensor The check is diffi cult due to the problem in moving the timing disc Fig...

Page 214: ...y 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 ...

Page 215: ...fore 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 Figure 1 Component location Figure 2 Circuit diagram Feed solenoid SOL08 050 Width sensor guide Q07 350 Tray empt...

Page 216: ...ck 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 si...

Page 217: ...y 1 paper size table Paper Size switch 4 S07 314 Size switch 3 S07 313 Size switch 2 S07 312 Size switch 1 S07 311 A4 LEF 5V 5V 0V 5V A4 SEF 0V 5V 0V 5V A5 LEF 0V 0V 0V 5V A3 SEF 5V 0V 5V 5V 216 x 315mm SEF 0V 5V 5V 0V 216 x 330mm SEF 0V 0V 5V 0V 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...

Page 218: ...Tray 2 size switch test point Table 2 Tray 2 paper size table Paper Size switch 4 S07 324 Size switch 3 S07 323 Size switch 2 S07 322 Size switch 1 S07 321 A4 LEF 5V 5V 0V 5V A4 SEF 0V 5V 0V 5V A5 LEF 0V 0V 0V 5V Size switch 4 test point Size switch 3 test point Size switch 2 test point Size switch 1 test point ...

Page 219: ... the actuator is missing from the tray empty sensor Procedure Go to the relevant procedure 07G Tray 3 or Tray 4 Out of Paper RAP W TAG 151 07L Tray 3 or Tray 4 Out of Paper RAP W O TAG 151 A3 SEF 5V 0V 5V 5V 216 x 315mm SEF 0V 5V 5V 0V 216 x 330mm SEF 0V 0V 5V 0V 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 ...

Page 220: ...pty 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 Actuate the tray empty sensor with a piece of paper 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 J1 HCF control PWB Tray 4 P J3 HCF control PWB 01E 5V Distribution RAP ...

Page 221: ...ower cord Electricity can cause death or injury Moving parts can cause injury Switch off the machine then switch on the machine GP 14 Check that the tray elevator cables and mechanisms are located correctly Check that the tray is pushed fully home Check for obstructions behind the tray Check the feed heads Procedure If tray 1 or tray 2 are out of service Check the following and install new compone...

Page 222: ...nd empty Figure 1 Check the sensor for contamination Procedure Enter dC330 code 07 401 tray 5 empty sensor Press Start Manually actuate the tray empty sensor The display changes Y N Go to Flag 1 Check Q07 401 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 empty sensor PL 8 45 Item 6 Tray 5 co...

Page 223: ...y 4 Elevator Lift Up Failure RAP Pull out the tray and load a ream of paper 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 NOTE In this check place a piece of paper between the sensor The check is diffi c...

Page 224: ...May 2013 2 192 Xerox WorkCentre 5790 Family 07K Status Indicator RAPs Figure 1 Component location Figure 2 Circuit Diagram Tray 3 low paper sensor Tray 4 low paper sensor HCF control PWB P J 390 ...

Page 225: ...or 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 Actuate the tray empty sensor with a piece of paper 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 ...

Page 226: ...May 2013 2 194 Xerox WorkCentre 5790 Family 07L Status Indicator RAPs Figure 2 Circuit diagram ...

Page 227: ...ctions in the paper path 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 En...

Page 228: ...roll drives 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 Item 2 PL 8 25 Item 3 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 The transport rolls for wear PL 8...

Page 229: ...aper 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 compone...

Page 230: ...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 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 Figure 1...

Page 231: ...pair 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 Pro...

Page 232: ...s 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 elevator 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 dri...

Page 233: ...e 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...

Page 234: ...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 elevator 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 I...

Page 235: ...f 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 Procedure Go to the relevant procedure W TAG 151 go to the 08 103B 08 113B Tray 3 Misfeed RAP W TAG 151 W O TAG 151 go to the 08 103A 08 113A Tray 3 Misfeed RAP W O TAG 151 ...

Page 236: ...30 Item 8 PL 8 30 Item 9 CAUTION To prevent damage to the feed mechanism the paper tray must be pulled out before MOT 08 030 is run in diagnostics 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 com...

Page 237: ... 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 Figure 1 Component location Figure 2 Circuit diagram Tray 3 feed sensor Q08 103 Tray 3 and 4 transport motor MOT08 045 Tray 3 feed motor MOT08 030 HCF control PWB ...

Page 238: ...em 7 Drive belt PL 8 36 Item 6 Transport gear pulley PL 8 36 Item 12 CAUTION To prevent damage to the feed mechanism the paper tray must be pulled out before MOT 08 030 is run in diagnostics Enter dC330 code 08 030 tray 3 feed motor MOT08 030 Figure 1 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 J1 HCF control PWB 01G 24V Distr...

Page 239: ... install new compo nents PL 7 19 Item 7 If the fault still occurs refer to GP 7 and check the following The takeaway roll assembly PL 8 36 Item 2 The idler roll assembly PL 8 36 Item 8 The tray 3 and 4 transport roll PL 8 32 Item 4 The idler roll assembly PL 8 33 Item 2 Figure 1 Component location Figure 2 Component location HCF transport motor MOT08 045 HCF control PWB Tray 3 feed motor MOT08 030...

Page 240: ...ad edge of the paper failed to actuate the tray HCF exit sensor within the correct time after feeding paper from tray 4 W TAG 151 08 114 Tray 4 sensor did not de actuate within the correct time after the sensor was actuated W O TAG 151 08 114 The HCF exit sensor did not de actuate within the correct time after the sensor was actuated W TAG 151 Procedure Go to the relevant procedure W O TAG 151 go ...

Page 241: ... 2 The transport rolls rotate Y N Check the drive belt and gears GP 7 PL 8 30 Item 9 PL 8 30 Item 8 CAUTION To prevent damage to the feed mechanism the paper tray must be pulled out before MOT 08 040 is run in diagnostics Enter dC330 code 08 040 tray 4 feed motor MOT08 040 Pull out the tray Press Start The motor runs Y N Go to Flag 3 Check MOT08 040 Refer to GP 10 How to Check a motor P J391 HCF c...

Page 242: ...eck the tray 4 corner separation strip for paper cut damage If necessary install new components PL 7 15 Item 22 Check the tray 4 top edge flexure spring for paper cut damage If necessary install new components PL 7 17 Item 12 Figure 1 Component location Figure 2 Circuit diagram Tray 3 and 4 transport motor MOT08 045 Tray 4 feed sensor Q08 104 Tray 4 feed motor MOT08 040 HCF control PWB ...

Page 243: ... HCF control PWB PL 7 21 Item 2 Observe the tray 3 and 4 transport roll PL 8 32 Item 4 and the takeaway roll assembly PL 8 36 Item 2 The transport roll and takeaway roll rotate Y N Check the following Drive coupling PL 8 36 Item 7 Drive belt PL 8 36 Item 6 Transport gear pulley PL 8 36 Item 12 CAUTION To prevent damage to the feed mechanism the paper tray must be pulled out before MOT 08 040 is ru...

Page 244: ...4 check that the top surface of the metal paper tray is the same dis tance from the inside top of the slots 5 If the tray is not level then install new elevator cables PL 7 18 Item 4 PL 7 18 Item 5 and PL 7 18 Item 7 Check the tray 4 paper tray guide for paper cut damage If necessary install new compo nents PL 7 19 Item 6 Figure 1 Component location Figure 2 Component location HCF transport motor ...

Page 245: ...rrect size of paper is displayed If intermittent jams are occuring from all trays except the bypass tray clean the tray 1 feed sensor PL 7 30 Item 24 and the tray 2 feed sensor PL 7 30 Item 24 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 ...

Page 246: ... 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 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 ...

Page 247: ...n 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 cod...

Page 248: ...90 Family 08 107 Status Indicator RAPs Figure 1 Component location Figure 2 Component location Tray 3 and 4 transport motor MOT08 045 Tray 4 feed sensor Q08 104 Tray 3 paper path rolls Tray 4 paper path rolls Drive belt Drives coupling ...

Page 249: ... Tray 4 Paper Feed Jam Entry RAP 08 108 The lead edge of the paper was late to tray 2 feed sensor when feeding from tray 3 or tray 4 Procedure Go to the relevant procedure W O TAG 151 go to the 08 108A Tray 3 or Tray 4 Paper Feed Jam RAP W O TAG 151 W TAG 151 go to the 08 108B Tray 3 or Tray 4 Paper Feed Jam RAP W TAG 151 ...

Page 250: ...102 Press Start Manually actuate the sen sor Figure 1 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 Pres...

Page 251: ...May 2013 2 219 Xerox WorkCentre 5790 Family 08 108A Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Tray 2 feed sensor Q08 102 Tray 3 and 4 transport motor MOT08 045 ...

Page 252: ...30 code 08 102 tray 2 feed sensor Q08 102 Press Start Manually actuate the sen sor Figure 1 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 HCF t...

Page 253: ...ntre 5790 Family 08 108B Status Indicator RAPs Figure 1 Component location Figure 2 Component location Tray 2 feed sensor Q08 102 HCF transport motor MOT08 045 Drive coupling Drive belt Takeaway roll assembly Idler roll assembly ...

Page 254: ...t 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 R...

Page 255: ...5 Item 14 The feed roll rotates Y N Check the one way coupling feed roll and clutch Install new components as necessary One way coupling PL 8 45 Item 4 Clutch PL 8 45 Item 13 Feed roll PL 8 45 Item 12 The nudger roll rotates Y N Check the nudger roll and the one way gear Check the drive belt between the feed roll and the nudger roll Install new components as necessary One way gear PL 8 45 Item 3 D...

Page 256: ...2 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 ADJ 7 6 Tray 5 Stack Height Sensor and Retard Shield Clean the feed roll using a cloth dampened with water Install a new feed nudger and retard...

Page 257: ...May 2013 2 225 Xerox WorkCentre 5790 Family 08 115A 08 117A Status Indicator RAPs Figure 3 Circuit diagram ...

Page 258: ...P Install new components as necessary Tray 5 feed motor PL 8 40 Item 3 Tray 5 control PWB PL 7 68 Item 8 The feed shaft rotates Y N Check the drive gears between the motor and the feed shaft Install new components as necessary Motor drive gear PL 8 40 Item 5 Gear 30T bearing PL 8 40 Item 21 Gear PL 8 45 Item 14 The feed roll rotates Y N Check the one way coupling feed roll and clutch Install new c...

Page 259: ...E 5V Distribution RAP 01B 0V Distribution RAP 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 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 cont...

Page 260: ...May 2013 2 228 Xerox WorkCentre 5790 Family 08 115B 08 117B Status Indicator RAPs Figure 2 Component location Wait sensor Q08 100 Left hand door ...

Page 261: ...May 2013 2 229 Xerox WorkCentre 5790 Family 08 115B 08 117B Status Indicator RAPs Figure 3 Circuit diagram ...

Page 262: ... 32 Item 6 HCF control PWB PL 7 21 Item 2 CAUTION To prevent damage to the feed mechanism the paper tray must be pulled out before MOT 08 030 is run in diagnostics 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 J4 HCF control PWB 01G 24V Distribution RAP 01B 0V Distribution RAP ...

Page 263: ...May 2013 2 231 Xerox WorkCentre 5790 Family 08 131 Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram Tray 3 exit sensor Q08 109 ...

Page 264: ...Start Manually actuate the HCF exit sensor The display changes Y N Go to Flag 1 Check Q08 108 Refer to GP 11 How to Check a Sensor P J3 HCF control PWB 01E 5V Distribution RAP 01B 0V Distribution RAP Install new components as necessary HCF exit sensor PL 8 33 Item 3 HCF control PWB PL 7 21 Item 2 Enter dC330 code 08 045 HCF transport motor MOT08 045 Press Start The motor runs Y N Go to Flag 2 Chec...

Page 265: ...May 2013 2 233 Xerox WorkCentre 5790 Family 08 132 Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram Takeaway roll assembly Idler roll assembly Drive belt Drive coupling ...

Page 266: ... 08 108 HCF exit sensor Q08 104 Press Start Manually actuate the HCF exit sensor The display changes Y N Go to Flag 1 Check Q08 108 Refer to GP 11 How to Check a Sensor P J3 HCF control PWB 01E 5V Distribution RAP 01B 0V Distribution RAP Install new components as necessary HCF exit sensor PL 8 33 Item 3 HCF control PWB PL 7 21 Item 2 Enter dC330 code 08 045 HCF transport motor MOT08 045 Press Star...

Page 267: ...r 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 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 150A 08 151A Registration Jam RAP 35 55 ppm If the speed of the machine is 65 9...

Page 268: ...gistration 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 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 08 100 wait sensor Q08 100 Press Start Open the ...

Page 269: ... Family 08 150A 08 151A Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Registration sensor Q08 150 Wait sensor Q08 100 Registration rolls Registration clutch CL08 070 Registration transport rolls Left hand door ...

Page 270: ...and 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 1 10 Item 2 Enter dC330 code 08 100 wait sensor Q0...

Page 271: ...amily 08 150B 08 151B Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Registration sensor Q08 150 Wait sensor Q08 100 Registration nip rolls Registration clutch CL08 070 Registration transport rolls Left hand door ...

Page 272: ...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 Ste...

Page 273: ...m 2 Perform the following Check the registration transport rolls and registration nip rolls Figure 2 PL 8 15 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 I...

Page 274: ...amily 08 155A 08 156A Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram Registration sensor Q08 150 Registration clutch CL08 070 Registration nip rolls Wait sensor Q08 100 Left hand door Registration transport rolls ...

Page 275: ... 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 P...

Page 276: ...e 1 Component location Figure 2 Component location Feed solenoid SOL08 050 Feed roll Feed roll drive gear Upper guide and idler rolls Bypass tray Registration sensor Q08 150 Registration clutch CL08 070 Registration nip rolls Wait sensor Q08 100 Left hand door Registration transport rolls ...

Page 277: ...rrect 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 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 160A 08 161A Duplex Paper Path Jam RAP 35 55 ppm If the spee...

Page 278: ...ns 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 Duplex motor driver PWB 35 55 ppm PL 8 22 Item 9 Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed PL 1 10 Item ...

Page 279: ...T PWB is installed PL 1 10 Item 2 Check the following refer to GP 7 Duplex nip rolls 35 55 ppm PL 8 22 Item 7 Nip split shaft assembly PL 10 11 Item 4 Idler rolls PL 10 12 Item 15 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 Figure 1 Component location Duplex sensor Q08 160 Duplex motor MOT08 ...

Page 280: ...May 2013 2 248 Xerox WorkCentre 5790 Family 08 160A 08 161A Status Indicator RAPs Figure 2 Circuit diagram Figure 3 Circuit diagram ...

Page 281: ...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 65 90 ppm PL 8 20 Item 8 Duplex motor driver PWB 65 90 ppm PL 8 20 Item 9 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 the drive belt and pulleys 65 90 ppm PL 8 20 I...

Page 282: ...m PL 8 20 Item 7 Nip split shaft assembly PL 10 11 Item 4 Idler rolls PL 10 12 Item 15 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 Figure 1 Component location Figure 2 Circuit diagram Duplex sensor Q08 160 Duplex motor MOT08 060 Inverter motor MOT10 030 Inverter nip solenoid SOL10 050 Inverte...

Page 283: ...he power cord Electricity can cause death or injury Moving parts can cause injury 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 correc...

Page 284: ...80 The machine has detected that the previous sheet has not correctly fed through the paper path Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Clear the paper path Procedure 35 55 ppm Perform the follow...

Page 285: ...roblem 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 08 182 Unexpected Time Out in Duplex Mode RAP 08 182 The IOT detected an unexpected time out for a known duplex sheet of paper Initi...

Page 286: ...se injury 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 punch sensor PL 11 6 Item 7 HVF paper edg...

Page 287: ...do not resolve the image quality problem return to IQ3 Xerographic RAP NOTE The following are the only values that can be measured from the HVPS Charge scorotron grid 425V 21V The two terminals identified as G are the same output Registration chute bias 490V 25V The two terminals identified as CB are the same output Developer bias 370V 20V 50V NOTE The charge transfer and detack corotron have 47k ...

Page 288: ...as 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 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 The high display indicates that the developer bias harness is shorted to ground Confirm this diagnosis by disconnecting the developer bias harness from the HVPS and mak...

Page 289: ...on connector Detack corotron connector 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 terminals identified as CB are the same output Bias contact Halo guide Registration guide Registration chute bias connection ...

Page 290: ...May 2013 2 258 Xerox WorkCentre 5790 Family 09 060 Status Indicator RAPs Figure 4 Component location Figure 5 Circuit diagram Developer bias connection ...

Page 291: ...B 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 module 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 Check the toner dispense drive gears Figure 1 and Figure 2 If necessary install a new toner dispense module 35 55 ppm ...

Page 292: ... Family 09 310 09 390 Status Indicator RAPs Figure 2 Component Location Figure 3 Circuit diagram Low toner sensor Q09 310 Toner cartridge motor MOT 09 045 Toner cartridge drive gears In line connector PJ75 Toner dispense motor MOT 09 040 ...

Page 293: ...P 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 Perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed PL 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 disp...

Page 294: ...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 perform the 01G 24V ...

Page 295: ... 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 Figure 1 Component location Figure 2...

Page 296: ...sor Failure RAP If not continue at the Procedure NOTE If the machine is unable to make 20 prints perform the TC Increase Adjustment 1 The prints or copies are faint 2 The toner cartridge is not rotating 3 The low toner sensor 09 310 reading is high Procedure NOTE The door interlock switch must be cheated when checking 24V components Enter dC330 code 04 010 to run the main drive motor Go to Flag 1 ...

Page 297: ...ue 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 ...

Page 298: ...6 Xerox WorkCentre 5790 Family 09 360 09 361 09 362 09 363 Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram TC sensor Q09 360 Toner dispense drive gears Toner dispense motor MOT09 040 P J93 ...

Page 299: ...dity sensor ambient temperature sensor 35 ppm PL 9 22 Item 4 40 90 ppm PL 9 20 Item 4 If the fault continues perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is 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...

Page 300: ...terlock 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 01E 5V Distribution RAP 01B 0V 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...

Page 301: ...May 2013 2 269 Xerox WorkCentre 5790 Family 09 370 Status Indicator RAPs Figure 1 Component Location Figure 2 Circuit diagram Temperature sensor Q09 370 P J47 ...

Page 302: ...f the fault persists perform OF7 IOT PWB Diagnostics RAP before a new IOT PWB is installed PL 1 10 Item 2 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 Enter dC330 code 09 375 ambient temperature sensor Q09 375 Press s...

Page 303: ...parts can cause injury 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 s...

Page 304: ...May 2013 2 272 Xerox WorkCentre 5790 Family 09 380 Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Waste toner door Waste toner door switch S09 380 Waste toner bottle ...

Page 305: ... is no communication with the CRUM when the system is configured to aftermarket 3rd party 5 If the fault persists perform the following a Reset the machine configuration perform GP 15 How to Set the Machine Configura tion b 03 371 03 372 Fuser and Xerographic CRUM Communication Error RAP To Change the Service Plan Type 1 Ensure a xerographic module to match the new service plan is installed in the...

Page 306: ...electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Check if the waste toner 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 ...

Page 307: ...May 2013 2 275 Xerox WorkCentre 5790 Family 09B Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Waste toner full sensor Q09 350 P J48 ...

Page 308: ... is running Y N Go to Flag 1 Check the photoreceptor fan motor Refer to GP 10 How to Check a Motor Check the following 11V at P J42 during standby rising to 15V during run 11V at P J17 during standby rising to 15V during run Continuity between PJ42 and P J17 If necessary repair the harness REP 1 2 Install new components as necessary Photoreceptor fan assembly PL 9 25 Item 6 LVPS and base module PL...

Page 309: ...n the correct time after the registration clutch was energized for a duplex sheet side 2 Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury WARNING Do not touch the fuser while it is hot Make sure that the c...

Page 310: ...5 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 ...

Page 311: ...rkCentre 5790 Family 10 101A 10 102A 10 103A Status Indicator RAPs Figure 1 Component location Figure 2 Component location Fuser exit switch S10 100 Registration sensor Q08 150 Registration clutch CL08 070 Registration rolls ...

Page 312: ...13 2 280 Xerox WorkCentre 5790 Family 10 101A 10 102A 10 103A Status Indicator RAPs Figure 3 Component location Figure 4 Circuit diagram Vacuum transport fan MOT10 065 Transport rolls Transfer detack corotron ...

Page 313: ...s 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 Ite...

Page 314: ...tem 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...

Page 315: ...01B 10 102B 10 103B Status Indicator RAPs Figure 2 Component location Figure 3 Component location Registration sensor Q08 150 Registration clutch CL08 070 Registration nip rolls Vacuum transport fan MOT10 065 Transport rolls Transfer detack corotron ...

Page 316: ...cause injury WARNING Do not touch the fuser while it is hot WARNING Take care during this procedure Motors will become hot during normal operation 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 P...

Page 317: ...otates counterclockwise Y N Go to Flag 3 Check MOT10 030 Refer to GP 10 How to Check a Motor P J4 IOT PWB P J45 P J55 inverter motor driver PWB 01G 24V Distribution RAP 01E 5V Distribution RAP 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...

Page 318: ...ay 2013 2 286 Xerox WorkCentre 5790 Family 10 107 10 108 10 109 10 110 Status Indicator RAPs Figure 2 Component location 35 55 ppm Inverter path solenoid SOL10 045 Upper baffle Fuser exit switch S10 100 ...

Page 319: ...May 2013 2 287 Xerox WorkCentre 5790 Family 10 107 10 108 10 109 10 110 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 320: ...avity gate mylar kit Check for obstructions in the exit area Check that the output device is parallel to the machine Refer to the appropriate adjust ment ADJ 11 2 110 Machine to 2K LCSS Alignment ADJ 11 1 171 Machine to HVF HVF BM HVF BM to Tri folder Alignment 35 55 ppm Only For 10 126 faults If the machine has a OCT make sure that the OCT fingers are installed correctly Refer to REP 12 1 For 10 ...

Page 321: ...cessary 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 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 ...

Page 322: ... 10 126 Status Indicator RAPs Figure 2 Component location 65 90 ppm Figure 3 Component location Fuser exit switch S10 100 IOT exit sensor Q10 120 Inverter path solenoid SOL10 045 Inverter nip solenoid SOL10 050 5 Upper gravity fingers 4 Lower gravity fingers ...

Page 323: ...May 2013 2 291 Xerox WorkCentre 5790 Family 10 120 10 121 10 126 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 324: ...em 4 Check the inverter upper baffle assembly Figure 1 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 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 Dis...

Page 325: ...May 2013 2 293 Xerox WorkCentre 5790 Family 10 132 10 133 10 134 Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram Inverter nip split solenoid SOL10 055 Inverter sensor Q10 105 ...

Page 326: ...bstructions in the exit area If the fault is caused by a multifeed of sheets go to OF8 Multifeed RAP Procedure 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 105 Refer to GP 11 How to Check a Sensor Figure 3 P J61 IOT PWB 01E 5V ...

Page 327: ...tribution RAP 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 Install a new inverter motor driver PWB PL 10 11 Item 22 Check the following components refer to GP 7 Idler roll PL 10 12 Item 15 Upper baffle 65 90ppm PL 10 12 Item ...

Page 328: ...tre 5790 Family 10 135 10 136 10 137 10 138 Status Indicator RAPs Figure 2 Component location Figure 3 Inverter assembly 5 Upper gravity fingers 4 Lower gravity fingers Inverter nip split solenoid SOL10 055 Inverter sensor Q10 105 ...

Page 329: ...May 2013 2 297 Xerox WorkCentre 5790 Family 10 135 10 136 10 137 10 138 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 330: ...erature 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 values are set to the default level If the values are not at default then 10 320 10 321 10 340 a...

Page 331: ... 5790 Family 10 315 10 320 10 321 10 323 10 340 10 350 10 Status Indicator RAPs Figure 2 Component location Figure 3 Component location 35 ppm Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 P J100 LVPS IOT PWB HVPS PJ24 ...

Page 332: ...May 2013 2 300 Xerox WorkCentre 5790 Family 10 315 10 320 10 321 10 323 10 340 10 350 10 360 Status Indicator RAPs Figure 4 Component location 40 90 ppm HVPS PJ24 IOT PWB LVPS ...

Page 333: ...May 2013 2 301 Xerox WorkCentre 5790 Family 10 315 10 320 10 321 10 323 10 340 10 350 10 Status Indicator RAPs Figure 5 Circuit diagram ...

Page 334: ...ngs in dC131 are set to default If the fuser 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 ...

Page 335: ...10 330 10 370 Status Indicator RAPs Figure 1 Component location Figure 2 Component location Pin 5 Pin 6 Pin 4 Pin 3 Pin 10 Pin 9 Pin 8 Pin 7 Pin 2 Pin 1 CRUM Fuser drive gear Web drive gear P J 100 Pin 2 Pin 3 Pin 1 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 P J 100 ...

Page 336: ...2 304 Xerox WorkCentre 5790 Family 10 322 10 324 10 325 10 330 10 370 Status Indicator RAPs Figure 3 Component location 35 ppm Figure 4 Component location 40 90 ppm LVPS IOT PWB HVPS P J24 HVPS PJ24 IOT PWB LVPS ...

Page 337: ...May 2013 2 305 Xerox WorkCentre 5790 Family 10 322 10 324 10 325 10 330 10 370 Status Indicator RAPs Figure 5 Circuit diagram ...

Page 338: ...se death or injury Moving parts can cause injury WARNING Do not touch the fuser while it is hot Check the fuser web motor drive coupling Figure 2 Check the fuser drawer connector Figure 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...

Page 339: ...y 10A Status Indicator RAPs Figure 1 Component location Figure 2 Component location Fuser web motor assembly MOT10 010 Fuser drawer connector P J100 Drive coupling for the web assembly Fuser module Fuser drawer connector P J100 Fuser drive gear ...

Page 340: ...May 2013 2 308 Xerox WorkCentre 5790 Family 10A Status Indicator RAPs Figure 3 Circuit diagram ...

Page 341: ...ate 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 ...

Page 342: ...May 2013 2 310 Xerox WorkCentre 5790 Family 11 005 110 11 006 110 11 310 110 11 311 110 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 343: ...rade 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 ...

Page 344: ...tre 5790 Family 11 007 110 11 008 110 11 312 110 11 313 110 11 Status Indicator RAPs Figure 1 Component Location Rear tamper motor MOT11 004 located at the front Rear tamper away home sensor Q11 319 Rear tamper home sensor Q11 311 ...

Page 345: ...May 2013 2 313 Xerox WorkCentre 5790 Family 11 007 110 11 008 110 11 312 110 11 313 110 11 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 346: ...ut 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 s...

Page 347: ...May 2013 2 315 Xerox WorkCentre 5790 Family 11 024 110 11 025 110 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 348: ...by poorly stacked sets failing to actuate the bin 1 upper level sensor Perform the relevant check If paper is overflowing the tray when it is at the lower limit check the tray 90 full sensor If paper cannot be fed to bin 1 when it is at the highest position check the bin 1 paper sensor low and bin 1 paper sensor high Check the front and rear bin 1 drive belts If necessary install new components PL...

Page 349: ...ter dC330 code 11 331 actuate the bin 1 90 full sensor Q11 331 The display changes Y N Go to Flag 7 Check Q11 331 Refer to 11G 110 2K LCSS PWB Damage RAP GP 11 How to Check a Sensor P J316 2K LCSS PWB 11D 110 2K LCSS Power Distribution RAP Repair or install new components as necessary Bin 1 90 full sensor Q11 331 PL 11 10 Item 5 2K LCSS PWB PL 11 26 Item 1 As final actions check the following sequ...

Page 350: ... 110 11 335 110 11 336 110 Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram Bin 1 elevator motor MOT11 030 Bin 1 motor encoder sensor Q11 336 Bin 1 90 full sensor Q11 331 Bin 1 upper limit switch S11 334 Bin 1 lower limit switch S11 335 ...

Page 351: ...May 2013 2 319 Xerox WorkCentre 5790 Family 11 030 110 11 334 110 11 335 110 11 336 110 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 352: ...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 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 Check Q11 350 Refer to 11G 110 2K LCSS PWB Damage RAP GP 11 How to Check a Sensor P J307...

Page 353: ...5790 Family 11 043 110 11 350 110 Status Indicator RAPs Figure 1 Component location Figure 2 Component location Punch head home sensor Q11 350 Hole punch motor MOT11 042 Punch head present sensor Q11 351 Chad bin level sensor Q11 348 ...

Page 354: ...May 2013 2 322 Xerox WorkCentre 5790 Family 11 043 110 11 350 110 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 355: ...e 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 NO...

Page 356: ...y 11 050 110 11 360 110 Status Indicator RAPs Figure 1 Component location Staple head including MOT11 050 and staple head 1 home sensor Q11 360 SU1 safety gate switch S11 365 Safety gate switch connector Switch cam Spring Switch support bracket ...

Page 357: ...May 2013 2 325 Xerox WorkCentre 5790 Family 11 050 110 11 360 110 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 358: ...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 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 Check MOT11 053 Refer t...

Page 359: ...May 2013 2 327 Xerox WorkCentre 5790 Family 11 053 110 11 370 110 Status Indicator RAPs Figure 1 Component location SU1 motor MOT11 053 SU1 home sensor Q11 370 SU1 front index sensor Q11 371 ...

Page 360: ...May 2013 2 328 Xerox WorkCentre 5790 Family 11 053 110 11 370 110 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 361: ...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 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 swit...

Page 362: ...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 ...

Page 363: ...May 2013 2 331 Xerox WorkCentre 5790 Family 11 110 110 Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Punch sensor Q11 110 ...

Page 364: ...y Damage in the 2K LCSS RAP and the 11J 110 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 2K LCSS interlocks must be made to supply 24V to the motors NOTE In diagnostics actuating any 2K LCSS sensor or switch can change th...

Page 365: ...3 Xerox WorkCentre 5790 Family 11 130 110 11 132 110 Status Indicator RAPs Figure 1 Component location Top exit sensor Q11 130 Diverter gate solenoid S11 002 Transport motor 2 MOT11 001 Transport motor 1 MOT 11 000 ...

Page 366: ...May 2013 2 334 Xerox WorkCentre 5790 Family 11 130 110 11 132 110 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 367: ... 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 1 to the compiler and for poor stacking on bin 1 Ensure that the 2K LCSS is fully latched to the machine refer to REP 11 13 110 Torn paper fragments from a previous jam clearance action If the paper has dog ear on the inboard corner install TAG 005 Rear gravity gate ...

Page 368: ...nstall 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 Figure 1 Component location Transport motor 2 MOT11 001 Diverter gate solenoid S11 002...

Page 369: ...May 2013 2 337 Xerox WorkCentre 5790 Family 11 140 110 11 142 110 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 370: ... RAP 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 Ent...

Page 371: ...May 2013 2 339 Xerox WorkCentre 5790 Family 11 300 110 11 302 110 11 303 110 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 372: ...ejector home sensor Q11 320 The display changes Y N Go to Flag 1 Check Q11 320 Refer to 11G 110 2K LCSS PWB Damage RAP GP 11 How to Check a Sensor Figure 1 P J304 2K LCSS PWB 11D 110 2K LCSS Power Distribution RAP Repair or install new components as necessary Ejector home sensor Q11 320 PL 11 18 Item 3 2K LCSS PWB PL 11 26 Item 1 Enter dC330 code 11 023 ejector cycle check the operation of the eje...

Page 373: ... 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 Figure 1 Component location Ejector home sensor Q11 320 Ejector out sensor Q11 322 Ejector motor MOT11 020 Ej...

Page 374: ...May 2013 2 342 Xerox WorkCentre 5790 Family 11 320 110 11 322 110 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 375: ...cs 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 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 insta...

Page 376: ...May 2013 2 344 Xerox WorkCentre 5790 Family 11 364 110 Status Indicator RAPs Figure 2 Staple cartridge open Figure 3 Staple cartridge closed Forming plate open Primed staples Forming plate fully closed ...

Page 377: ...May 2013 2 345 Xerox WorkCentre 5790 Family 11 364 110 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 378: ...d for stapling when both sensors are made The paddle motor drives in reverse to lower the safety gate until the safety gate interlock switch is made This process is a safety feature The stapler is then cycled once to staple the set 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 Ente...

Page 379: ...ock 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 Figure 1 Component location Figure 2 Component location Edg...

Page 380: ...May 2013 2 348 Xerox WorkCentre 5790 Family 11A 110 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 381: ...gnostics 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 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 o...

Page 382: ...ood 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 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 30...

Page 383: ...to Flag 1 ACL is available at CN1 between pins 1 and 3 Y N Go to the 01C AC Power RAP and check the AC output voltages Check the wiring between CN2 and P J300 The wiring is good Y N Repair the wiring Install a new power supply module PL 11 26 Item 2 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 ...

Page 384: ...a new power supply module PL 11 26 Item 2 Check for a short circuit or overload in the wiring or components connected to 5V on the 2K LCSS PWB Refer to GP 7 Perform the 11G 110 2K LCSS PWB Damage RAP if necessary install a new 2K LCSS PWB PL 11 26 Item 1 Figure 1 Component location Power Supply Module D E ...

Page 385: ...May 2013 2 353 Xerox WorkCentre 5790 Family 11D 110 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 386: ...NG Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Problems that can result from incorrect DIP switch settings are False jam clearance instructions for the 2K LCSS and or the machine exit area Communication errors between the 2K...

Page 387: ...f 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 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 causi...

Page 388: ...A11 29 ohms pin A8 to A12 29 ohms W Tag F 010 PJ312 pin A7 to A9 20 ohms pin A7 to A10 20 ohms pin A8 to A11 20 ohms pin A8 to A12 20 ohms Tamper assembly PL 11 16 Item 1 11 005 110 11 006 110 11 310 110 11 311 110 RAP U14 Transport motor 1 PJ305 pin 1 to 4 4 ohms pin 1 to 5 infinity pin 2 to 6 4 ohms pin 2 to 3 infinity Transport motor 1 PL 11 14 Item 2 11 130 110 11 132 110 RAP U15 Transport mot...

Page 389: ...lectricity Refer to GP 14 Disconnect the power cord 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 For other copy print damage and dog ears go to the 11H 110 Copy Damage i...

Page 390: ...he 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 0...

Page 391: ... 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...

Page 392: ...May 2013 2 360 Xerox WorkCentre 5790 Family 11 005 120 11 006 120 11 310 120 11 311 120 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 393: ...e 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 Sta...

Page 394: ...tre 5790 Family 11 007 120 11 008 120 11 312 120 11 313 120 11 Status Indicator RAPs Figure 1 Component Location Rear tamper motor MOT11 004 located at the front Rear tamper away home sensor Q11 319 Rear tamper home sensor Q11 311 ...

Page 395: ...May 2013 2 363 Xerox WorkCentre 5790 Family 11 007 120 11 008 120 11 312 120 11 313 120 11 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 396: ...over 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 a new paddle wheel shaft assembly PL 11 104 Item 4 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 sen...

Page 397: ...May 2013 2 365 Xerox WorkCentre 5790 Family 11 024 120 11 025 120 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 398: ... there is a large jam of paper above bin 1 this has probably been caused by poorly stacked sets failing to actuate the bin 1 upper level sensor Perform the relevant check If paper is overflowing the tray when it is at the lower limit check the tray 90 full sensor If paper cannot be fed to bin 1 when it is at the highest position check the bin 1 paper sensor low and bin 1 paper sensor high Check th...

Page 399: ...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 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 fin...

Page 400: ...0 11 336 120 Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram Bin 1 elevator motor MOT11 030 Bin 1 motor encoder sensor Q11 336 Bin 1 90 full sensor Q11 331 Bin 1 upper limit switch S11 334 Bin 1 lower limit switch S11 335 Bin 1 elevator motor damper ...

Page 401: ...May 2013 2 369 Xerox WorkCentre 5790 Family 11 030 120 11 334 120 11 335 120 11 336 120 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 402: ...P 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...

Page 403: ...May 2013 2 371 Xerox WorkCentre 5790 Family 11 050 120 11 360 120 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 404: ...heck 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 p...

Page 405: ...ive 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 t...

Page 406: ...CSS PWB PL 11 124 Item 1 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 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 Top exit sensor PL 11 118 Item 11 1K LCSS PWB PL 11 124 Item 1 Enter dC330 code 11 000 tra...

Page 407: ...May 2013 2 375 Xerox WorkCentre 5790 Family 11 130 120 11 132 120 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 408: ...the paper has dog ear on the inboard corner install TAG 005 Rear gravity gate mylar kit A paper jam in the path to bin 1 to the compiler and for poor stacking on bin 1 Ensure that the 1K LCSS is fully latched to the machine refer to REP 11 11 120 Torn paper fragments from a previous jam clearance action Refer to the 11G 120 Copy Damage in the 1K LCSS RAP and the 11H 120 Mis Registration in Stapled...

Page 409: ...s 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 Figure 1 Component location Transport motor 2 MOT11 001 Diverter gate solenoid S11 002 2nd to top exit sensor Q11 140 Transport motor 1 MOT11 000 A ...

Page 410: ...May 2013 2 378 Xerox WorkCentre 5790 Family 11 140 120 11 142 120 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 411: ...porting 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 ...

Page 412: ...tre 5790 Family 11 300 120 11 302 120 11 303 120 Status Indicator RAPs Figure 1 Component location Figure 2 Component location Docking interlock switch S11 300 Top cover interlock switch S11 302 Front door interlock switch S11 303 ...

Page 413: ...May 2013 2 381 Xerox WorkCentre 5790 Family 11 300 120 11 302 120 11 303 120 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 414: ...sensor Q11 322 PL 11 114 Item 3 1K LCSS PWB PL 11 124 Item 1 Enter dC330 code 11 320 ejector home sensor Q11 320 Actuate Q11 320 The display changes Y N Go to Flag 1 Check Q11 320 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 Ejector home sensor Q11 320 PL 11 114 Item 3 1K LC...

Page 415: ...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 Figure 1 Component location Ejector out sensor Q11 322 Ejector motor MOT11 020 Ejector motor encoder sensor Ejector hom...

Page 416: ...May 2013 2 384 Xerox WorkCentre 5790 Family 11 320 120 11 322 120 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 417: ...re 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 GP 10 How to Check a Sensor 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 1K LCSS PWB PL 11 124 Item 1 NOTE If the SH1 priming sensor does not see ...

Page 418: ...May 2013 2 386 Xerox WorkCentre 5790 Family 11 364 120 Status Indicator RAPs Figure 2 Staple cartridge open Figure 3 Staple cartridge closed Primed staples Forming plate open Forming plate fully closed ...

Page 419: ...May 2013 2 387 Xerox WorkCentre 5790 Family 11 364 120 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 420: ...OTE 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 ...

Page 421: ...can cause injury 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 In...

Page 422: ...CSS 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 PJ22 on the Power and Control Assembly ACL is available at PJ22 between pins 1 and...

Page 423: ...e 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 avail able at PJ22 between pins 1 and 3 on the LVPS and base module Y N Go to the 01C AC Power RAP Remove the 1K LCSS REP 11 12 120 Loosen the 2 screws and lift the power supply module away from the 1K LCSS frame Go to Flag 2 Check the wiring betwee...

Page 424: ...May 2013 2 392 Xerox WorkCentre 5790 Family 11C 120 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 425: ...3 410 03 418 IOT to Output Device Error Rap 11E 120 1K LCSS PWB DIP Switch Settings RAP To show the correct settings for the DIP switches on the 1K LCSS PWB Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Probl...

Page 426: ... 28 ohms Pin 2 to 5 28 ohms Pin 2 to 6 28 ohms Paddle motor assembly PL 11 104 Item 10 11 024 120 11 025 120 RAP U10 Staple head motor MOT11 050 At PJ7 Pin 8 to 10 12 6 ohms Pin 9 to 11 12 6 ohms Staple head unit PL 11 116 Item 5 11 050 120 11 360 120 RAP U11 Bin 1 elevator motor MOT11 030 At PJ12 Pin 1 to 2 6 4 ohms Bin 1 elevator motor PL 11 10 Item 8 11 030 120 11 334 120 11 335 120 11 336 120 ...

Page 427: ...s RAP to identify and correct the causes of copy damage in the 1K LCSS Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Check the following Look for torn paper in the 1K LCSS paper path Torn fragments can pass t...

Page 428: ...e 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 11J 120 1K LCSS Poor Stacking RAP Use this RAP to find the cause of poor stacking in the 1K LCSS Procedure WA...

Page 429: ...or 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 HVF control PWB PL 11 157 Item 2 Stack the code 11 326...

Page 430: ...May 2013 2 398 Xerox WorkCentre 5790 Family 11 024 171 11 026 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 431: ...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 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 assembl...

Page 432: ...entre 5790 Family 11 044 171 to 11 047 171 Status Indicator RAPs Figure 1 Component location 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 ...

Page 433: ...May 2013 2 401 Xerox WorkCentre 5790 Family 11 044 171 to 11 047 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 434: ... Motor P J701 HVF Control PWB P J4 P J12 Inserter PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Inserter Motor MOT 11 078 PL 11 181 Item 1 HVF control PWB PL 11 157 Item 2 Enter dC330 code 11 156 for the inserter bottom plate sensor and actuate the sensor The display changes Y N Go to Flag 1 and Flag 2 Check the wiring from the sensor to the HVF control PWB Repair as n...

Page 435: ...May 2013 2 403 Xerox WorkCentre 5790 Family 11 056 171 11 057 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 436: ... 165 Item 8 Procedure Enter dC330 code 11 416 Actuate the BM crease blade home sensor Figure 1 by rotating the crease blade knob so that the actuator moves into and out of the home sensor The display changes Y N Go to Flag 1 Check the BM crease blade home sensor Q11 416 Refer to GP 11 How to Check a Sensor P J552 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM PWB ...

Page 437: ...rkCentre 5790 Family 11 061 171 11 416 171 Status Indicator RAPs Figure 1 Component location BM crease blade home sensor Q11 416 BM crease blade motor encoder sensor Q11 418 BM crease blade motor MOT 11 061 Crease blade knob ...

Page 438: ...May 2013 2 406 Xerox WorkCentre 5790 Family 11 061 171 11 416 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 439: ...330 code 11 419 Actuate the BM crease roll motor encoder sensor by rotating the crease rolls slowly by hand The display changes Y N Go to Flag 1 Check the BM crease roll motor encoder sensor Q11 419 Figure 1 Refer to GP 11 How to Check a Sensor P J552 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM PWB PL 11 166 Item 10 BM crease roll motor encoder sensor PL 11 166...

Page 440: ...May 2013 2 408 Xerox WorkCentre 5790 Family 11 062 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 441: ...he display changes Y N Go to Flag 1 Check the BM staple head carrier closed sensor Q11 421 Refer to GP 11 How to Check a Sensor P J552 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM staple head carrier closed sensor PL 11 168 Item 18 BM PWB PL 11 166 Item 10 Remove the HVF front door and door support refer to REP 11 1 171 HVF Covers Pull out the BM module Remove t...

Page 442: ...May 2013 2 410 Xerox WorkCentre 5790 Family 11 063 171 11 411 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 443: ...tuate the BM backstop guide home sensor Figure 1 The dis play changes Y N Go to Flag 1 Check the sensor Q11 383 Refer to GP 11 How to Check a Sensor P J556 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM backstop guide home sensor PL 11 163 Item 18 BM PWB PL 11 166 Item 10 Enter dC330 code 11 065 to run the BM backstop motor MOT 11 065 Figure 1 The motor runs Y N G...

Page 444: ...May 2013 2 412 Xerox WorkCentre 5790 Family 11 065 171 11 383 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 445: ...ensor Figure 1 The display changes Y N Go to Flag 1 Check the sensor Q11 384 Refer to GP 11 How to Check a Sensor P J556 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM PWB PL 11 166 Item 10 BM tamper 1 home sensor PL 11 162 Item 1 Enter dC330 code 11 066 to run the BM tamper 1 motor MOT 11 066 Figure 1 The motor runs Y N Go to Flag 2 and Flag 3 Check the motor MOT...

Page 446: ...May 2013 2 414 Xerox WorkCentre 5790 Family 11 066 171 11 384 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 447: ... 2 Go to Flag 4 Check the stapler gate safety switch S11 365 Refer to GP 13 How to check a switch P J304 HVF Control PWB 11A 171 HVF Power Distribution RAP The switch is good Y N Install new components as necessary Sensor assembly PL 11 145 Item 22 HVF Control PWB PL 11 157 Item 2 Enter dC330 code 11 171 Manually operate the paper pusher upper sensor Q11 171 The display changes Y N Go to Flag 1 Ch...

Page 448: ...May 2013 2 416 Xerox WorkCentre 5790 Family 11 083 171 11 440 171 to 11 443 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 449: ...The dis play changes Y N Go to Flag 1 Check the sensor Q11 100 Refer to GP 11 How to Check a Sensor P J101 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Entry sensor PL 11 156 Item 2 HVF Control PWB PL 11 157 Item 2 Enter dC330 code 11 000 to run the Entry feed motor 1 MOT 11 000 Figure 1 The motor runs Y N Go to Flag 2 Check the entry feed motor 1 MOT 11 0...

Page 450: ...May 2013 2 418 Xerox WorkCentre 5790 Family 11 100 171 11 101 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 451: ... dC330 code 11 002 Energize the exit diverter solenoid SOL 11 002 Figure 1 The solenoid energizes Y N Go to Flag 2 Check the solenoid SOL 11 002 Refer to GP 12 How to Check a Solenoid or Clutch P J102 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Exit diverter solenoid PL 11 150 Item 4 HVF control PWB PL 11 157 Item 2 Enter dC330 code 11 001 to run the exit...

Page 452: ...May 2013 2 420 Xerox WorkCentre 5790 Family 11 130 171 11 132 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 453: ... dC330 code 11 002 Energize the exit diverter solenoid SOL 11 002 Figure 1 The solenoid energizes Y N Go to Flag 2 Check the solenoid SOL 11 002 Refer to GP 12 How to Check a Solenoid or Clutch P J102 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Exit diverter solenoid PL 11 150 Item 4 HVF control PWB PL 11 157 Item 2 Enter dC330 code 11 001 to run the exit...

Page 454: ...May 2013 2 422 Xerox WorkCentre 5790 Family 11 140 171 11 142 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 455: ...1 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Buffer position sensor PL 11 156 Item 2 HVF Control PWB PL 11 157 Item 2 Enter dC330 code 11 000 to run the entry feed motor 1 MOT 11 000 Figure 1 The motor runs Y N Go to Flag 2 Check the entry feed motor 1 MOT 11 000 Refer to GP 10 How to Check a Motor P J102 HVF Control PWB 11A 171 HVF Power Distribution RA...

Page 456: ...May 2013 2 424 Xerox WorkCentre 5790 Family 11 157 171 11 161 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 457: ...lenoid energizes Y N Go to Flag 2 Check the solenoid SOL 11 074 Refer to GP 12 How to Check a Solenoid or Clutch P J102 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM diverter solenoid PL 11 150 Item 4 HVF control PWB PL 11 157 Item 2 Enter dC330 code 11 080 to run the bypass feed motor MOT 11 080 Figure 1 The motor runs Y N Go to Flag 3 Check the bypass ...

Page 458: ...ermittent check for damaged wiring or bad connectors REP 1 2 If neces sary install new components HVF booklet exit sensor PL 11 156 Item 3 BM diverter solenoid PL 11 150 Item 4 BM diverter gate PL 11 153 Item 9 BM compiler motor PL 11 166 Item 1 Bypass feed motor 2 PL 11 150 Item 2 HVF control PWB PL 11 157 Figure 1 Component location Figure 2 Component location BM diverter solenoid SOL11 074 Bypa...

Page 459: ...May 2013 2 427 Xerox WorkCentre 5790 Family 11 158 171 11 160 171 162 171 163 171 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 460: ...the buffer path sensor Q11 164 Figure 1 The display changes Y N Go to Flag 1 Check the sensor Q11 164 Refer to GP 11 How to Check a Sensor P J101 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Buffer path sensor PL 11 156 Item 2 HVF Control PWB PL 11 157 Item 2 Enter dC330 code 11 079 to run the Buffer feed motor 1 MOT 11 079 Figure 1 The motor runs Y N Go t...

Page 461: ...May 2013 2 429 Xerox WorkCentre 5790 Family 11 164 171 11 165 171 Status Indicator RAPs Figure 1 Component location Buffer path sensor Q11 164 Buffer feed motor MOT11 079 ...

Page 462: ...May 2013 2 430 Xerox WorkCentre 5790 Family 11 164 171 11 165 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 463: ...o GP 11 How to Check a Sensor P J556 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM paper present sensor PL 11 168 Item 5 BM PWB PL 11 166 Item 10 Go to Flag 1 Check the connectors and harness between PJ568 and P J556 Refer to GP 7 The wiring and connectors are good Y N Repair the wiring REP 1 2 or install new components as necessary Enter dC330 code 11 060 BM com...

Page 464: ...ay 2013 2 432 Xerox WorkCentre 5790 Family 11 172 171 Status Indicator RAPs Figure 1 Component location Stapler bracket assembly BM paper present sensor Q11 190 BM compiler motor MOT11 060 BM entry roll ...

Page 465: ...May 2013 2 433 Xerox WorkCentre 5790 Family 11 172 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 466: ...Q11 187 Figure 1 The display changes Y N Go to Flag 2 Check the sensor Q11 187 Refer to GP 11 How to Check a Sensor P J302 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Offset index sensor PL 11 140 Item 15 Ejector assembly PL 11 140 Item 2 HVF Control PWB PL 11 157 Item 2 Enter dC330 code 11 176 Manually activate the offset away sensor Q11 176 Figure 1 The...

Page 467: ...May 2013 2 435 Xerox WorkCentre 5790 Family 11 173 171 to 11 177 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 468: ... to GP 11 How to Check a Sensor P J552 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM PWB PL 11 166 Item 10 BM crease roll motor encoder sensor PL 11 166 Item 9 Enter dC330 code 11 409 Actuate the BM exit sensor Q11 409 Figure 2 The display changes Y N Go to Flag 3 Check sensor Q11 409 Refer to GP 11 How to Check a Sensor P J556 BM PWB 11A 171 HVF Power Distributi...

Page 469: ...icator RAPs Figure 1 Component location Figure 2 Component location BM crease roll motor encoder sensor Q11 419 BM crease roll motor MOT11 062 BM crease blade motor MOT11 061 BM crease blade motor encoder sensor Q11 418 BM crease roll gate motor MOT11 401 BM exit sensor Q11 409 ...

Page 470: ...May 2013 2 438 Xerox WorkCentre 5790 Family 11 180 171 11 182 171 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 471: ...e sensor Q11 409 Refer to GP 11 How to Check a Sensor P J556 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM PWB PL 11 166 Item 10 BM exit sensor PL 11 168 Item 17 Enter dC330 code 11 160 Manually actuate the BM entry sensor Q11 160 Figure 1 The dis play changes Y N Go to Flag 3 Check sensor Q11 160 Refer to GP 11 How to Check a Sensor P J551 BM PWB 11A 171 HVF Pow...

Page 472: ... 440 Xerox WorkCentre 5790 Family 11 183 171 11 184 171 Status Indicator RAPs Figure 1 Component location Figure 2 Component location BM entry sensor Q11 160 BM paper present sensor Q11 190 BM exit sensor Q11 409 ...

Page 473: ...May 2013 2 441 Xerox WorkCentre 5790 Family 11 183 171 11 184 171 Status Indicator RAPs Figure 3 Component location Tri folder entry sensor Q11 183 ...

Page 474: ...May 2013 2 442 Xerox WorkCentre 5790 Family 11 183 171 11 184 171 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 475: ...563 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Folder exit sensor PL 11 197 Item 12 Tri folder control PWB PL 11 193 Item 16 BM PWB PL 11 166 Item 10 Enter dC330 code 11 085 to energize the tri folder diverter solenoid SOL 11 085 The sole noid energizes Y N Go to Flag 5 and Flag 6 Check the solenoid SOL 11 085 Refer to GP 12 How to Check a Solenoid or Clutch P J6...

Page 476: ...1 HVF Power Distribution RAP Install new components as necessary BM crease roll motor PL 11 166 Item 8 BM PWB PL 11 166 Item 10 Perform SCP 6 Final Actions Figure 1 Component location Figure 2 Component location TF Assist sensor Q11 184 TF diverter solenoid SOL11 085 Drive clutch CL11 087 TF Assist gate solenoid SOL11 086 TF Exit sensor Q11 185 B ...

Page 477: ...May 2013 2 445 Xerox WorkCentre 5790 Family 11 185 171 to 11 187 171 Status Indicator RAPs Figure 3 Component location BM crease roll motor MOT11 062 ...

Page 478: ...May 2013 2 446 Xerox WorkCentre 5790 Family 11 185 171 to 11 187 171 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 479: ...May 2013 2 447 Xerox WorkCentre 5790 Family 11 185 171 to 11 187 171 Status Indicator RAPs Figure 5 Circuit diagram ...

Page 480: ... Check a Motor P J102 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Nip split motor PL 11 153 Item 15 HVF control PWB PL 11 157 Item 2 Enter dC330 code 11 159 Manually actuate the Nip home sensor Q11 159 Figure 1 The display changes Y N Go to Flag 1 Check the sensor Q11 159 Refer to GP 11 How to Check a Sensor P J101 HVF Control PWB 11A 171 HVF Power Distri...

Page 481: ...May 2013 2 449 Xerox WorkCentre 5790 Family 11 188 171 11 189 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 482: ... the acceleration sensor Figure 1 The voltage changes Y N Go to Flag 3 and Flag 4 Check the sensor Refer to GP 11 How to Check a Sensor P J6 P J4 Inserter PWB P J701 HVF Control PWB Install new components as necessary Acceleration sensor PL 11 175 Item 10 Inserter PWB PL 11 179 Item 9 HVF control PWB PL 11 157 Item 2 Measure the voltage at pin 2 of P J702 on the HVF PWB Open the front door and ope...

Page 483: ...y 11 191 171 11 193 171 11 194 171 11 196 171 Status Indicator RAPs Figure 1 Component location Inserter clutch CL11 077 Inserter motor MOT11 078 Inserter TE sen sor Q11 155 Inserter standby sensor Inserter LE sensor Q11 154 Acceleration sensor ...

Page 484: ...May 2013 2 452 Xerox WorkCentre 5790 Family 11 191 171 11 193 171 11 194 171 11 196 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 485: ...May 2013 2 453 Xerox WorkCentre 5790 Family 11 191 171 11 193 171 11 194 171 11 196 171 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 486: ...157 Item 2 Enter dC330 code 11 164 Manually activate the buffer path sensor Q11 164 Figure 1 The display changes Y N Go to Flag 3 Check the sensor Q11 164 Refer to GP 11 How to Check a Sensor P J101 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Buffer path sensor PL 11 156 Item 2 HVF Control PWB PL 11 157 Item 2 Enter dC330 code 11 140 Manually activate the...

Page 487: ... Family 11 198 171 11 199 171 Status Indicator RAPs Figure 1 Component location Top exit sensor Q11 130 Stacker sensor Q11 140 Buffer path sensor Q11 164 HVF booklet exit sensor Q11 158 Buffer position sensor Q11 157 Entry sensor Q11 100 ...

Page 488: ...May 2013 2 456 Xerox WorkCentre 5790 Family 11 198 171 11 199 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 489: ...1 300 Figure 1 Check the switch actuator mounted on the machine is correctly installed and un broken Enter dC330 code 11 300 actuate the switch and check the display Refer to GP 13 How to Check a Switch P J112 HVF Control PWB Figure 1 Flag 3 Check the wiring GP 7 If necessary install new components Docking interlock switch PL 11 130 Item 16 11 302 171 Top Cover Interlock RAP Check the top cover in...

Page 490: ... Xerox WorkCentre 5790 Family 11 300 171 11 302 171 11 303 171 Status Indicator RAPs Figure 1 Component location Front door interlock switch S11 303 Docking interlock switch S11 300 Top cover interlock switch S11 302 ...

Page 491: ...May 2013 2 459 Xerox WorkCentre 5790 Family 11 300 171 11 302 171 11 303 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 492: ... Enter dC330 code 11 306 Open and close the top cover to actuate the switch Figure 1 The display changes Y N Refer to GP 13 How to Check a Switch Figure 1 Flag 1 and Flag 2 P J1 P J5 P J4 Inserter PWB P J701 P J703 HVF Control PWB Check the wiring GP 7 If necessary install new components Inserter top cover interlock switch PL 11 177 Item 8 Inserter PWB PL 11 179 Item 9 HVF Control PWB PL 11 157 It...

Page 493: ...May 2013 2 461 Xerox WorkCentre 5790 Family 11 306 171 11 309 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 494: ...131 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Top cover interlock switch PL 11 197 Item 3 Front door interlock switch PL 11 197 Item 2 Tri folder PWB PL 11 193 Item 16 BM PWB PL 11 166 Item 10 HVF PWB PL 11 157 Item 2 Enter dC330 code 11 393 Open the tri folder front door The display changes Y N Go to Flag 4 and Flag 5 Check the wiring and repair as nec...

Page 495: ...May 2013 2 463 Xerox WorkCentre 5790 Family 11 307 171 11 308 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 496: ...801 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Stapler assembly PL 11 140 Item 14 HVF control PWB PL 11 157 Item 2 With the stapler unit still at the inboard end enter dC330 code 11 360 stapler home sensor Manually activate the stapler home sensor Q11 360 Figure 2 The display changes Y N Go to Flag 1 Check the sensor Q11 360 Refer to GP 11 How to Check a...

Page 497: ... 11 157 Item 2 Enter dC330 code 11 360 to monitor the staple home sensor Q11 360 stack the code 11 050 to cycle the staple head The display changes Y N Go to Flag 3 Check for a change in signal level at P J301 pin 12 while code 11 050 is running The signal level changes Y N Check the wiring between P J301 pin 12 and the staple head unit The wiring is good Y N Repair the wiring REP 1 2 or install a...

Page 498: ...re 5790 Family 11 371 171 to 11 377 171 Status Indicator RAPs Figure 1 Component location Figure 2 Component location Stapler gate safety switch S11 365 Paper pusher Stapler unit mid home sensor Q11 175 Stapler home sensor Q11 360 ...

Page 499: ...May 2013 2 467 Xerox WorkCentre 5790 Family 11 371 171 to 11 377 171 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 500: ...May 2013 2 468 Xerox WorkCentre 5790 Family 11 371 171 to 11 377 171 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 501: ...d Figure 2 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 11 000 entry feed motor 1 to check that the motor runs The motor runs Y N Go to Flag 2 Check the wiring and repair as necessary REP 1 2 Check entry feed motor 1 MOT11 ...

Page 502: ...May 2013 2 470 Xerox WorkCentre 5790 Family 11 380 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 503: ...1 2 Check the front tamper motor MOT11 003 Refer to GP 10 How to Check a Motor P J902 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Front tamper motor MOT11 003 PL 11 153 Item 6 HVF control PWB PL 11 157 Item 2 Stack the dC330 code 11 310 front tamper home sensor Move the motor using its control code 11 003 or 11 005 The display changes Y N Go to Flag 2 Che...

Page 504: ...May 2013 2 472 Xerox WorkCentre 5790 Family 11 392 171 to 11 395 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 505: ...the rear tamper motor MOT11 004 Refer to GP 10 How to Check a Motor P J801 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Rear tamper PL 11 140 Item 13 HVF control PWB PL 11 157 Item 2 Stack the dC330 code 11 311 rear tamper home sensor Move the tamper motor using the code 11 006 move motor inboard The display changes Y N Go to Flag 2 Check the wiring and re...

Page 506: ...May 2013 2 474 Xerox WorkCentre 5790 Family 11 396 171 to 11 399 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 507: ...n and close the staple head carrier The display changes Y N Go to Flag 1 Check the staple head carrier closed sensor Q11 421 Refer to GP 11 How to Check a Sensor P J552 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM staple head carrier closed sensor PL 11 168 Item 18 BM PWB PL 11 166 Item 10 Remove the HVF front door and door support refer to REP 11 1 171 HVF Cove...

Page 508: ...May 2013 2 476 Xerox WorkCentre 5790 Family 11 403 171 11 413 171 11 414 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 509: ...roll gate home sensor Q11 415 The dis play changes Y N Go to Flag 1 Check the BM crease roll gate home sensor Q11 415 Refer to GP 11 How to Check a Sensor P J552 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM PWB PL 11 166 Item 10 BM crease roll gate home sensor PL 11 166 Item 9 Enter dC330 code 11 401 to run the BM crease roll gate motor MOT 11 401 The motor runs...

Page 510: ...May 2013 2 478 Xerox WorkCentre 5790 Family 11 415 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 511: ...TE All HVF BM interlocks must be made to supply 24V to the motors Enter dC330 code 11 390 to check the BM flapper motor MOT11 390 Figure 1 The BM flapper rotates Y N Go to Flag 2 Check MOT11 390 Refer to GP 10 How to Check a Motor P J560 BM PWB 11A 171 HVF Power Distribution RAP Install new components as necessary BM flapper motor PL 11 166 Item 1 BM PWB PL 11 166 Item 10 BM flapper PL 11 161 Item...

Page 512: ...May 2013 2 480 Xerox WorkCentre 5790 Family 11 417 171 11 418 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 513: ...on RAP Install new components as necessary Ejector assembly PL 11 140 Item 2 HVF control PWB PL 11 157 Item 2 Go to Flag 1 Check the wiring and repair as necessary REP 1 2 Check the ejector home sensor Q11 320 Refer to GP 11 How to Check a Sensor P J401 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Ejector assembly PL 11 140 Item 2 HVF control PWB PL 11 157...

Page 514: ...Family 11 450 171 11 456 171 to 11 459 171 Status Indicator RAPs Figure 1 Component location Ejector Home Sensor Q11 320 Ejector Unit Out Sensor Q11 322 Ejector Unit Motor MOT11 023 Ejector Motor Encoder Sensor Q11 177 Left view of ejector ...

Page 515: ...May 2013 2 483 Xerox WorkCentre 5790 Family 11 450 171 11 456 171 to 11 459 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 516: ...VF control PWB PL 11 157 Item 2 Enter the dC330 code 11 178 ejector plater encoder sensor Enter the code 11 088 to rotate the ejector roll motor one cycle of the ejector plates in the forward direction The display changes Y N The ejector roll motor turned Y N Go to Flag 2 Check the wiring and repair as necessary REP 1 2 Check the ejector roll motor MOT 11 088 Refer to GP 10 How to Check a Motor P ...

Page 517: ...tus Indicator RAPs Figure 1 Component location Figure 2 Component location Ejector roll motor MOT11 088 Ejector plate encoder sensor Q11 178 Ejector plate home sensor Q11 179 LEFT SIDE VIEW OF EJETOR Ejector lower paddle home switch S11 180 RIGHT UNDER SIDE VIEW OF EJECTOR ...

Page 518: ...May 2013 2 486 Xerox WorkCentre 5790 Family 11 451 171 to 11 455 171 Status Indicator RAPs Figure 3 Component location Rotate paddle 1 complete turn Ejector paper present sensor ...

Page 519: ...May 2013 2 487 Xerox WorkCentre 5790 Family 11 451 171 to 11 455 171 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 520: ...ode 11 334 bin 1 upper limit switch Manually actuate the switch The display changes Y N Go to Flag 5 Check the wiring and repair as necessary REP 1 2 Check the bin 1 upper limit switch S11 334 Refer to GP 13 How to Check a Switch P J602 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Bin 1 upper limit switch PL 11 135 Item 7 HVF control PWB PL 11 157 Item 2 I...

Page 521: ... Flag 8 Check the wiring and repair as necessary REP 1 2 Check the bin 1 rear wall sensor Q11 196 Refer to GP 11 How to Check a Sensor P J403 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Bin 1 rear wall sensor PL 11 140 Item 17 HVF control PWB PL 11 157 Item 2 If the fault is random and Bin 1 has an erratic up down movement and poor stacking Check that the...

Page 522: ...May 2013 2 490 Xerox WorkCentre 5790 Family 11 460 171 to 11 462 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 523: ...May 2013 2 491 Xerox WorkCentre 5790 Family 11 460 171 to 11 462 171 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 524: ...available at P J111 between pins 1 and 4 Y N Refer to Figure 1 24V is available at T001 on the HVF power supply between pins 1 and 5 Y N Install a new HVF power supply module PL 11 157 Item 1 Check the connectors and harness between T001 and PJ111 Repair the harness as necessary REP 1 2 Go to Flag 3 24V is available at P J111 between pins 1 and 4 between pins 2 and 5 and between pins 3 and 6 Y N G...

Page 525: ...May 2013 2 493 Xerox WorkCentre 5790 Family 11 463 171 11 464 171 Status Indicator RAPs Figure 1 Component location HVF power supply module HVF control PWB BM PWB Tri folder unit ...

Page 526: ...May 2013 2 494 Xerox WorkCentre 5790 Family 11 463 171 11 464 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 527: ...stribution RAP Install new components as necessary Paddle module driving motor assembly PL 11 150 Item 6 HVF control PWB PL 11 157 Item 2 Enter dC330 code 11 027 to check the paddle unit motor MOT11 027 Figure 1 The paddle unit moves Y N Check the drive gears on the paddle unit Install new components as necessary PL 11 145 Item 2 Enter dC330 code 11 194 paddle unit upper sensor Q11 194 Select code...

Page 528: ...May 2013 2 496 Xerox WorkCentre 5790 Family 11 465 171 to 11 468 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 529: ...57 Item 2 Enter the dC330 code 11 191 and continue turning the gear wheel When the support fingers have extended by about 25mm the support finger init sensor changes state The display changes from High to Low Y N Go to Flag 2 Check the support finger init sensor Q11 191 Refer to GP 11 How to Check a Sensor P J402 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessar...

Page 530: ...11 473 171 to 11 478 171 Status Indicator RAPs Figure 1 Component location Support Finger Out Sensor Q11 193 Support Finger Motor Encoder Sensor Support Finger Init Sensor Q11 191 Support Finger Home Sensor Q11 192 Support Finger Motor Gear wheel ...

Page 531: ...May 2013 2 499 Xerox WorkCentre 5790 Family 11 473 171 to 11 478 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 532: ...May 2013 2 500 Xerox WorkCentre 5790 Family 11 473 171 to 11 478 171 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 533: ...155 TE sensor Use a piece of paper to actuate the sensor The sensor display changes state Y N Go to Flag 5 and Flag 6 Check Q11 155 Refer to GP 11 How to Check a Sensor P J6 P J4 Inserter PWB P J701 HVF Control PWB 11A 171 HVF Power Distribution RAP Install new components as necessary TE sensor PL 11 179 Item 11 Inserter PWB PL 11 179 Item 9 HVF control PWB PL 11 157 Item 2 Enter the dC330 code 11...

Page 534: ... 5790 Family 11 479 171 Status Indicator RAPs Figure 1 Component location Sheet size detector 1 sensor Q11 150 Sheet size detector 2 sensor Q11 151 LE sensor Q11 154 Inserter clutch CL11 077 Inserter motor MOT11 078 TE sensor Q11 155 ...

Page 535: ...May 2013 2 503 Xerox WorkCentre 5790 Family 11 479 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 536: ...May 2013 2 504 Xerox WorkCentre 5790 Family 11 479 171 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 537: ...VF has a short circuit Reconnect each PJ one at a time until short circuit is found When the short circuit is found repair the harness REP 1 2 or install new components as necessary Disconnect P J113 Go to Flag 2 5V is available at the harness end of P J113 between pins 1 and 2 Y N Check the connectors and harness between T001 and P J113 Repair the har ness as necessary REP 1 2 Install a new HVF c...

Page 538: ...ther cases this LED is OFF LED 7 red This LED is used during the machine production and is connected with the activity of the stacker nearly full sensor LED 8 red steady This indicates that the HVF top cover front door and docking inter locks are all closed and 24V is available at the HVF module LED 9 red steady This indicates that the 5V supply is present in the HVF module Figure 1 LEDs on the HV...

Page 539: ...May 2013 2 507 Xerox WorkCentre 5790 Family 11A 171 Status Indicator RAPs Figure 3 Component location HVF power supply module HVF control PWB BM PWB Tri folder unit In line fuse ...

Page 540: ...May 2013 2 508 Xerox WorkCentre 5790 Family 11A 171 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 541: ...rol PWB For communications between the HVF control PWB and the machine go to the 03 360 03 408 to 03 410 03 418 IOT to Output Device Error RAP The pulses on the connections at Flag 1 cannot be measured but may be detected using a meter that can record maximum and minimum voltage levels or by using an AC voltage range Check the wiring and repair as necessary REP 1 2 Refer to P J133 HVF Control PWB ...

Page 542: ... Go to Flag 1 Check Q11 389 Refer to GP 11 How to Check a Sensor P J556 BM PWB 11A 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 11 402 to run the BM conveyor belts drive motor MOT11 402 MOT11 402 runs Y N If a tri folder is installed...

Page 543: ...May 2013 2 511 Xerox WorkCentre 5790 Family 11C 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 544: ... to the BM compiling area Procedure Produce three 4 sheet 16 page booklets using 80gsm 20lb paper Paper size and weight must conform the specification in GP 20 Paper and Media Size Specification Examine the booklets for defects Refer to the following Top and Bottom Edge Alignment Open Side Edge Alignment Badly Formed Booklet Staples Booklet Compiler is Not Correct Skewed Booklet Crease Booklet Cre...

Page 545: ...ntamination or debris in the compiling area of the BM that could cause the mis align ment Badly Formed Booklet Staples If the booklet staples are not formed correctly perform ADJ 11 3 171 Staple Anvil Alignment Booklet Compiler is Not Correct If the page order of the booklets is not correct perform ADJ 11 6 171 Booklet Compiling Position Skewed Booklet Crease Figure 3 open out the booklet at the c...

Page 546: ... the position of the booklet crease Figure 4 Booklet crease position If the booklet crease position does not conform to the specification in Table 5 perform ADJ 11 7 171 Booklet Crease Position Booklet Staple Position is Not On The Fold Figure 5 open out the booklet at the centre page and press it onto a flat surface Measure the position of the booklet staple from the crease line Figure 5 Booklet ...

Page 547: ...am clearance guides Refer to ADJ 4 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 siz...

Page 548: ...r carriage tampers move to the correct paper size Make sure that the BM tampers move to the correct paper size refer to 11 066 171 11 384 171 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 11G 171 HVF BM Poor Stacking RAP Use this RAP to find the cause of poor stacking in t...

Page 549: ...o not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Figure 1 shows the component locations Go to Flag 1 Check the wiring and the voltages Refer to P J901 Repair the wiring as necessary REP 1 2 Install new components as neces sary Pause to unload PWB PL 11 157 Item 3 HVF control PWB PL 11 157 Item 2 Figure 1 Component l...

Page 550: ...ensor 1 Q11 152 while sliding paper width guide The voltage changes Y N Check the inserter paper width sensor 1 Q11 152 Refer to GP 11 How to Check a Sensor P J8 and P J4 Inserter PWB 11A 171 HVF Power Distribution RAP Install new components as necessary Inserter paper width sensor 1 PL 11 175 Item 13 Inserter PWB PL 11 179 Item 9 HVF control PWB PL 11 157 Item 2 Go to Flag 5 and Flag 6 Measure th...

Page 551: ...90 Family 11J 171 Status Indicator RAPs Figure 1 Component location Figure 2 Component location Inserter unit empty sensor Q11 153 IDG pickup sensor Acceleration sensor inserter paper width sensor 1 Q11 152 inserter paper width sensor 2 ...

Page 552: ...May 2013 2 520 Xerox WorkCentre 5790 Family 11J 171 Status Indicator RAPs Figure 3 Circuit diagram ...

Page 553: ...May 2013 2 521 Xerox WorkCentre 5790 Family 11J 171 Status Indicator RAPs Figure 4 Circuit diagram ...

Page 554: ...n The booklet maker is initialized as follows 1 The BM tampers are driven to their home position unless already home 2 The BM backstop is driven to the home position unless already home 3 The BM crease roll gate is driven to the home position unless already home 4 The BM crease blade is driven to the home position unless already home 5 The BM staple heads are driven to their home position unless a...

Page 555: ...cedure Go to Flag 1 Check the wiring of the tri folder present link and repair as necessary REP 1 2 Check for 0V at P J563 pin 7 Refer to P J563 BM PWB 11A 171 HVF Power Distribution RAP Figure 1 Circuit diagram 11M 171 Curl Suppressor RAP Use this RAP to fix curl suppressor problems Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not nee...

Page 556: ...May 2013 2 524 Xerox WorkCentre 5790 Family 11M 171 Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Curl suppressor solenoid SOL11 084 ...

Page 557: ...in and operate the sen sor manually The display changes Y N Go to Flag 1 Check the wiring Repair as necessary REP 1 2 Check the chad bin present sensor Q11 112 Refer to GP 11 How to Check a Sensor P J501 HVF Control PWB 11A 171 HVF Power Distribution RAP As necessary install new components Chad bin present sensor PL 11 153 Item 18 HVF control PWB PL 11 157 Item 2 Enter the dC330 code 11 348 chad b...

Page 558: ...May 2013 2 526 Xerox WorkCentre 5790 Family 11N 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 559: ...ry Moving parts can cause injury Check that the solenoid and the clamp can move freely without obstruction Procedure Figure 1 shows the location of the components Enter the dC330 code 11 082 buffer clamp solenoid The solenoid actuates Y N Go to Flag 1 Check the wiring Repair as necessary REP 1 2 Check the buffer clamp solenoid SOL 11 082 Refer to GP 12 How to Check a Solenoid or Clutch P J104 HVF ...

Page 560: ...May 2013 2 528 Xerox WorkCentre 5790 Family 11P 171 Status Indicator RAPs Figure 2 Circuit diagram ...

Page 561: ...0 Item 1 35 55 ppm Only Make sure that the OCT fingers are installed correctly Refer to REP 12 1 Procedure Figure 1 Go to Flag 1 and Flag 2 Check the OCT wiring GP 7 The wiring is good Y N Repair the wiring or install a new OCT PL 12 10 Item 1 Enter dC330 code 12 005 to check the OCT motor MOT12 005 MOT12 005 runs Y N Install a new OCT PL 12 10 Item 1 Enter dC330 code 12 005 and stack code 12 301 ...

Page 562: ...May 2013 2 530 Xerox WorkCentre 5790 Family 12 301 Status Indicator RAPs Figure 2 Circuit Diagram ...

Page 563: ... board controller PWB If the harness was under the PWB examine the harness sleeving for punctures or other damage If necessary install a new DADH power distribution PWB harness PL 3 24 Item 6 Route the new harness to the right away from the single board controller PWB If this has caused a blown fuse F1 on the power distribution PWB install a new power distribu tion PWB PL 3 24 Item 5 NOTE This fau...

Page 564: ... Scan carriage home sensor PL 14 25 Item 16 Scanner PWB PL 14 25 Item 4 Scanner PL 14 20 Item 1 Perform ADJ 14 1 Optics Cleaning Procedure Switch off the machine GP 14 Open the DADH or document cover Switch on the machine GP 14 Observe the scan carriage as the machine initializes The scan carriage moves away from and back to the scan carriage home sensor Y N Go to Flag 2 Check the wiring and P J45...

Page 565: ...May 2013 2 533 Xerox WorkCentre 5790 Family 14 110A Status Indicator RAPs Figure 2 Correct position of the scan cable Cable anchor slot The scan cable upper run must not go through cable anchor slot ...

Page 566: ...May 2013 2 534 Xerox WorkCentre 5790 Family 14 110A Status Indicator RAPs Figure 3 Circuit diagram ...

Page 567: ...r PWB If necessary install a new single board controller PWB DADH comms scanner power harness PL 14 15 Item 5 Go to the 14D Exposure Lamp Failure RAP Check that 5V is available in the scanner by entering the dC330 input code 14 310 actuate the input module angle sensor by opening and closing the DADH The display changes Y N Go to Flag 4 Check for 5V on P J136 between pins 1 to 4 on the PDB PWB Als...

Page 568: ... Family 14 110B Status Indicator RAPs Figure 1 Carriage home sensor Figure 2 Correct position of the scan cable Scan carriage home sensor Q14 100 Scanner PWB Cable anchor slot The scan cable upper run must not go through cable anchor slot ...

Page 569: ...May 2013 2 537 Xerox WorkCentre 5790 Family 14 110B Status Indicator RAPs Figure 3 Circuit diagram ...

Page 570: ...UI but do not install the screws Re connect the power cord and switch on the machine GP 14 Go to Flag 1 Check the following voltages at P J455 on the scanner PWB Figure 1 24V between pins 1 and 3 24V between pins 2 and 4 The voltages are good Y N Check for a open circuit on the harness between P J135 and P J455 Repair the harness REP 1 2 or install a new harness PL 14 25 Item 13 Perform ADJ 14 1 O...

Page 571: ...May 2013 2 539 Xerox WorkCentre 5790 Family 14 310 Status Indicator RAPs Figure 1 Component location Figure 2 Circuit diagram Scanner PWB CCD PWB ...

Page 572: ...J102 pin 1 on the single board controller PWB Refer to wiring diagram WD 12 a W TAG 150 Check between PJ921 pin 5 on the Scanner PWB W TAG 150 inline connector PJ102 PJ152 pin 17 and PJ188 pin 5 on the DADH PWB Refer to wiring diagrams WD 13 and WD 16 14 322 Platen Active Hot Line in Wrong State RAP W O TAG 150 14 322 The platen active hot line is in the wrong state before a scan calibration or sc...

Page 573: ...librate as the pixel gain is too high 14 704 The scanner PWB failed to calibrate as the pixel gain is too low 14 705 The scanner PWB failed to calibrate as one or more pixels are offset higher than the required level 14 706 The scanner PWB failed to calibrate as one or more pixels are offset lower than the required level 14 712 The scanner PWB failed to calibrate due as overall gain is at maximum ...

Page 574: ...the mirror alignment clear the light path or install a new scanner PL 14 20 Item 1 Check the CCD assembly for loose electrical connections or misalignment of the assembly Figure 2 The CCD assembly is good Y N Correct the problem or install a new scanner PL 14 20 Item 1 Check the scanner PWB for loose connections or damage Figure 2 The scanner PWB is good Y N Install a new scanner PWB PL 14 25 Item...

Page 575: ...May 2013 2 543 Xerox WorkCentre 5790 Family 14 703A to 14 706A 712A 714A 716A 718A Status Indicator RAPs Figure 2 Component location Figure 3 Circuit diagram Scanner PWB CCD PWB ...

Page 576: ...glass and document glass The calibration strips are undamaged Y N Install a new CVT glass PL 14 20 Item 4 and or a new document glass PL 14 20 Item 5 Clean the white CVT strips under the front edges of the document glass and the CVT glass using a cleaning cloth dampened with film remover PL 26 10 Item 4 Re assemble the parts If the fault persists install new components as necessary Scan carriage r...

Page 577: ...ge assembly PL 14 15 Item 26 24V is available at P J1 between pins 5 and 3 also between pins 6 and 1 Flag 3 Y N Install a new scan carriage ribbon harness PL 14 15 Item 10 Measure the lamp enable signal at P J926 pin 4 on the scanner PWB W TAG 150 enter the dC330 output code 14 005 The signal voltage changes from 24V to 0V when the code is active Y N Install a new scanner PWB W TAG 150 PL 14 15 It...

Page 578: ...May 2013 2 546 Xerox WorkCentre 5790 Family 14 703B to 14 706B 712B 714B 718B Status Indicator RAPs Figure 2 Circuit diagram ...

Page 579: ...s that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Switch off the machine then switch on the machine GP 14 The fault is still present Y N Perform SCP 6 Final Actions Perform dC132 NVM Initialization copier NVM initialization 14 720 Scan Length Out Of Range RAP 14 720 The scan length request from the single boa...

Page 580: ...mine the harness sleeving for punctures or other damage If necessary install a new DADH power distribution PWB harness PL 3 24 Item 6 Route the new harness to the right away from the single board controller PWB If this has caused a blown fuse F1 on the power distribution PWB install a new power distribu tion PWB PL 3 24 Item 5 NOTE This fault has been caused on a number of machines by bad routing ...

Page 581: ...ess PL 14 25 Item 13 Go to Flag 3 Check for 5V on P J451 between pins 1 and 2 on the scanner PWB The voltage is good Y N Install a new scanner PL 14 20 Item 1 Go to Flag 3 Check for 5V on P J452 between pins 17 and 18 The voltage is good Y N Check the connectors on the ribbon cable between P J451 and P J452 are correctly installed If necessary install a new harness PL 14 25 Item 5 5V is available ...

Page 582: ...May 2013 2 550 Xerox WorkCentre 5790 Family 14B Status Indicator RAPs Figure 1 Component location Document size sensor 1 Q14 315 Document size sensor 2 Q14 320 Input module angle sensor Q14 310 ...

Page 583: ...May 2013 2 551 Xerox WorkCentre 5790 Family 14B Status Indicator RAPs Figure 2 Circuit diagram ...

Page 584: ... actuator PL 14 15 Item 21 Switch the machine off then switch the machine on GP 14 The fault is still present Y N Perform SCP 6 final actions Reinstall the DADH REP 5 19 Enter the dC330 input code 14 310 Document Handler Angle Sensor and actuate the input module angle sensor Q14 310 by opening and closing the DADH The display changes Y N Go to Flag 2 Check the input module angle sensor Q14 310 Ref...

Page 585: ...May 2013 2 553 Xerox WorkCentre 5790 Family 14C Status Indicator RAPs Figure 2 Circuit diagram ...

Page 586: ...14 2 to remove the fuse The fuse is good Y N Install a new fuse PL 14 25 Item 11 Re install the scanner top cover and GUI but do not install the screws Switch on the machine GP 14 Enter the dC330 output code 14 005 The new fuse fails Y N The lamp is lit Y N Go to Flag 1 Check the lamp ribbon harness between P J456 and P J463 for open or short circuits The lamp ribbon harness is good Y N Install a ...

Page 587: ...n the following order Exposure lamp PL 14 25 Item 9 Exposure lamp inverter PL 14 25 Item 12 Scanner PWB PL 14 25 Item 4 Perform ADJ 14 1 Optics Cleaning Procedure The automatic gain control circuit does not see the light from the exposure lamp Check for misplaced optics mirrors or an obstruction in the light path If necessary install a new scanner PL 14 20 Item 1 Figure 1 Exposure lamp inverter an...

Page 588: ...May 2013 2 556 Xerox WorkCentre 5790 Family 14D Status Indicator RAPs Figure 2 Circuit diagram ...

Page 589: ...njury Moving parts can cause injury NOTE The FTP SMB protocol will be followed by a colon and port number 21 is for FTP and 139 is for SMB Scan the document using the default template and one other template The fault is present on both templates Y N The template that failed is incorrectly configured Ask the customer or system administra tor to verify the settings of the web template that failed in...

Page 590: ...omers settings Y N Escalate the fault to the system Administrator If the customer does not have a System Administrator they should contact the Customer Support Centre or request a Xerox analyst troubleshoot their network which will be subject to a charge Retry the job The job was successful Y N Escalate the fault to the system Administrator If the customer does not have a System Administrator they...

Page 591: ... entered on the machines CWIS page NOTE The password is not printed on the configuration or confirmation reports 16C Remote Directory Lock Failed RAP Use this RAP when the customer reports that the machine has logged onto the scan server but cannot create a folder inside of the scan directory The creation of the scan folder is neces sary for the machine to successfully complete the can to file job...

Page 592: ...May 2013 2 560 Xerox WorkCentre 5790 Family 16B 16C Status Indicator RAPs ...

Page 593: ...L 3 24 Item 12 2 If the fault remains install a new components as necessary Memory module PL 3 24 Item 12 SBC PWB PL 3 24 Item 3 19 404 Compressor Time out RAP 19 404 Video compressor DVMA time out Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause deat...

Page 594: ...n the machine GP 14 Procedure Go to the 03 315 325 347 348 349 355 400 Single Board Controller PWB Failure RAP 19 407 19 408 Middle Function DVMA Time out RAP 19 407 Video middle function DVMA input time out 19 408 Video middle function DVMA output time out Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer t...

Page 595: ... electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury If the job has mixed originals make sure that Mixed Size Originals is selected on the UI Switch off the machine then switch on the machine GP 14 Procedure Go to the 03 315 325 347 348 349 355 400...

Page 596: ...May 2013 2 564 Xerox WorkCentre 5790 Family 19 409 Status Indicator RAPs ...

Page 597: ...inal Actions 20 305 Fax System Low Memory Unrecoverable RAP The embedded fax PWB will automatically reset itself 20 305 Unrecoverable fax system low memory due to hardware or software error Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or inj...

Page 598: ... routine Reformat The fault is cleared Y N Reload the software GP 4 Perform SCP 6 Final Actions 20 322 Fax Non Volatile Device not Present RAP 20 322 The non volatile device has not been installed on the embedded fax PWB Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Ele...

Page 599: ...ash memory PL 20 10 Item 3 Embedded fax PWB PL 20 10 Item 4 20 327 Extended Fax PWB Failure RAP 20 327 The registers cannot be accessed on the extended fax PWB Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause inj...

Page 600: ... 26 10 Item 3 The phone line connec tion is good Y N The telephone line has a fault inform the customer to have the line checked by the tele phone company Install new components in the following order Telephone cable PL 20 10 Item 8 Embedded fax PWB PL 20 10 Item 4 20 332 20 340 Fax Network Line 2 Fault RAP 20 332 No communication via the PSTN 2 port 20 340 Fault at port 2 on the extender fax PWB ...

Page 601: ...ocedure Switch off the machine then switch on the machine GP 14 The fault still occurs Y N Perform SCP 6 Final Actions W O TAG X 001 The compact flash PL 20 10 Item 3 is installed correctly Y N Remove then re install the compact flash memory PL 20 10 Item 3 If necessary install a new compact flash memory PL 20 10 Item 3 Clear the fax card NVM Go to dC132 NVM Initialization Select Embedded Fax NVM ...

Page 602: ...the embedded fax PWB PL 20 10 Item 4 and the riser PWB PL 3 22 Item 3 The connections are good Y N Install new components as necessary Riser PWB PL 3 22 Item 3 Embedded fax PWB PL 20 10 Item 4 The fault still occurs Y N Perform SCP 6 Final Actions Install a new compact flash memory PL 20 10 Item 3 If the fault remains reload the machine software GP 4 Perform SCP 6 Final Actions 20 701B Fax Phone B...

Page 603: ...lectricity 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 20 710 20 711 Image Overwrite Error Entry RAP Make a backup of the phone book and the customer settings using the NVM save and restore tool on the PWS Refer to Portable Work Station and Tools GP 5 Procedure Switch off the machine then switch on the ...

Page 604: ...Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Check that the telephone line cables are properly connected Fax line 1 from the tele phone line outlet connects to line 1 socket on the machine If fitted fax line 2 from the telephone line outlet connects to line 2 socket on the machine Figure 1 Use a hand set to dial remote number and list...

Page 605: ...Automatic Branch Exchange line is operational Connect a telephone handset into line outlet and listen for a dial tone Use a known good telephone handset The dial tone is present Y N Use the line test tool PL 26 10 Item 3 to check the telephone line The green normal indicator light is on Y N Ask the customer to request a line check by the telephone company Use a telephone handset to dial a known go...

Page 606: ...en for a dial tone or dialing and answer tones A fax tone is present Y N W O TAG X 001 Reset the value at the following locations 20 281 Line1CurrentDetect 0 20 282 Line2CurrentDetect 0 A Fax tone is present Y N Go to the 20G Embedded Fax Checkout Install new components as necessary Embedded fax PWB PL 20 10 Item 4 Telephone cable PL 20 10 Item 8 The fax is working correctly Send a three page test...

Page 607: ...to check the machine at the remote end Enter dC109 and print a Protocol Report The Protocol Report shows RNR Receive Not Ready is received from the remote Fax repeatedly until time out and DCN Disconnect Check communication failure after V34 PH2 V34 PH3 or DCS TCF The remote Fax receives and prints the Fax Y N Compatibility problem with remote Fax Print a Protocol Report and check for communicatio...

Page 608: ...d check for errors Reconnect the fax and call the fax number from a independent telephone line and listen for a Fax tone The machine answers and a fax tone is heard Y N Print Activity Report Check for receive calls on the Activity Report Machine probably does not bleep to indicate incoming call Check that the NVM values at location 20 222 and at location 20 654 to 20 658 are set to the correct def...

Page 609: ...witched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Switch off the machine then switch on the machine GP 14 Check for the correct installation of the embedded fax option Refer to the system admin istration guide CD1 for the install instruction Follow the screen prompts Procedure...

Page 610: ...set with an error message Refer to 20 327 Extended Fax PWB failure RAP For copy quality defects go to the IQ9 Unacceptable Received Facsimile Image Quality RAP Procedure Go to Flag 1 Check the voltages at P J155 The voltages are good Y N Refer to the following 01B 0V Distribution RAP 01D 3 3V Distribution RAP 01E 5V Distribution RAP 01F 12V Distribution RAP If necessary install a new riser PWB PL ...

Page 611: ...C if the machine has a ground problem or is in receipt a fax Perform the following 1 Switch off the machine GP 14 2 Disconnect the fax cable from the single board controller PWB 3 Remove the embedded fax PWB PL 20 10 Item 4 4 Remove the safety cover PL 20 10 Item 1 and the lower cover PL 20 10 Item 5 5 If installed remove the extended fax PWB PL 20 10 Item 2 6 Install the embedded fax PWB 7 Connec...

Page 612: ... off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Switch off the machine then switch on the machine GP 14 Check with the customer or IT person on what network the Fax service is being used and what is the quality of service Check that an analogue adapter or a connection for analogue ...

Page 613: ...the halo guide registration guide Check the bias contact connection Check that the bias is available at the halo guide while the machine is in run mode For the voltage range of the registration chute bias refer to 09 060 HVPS Fault RAP 6 Xerographic contamination may be caused by the failure of the scorotron cleaner go to the 09 341 09 342 Scorotron Cleaning Failure RAP NOTE If the fault has been ...

Page 614: ...hile performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Switch off the machine then switch on the machine GP 14 Check for and clear any obstructions in the paper path Procedure Perform the following 1 If a 22 315 fault code is displayed go to the 06 340 ROS Laser Failure RAP 2 If the problem per...

Page 615: ...tem manager failed to install the network scanning scan to file option 22 401 The system manager failed to install the server fax option 22 402 The system manager failed to install the E mail scan to E mail option 22 403 The system manager failed to install the internet fax option 22 423 The system manager failed to install the searchable fire format option 22 426 The system manager failed to inst...

Page 616: ...n Enter the kit option number found in the software options kit 22 407 Embedded Fax Install Failure RAP 22 407 The system manager failed to install the embedded fax option Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts c...

Page 617: ...ed will not appear in the machine user interface screen 3 If the fault persists reload the software GP 4 22 417 Embedded Fax Remove Failure RAP 22 417 The system manager failed to remove the embedded fax option Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cau...

Page 618: ...ded fax d Select Enable e Select Save f Select Exit Tools g The machine will reset with the new configuration When complete the optional fea ture removed will not appear in the machine user interface screen 22 421 Embedded Fax Disable Failure RAP 22 421 The system manager failed to disable embedded fax option Procedure Perform the following 1 Switch off the machine then switch on the machine GP 14...

Page 619: ...ured by the scanner is too dark i e low grey levels dark If this fault occurs the IQA image quality adjustment factor will not be readjusted and stay as it is Initial Actions Load A4 8 5x11 inch white paper LEF in the bypass tray Procedure Perform the following 1 Make print samples and if the images are dark or black refer to IQ1 Image Quality Entry RAP to resolve image quality defects for dark or...

Page 620: ...loper bias print level and reset value to default 6 If the fault still occurs the ROS output level may be too low Go to the RAP 03 395 396 852 853 IOT PWB Fault RAP 22 760 IQA Factor Set to Maximum RAP 22 760 The IQA image quality adjustment factor has been set to the maximum value dark The fault will occur if the test pattern is light but not light enough to create a 22 452 fault This may result ...

Page 621: ...reset value to 100 Reboot the machine and repeat the ADJ 9 2 Image Quality Adjustment Routine 3 Check in dC131 location 06 01 ROS light level is correct and not set high Enter dC131 location 06 01 ROS light level and reset value to default Reboot the machine and repeat the ADJ 9 2 Image Quality Adjustment Routine 4 Check that the developer bias is not set high Enter dC131 location 09 021 developer...

Page 622: ...833 List jobs request timed out between single board controller PWB and network controller scan to file 22 834 List jobs request timed out between single board controller PWB and network controller scan to fax server fax service 22 835 List jobs request timed out between queue utility and either DC job service or the embedded fax services 22 836 Network controller scan to distribution service not ...

Page 623: ... Remove the fuser module to eliminate the noise caused by the fuser If the source of the noise is the fuser go to the Fuser checkout To isolate the fuser module Release the jam clearance latch 3b4a on the fuser module to separate the pressure roll from the fuser roll Enter dC330 code 04 010 and add code 08 070 to energize the registration clutch The registration rolls and the jam clearance knob 4c...

Page 624: ...5 ppm PL 5 15 Item 18 or 40 90 ppm PL 5 17 Item 18 Noise from the DADH input tray Possible causes are Document guides Solution Clean the DADH input tray in the area below the input guides with antistatic fluid PL 26 10 Item 19 Squeaks from the DADH Possible causes are DADH exit roll assembly or takeaway roll assembly PL 5 35 Item 6 Solution Remove and clean the shafts and plastic bushes with antis...

Page 625: ...s Solution Check the tray 3 transport drives PL 8 36 Adjust and install new components as necessary PL 7 18 Check that the paper trays are correctly positioned and that the tray moves freely inside the tray assembly Install new components as necessary PL 7 18 Tray 5 Assembly Run the components as follows Open the tray 5 door to lower the elevator Close the door or actuate the interlock Enter the d...

Page 626: ...front and rear tampers PL 11 112 Item 1 Enter dC330 code 11 023 Eject Mot Cycle cycles the eject assembly PL 11 114 Item 1 Enter dC330 code 11 033 Bin 1 Elevator Motor Cycle to move bin 1 up and down PL 11 106 Item 8 NOTE The bin will move down and then move up to the home position Possible causes and potential solutions are 2 knocks for each stapled set Possible causes are LCSS set ejector Soluti...

Page 627: ... 11 135 Item 10 NOTE The tray moves down for 15 seconds and then stops Enter dC330 code 11 034 Bin 1 Offset Motor to offset sets and fed to Bin 1 PL 11 140 Item 19 Enter dC330 code 11 053 SU1 Motor Forward to move the stapler unit to the rear PL 11 140 Item 12 Enter dC330 code 11 054 SU1 Motor Reverse to move the stapler unit to the rear PL 11 140 Item 12 Enter dC330 code 11 060 BM Compiler Motor ...

Page 628: ...ath or injury Moving parts can cause injury Go to the Customer Tools application and adjust the backlight output level Refer to REP 2 1 to access the user interface assembly Check and re seat all connectors on the UI control PWB PL 2 10 Item 11 and UI touch screen PWB PL 2 10 Item 6 Enter dC305 UI test Perform the relevant tests to check the operation of the UI If the problem occurs while entering...

Page 629: ... touch screen PL 2 10 Item 5 Switch off the machine GP 14 Check the memory module PL 3 24 Item 12 The memory module is correctly installed Y N Correctly install the memory module refer to REP 3 4 Check the software module PL 3 24 Item 8 The software module is correctly installed Y N Correctly install the software module refer to REP 3 3 Install new components as necessary Memory module PL 3 24 Ite...

Page 630: ... J27on the test box P26 from the top of the IOT PWB to J26 on the test box The supplied test harness into J97 on the test box P24 from the test harness into J24 on top of the LVPS P25 from the test harness to J25 on the side of the LVPS P16 from the test harness to J16 on the side of the LVPS P17 from the test harness to J17 on the side of the LVPS The supplied connector with a loop wire into J5 o...

Page 631: ...er module Install new parts Fuser Module 35 55 ppm PL 10 8 Item 1 Fuser module 65 90 ppm PL 10 10 Item 1 LVPS and base module PL 1 10 Item 3 Disconnect P J27 on the IOT PWB Figure 2 On the IOT PWB less than 100 Ohms is measured between J27 pin 6 and the machine frame Y N Install a new IOT PWB PL 1 10 Item 2 Install a new LVPS and base module PL 1 10 Item 3 Disconnect P J5 on the IOT PWB Using a sm...

Page 632: ... power cord Reconnect P J25 Reconnect the power cord and then press the on off switch The LVPS is on IOT PWB LEDs CR12 CR13 CR14 and CR15 are lit also the LVPS fan is running and all stay on Y N This indicates that there is a short circuit on one of the 3 3V or 5V circuits connected to P J25 Go to the 01D 3 3V Distribution RAP and the 01E 5V Distribution RAP to trou bleshoot and repair the cause o...

Page 633: ...May 2013 2 601 Xerox WorkCentre 5790 Family OF3 Status Indicator RAPs Figure 2 IOT PWB LED and PJ locations Figure 3 LVPS PJ locations ...

Page 634: ...ve Messages Log Most recent fault and status codes can be displayed on the UI without entering diagnos tics by pressing the Machine Status button on the keypad touching the Fault tab on the UI then select as appropriate All Faults Active Messages status codes and a status message Error Log fault codes The tables in this procedure bring together the status codes the relevant RAP or procedure refere...

Page 635: ...2 704 02 706 RAP and the 03D Soft ware Module Failure RAP 02 532 Local interface problem detected Please switch the machine off and on again Fault declared UI software error Fault 02 320 called dur ing power on sequence Perform 02 320 02 380 RAP and the 03D Soft ware Module Failure RAP 02 533 Not all configurable ser vices have achieved a sta ble state Machine not achieved stable state five minute...

Page 636: ... and partially imaged sheets and dis card them Paper is delivered to the out put and a video complete has not been received by the sin gle board controller PWB Perform 03 423 424 433 434 821 822 831 832 RAP Table 2 02 5XX Status codes Status Code UI Message Reason for Message Reference Action 03 511 Output Bin full Touch pause to hold printing while emptying the bin The 90 full sensor is cleared b...

Page 637: ...ult Fault 03 350 is raised Perform 03 350 03 351 03 354 RAP 03 551 Fax service is unavailable Single board controller FAX comms error Fault 03 338 is raised Perform 03 338 RAP Table 3 03 5XX Status codes Status Code UI Message Reason for Message Reference Action 03 552 Tray 3 and 4 are unavail able Please call for assis tance IOT microprocessor to HCF comms error Fault 03 359 raised Perform 03 359...

Page 638: ... the machine GP 14 03 586 FAX service unavailable The fault 03 401 or 03 403 is raised Perform 03 401 03 403 Perform 20A RAP Table 3 03 5XX Status codes Status Code UI Message Reason for Message Reference Action 03 587 Machine unavailable The fault 03 417 is raised Perform 03 417 RAP 03 588 Fax service is unavailable Basic Fax not detected or con firmed Perform 03 401 03 403 Perform 20A RAP 03 589...

Page 639: ...r after jam Remove sheet Perform 05 350 05 352 RAP 05 523 Open the document feeder Sheet left over DADH registra tion sensor after jam Remove sheet Perform 05 340 RAP Table 3 03 5XX Status codes Status Code UI Message Reason for Message Reference Action 05 524 Open the document feeder Sheet left over DADH exit sen sor after jam Remove sheet Perform 05 345 05 346 RAP 05 525 Remove all documents fro...

Page 640: ...WB Perform 03 300 306 461 482 805 870 RAP 03 320 to 03 324 RAP 03 310 RAP If necessary reload the software GP 4 Table 4 05 5XX Status codes Status Code UI Message Reason for Message Reference Action Table 5 06 5XX Status codes Status Code UI Message Reason for Message Reference Action 06 520 The ROS motor has fail ure Switch the machine off wait 3 minutes then switch on the machine again If the fa...

Page 641: ...ode UI Message Reason for Message Reference Action 07 550 Tray 3 is lifting Tray 3 is lifting Perform 07 355 RAP 07 551 Tray 1 is lifting Tray 1 is lifting Perform 07 353 RAP 07 552 Tray 2 is lifting Tray 2 is lifting Perform 07 354 RAP 07 560 Tray 4 is lifting Tray 4 is lifting Perform 07 360 RAP 07 561 Tray 5 is lifting please wait Tray 5 is currently lifting Perform 07 373 07 562 Tray 5 is curr...

Page 642: ...y 1 Sheet near Tray 1 feed sensor 08 106 Jam clearance Per form 08 106 RAP 08 562 Open tray 2 Sheet near Tray 2 feed sensor Jam clearance Per form 08 106 RAP Table 6 07 5XX Status codes Status Code UI Message Reason for Message Reference Action 08 563 Open tray 3 Sheet near Tray 3 feed sensor Jam clearance W O TAG 151 Perform 08 107 RAP W TAG 151 Perform 08 131 RAP check the tray 3 exit sensor 08 ...

Page 643: ...UI Message Reason for Message Reference Action 09 588 The Xerographic Module is not compatible with this machine The system setting does not match the xerographic module market region ID setting Install correct xero graphic module or modify setting 09 589 The Xerographic Module is not compatible with this machine The system setting does not match the xerographic module speed setting Install correc...

Page 644: ...s not match the fuser type setting service offering Install new fuser mod ule or modify settings 10 531 Incompatible fuser module The system setting does not match the fuser type setting fuser voltage Install a new fuser or modify settings 10 532 Incompatible fuser module The system setting does not match the fuser OpCo ID set ting Market region Install a new fuser or modify OpCo ID set ting 10 53...

Page 645: ...door of the Finisher HVF Inserter left hand door is open Close cover Perform 11 306 171 11 309 171 RAP 11 510 Open output device door Sheet detected over entry sen sor Perform 11 100 110 RAP for 2K LCSS 11 100 120 for 2K LCSS 11 100 171 11 101 171 RAP for HVF 11 511 Open output device door Sheet near entry sensor at shutdown Perform 11 100 110 RAP for 2K LCSS 11 100 120 for 2K LCSS 11 100 171 11 1...

Page 646: ...o any bin other than bin 0 top bin Cleared when current job completed 11 539 Job in progress Please wait until Manual Stapling job is complete Offline stapling is Ready and a user requests a print job for out put to the stacker mailboxes or BM Cleared when offline stapling mode is can celled Table 10 11 5XX to 9XX Status codes Status Code UI Message Reason for Message Reference Action 11 540 Repla...

Page 647: ...r 1K LCSS 11 140 171 11 142 171 RAP for HVF Table 10 11 5XX to 9XX Status codes Status Code UI Message Reason for Message Reference Action 11 566 No message Bin status message received from the finisher indicating bin 2 out of service Perform 11 140 110 11 142 110 RAP for 2K LCSS 11 140 120 11 142 120 RAP for 1K LCSS 11 140 171 11 142 171 RAP for HVF 11 570 Finisher bin 0 full Fifty additional pri...

Page 648: ...ns in output tray 1 Tamper move or Bin 1 or com piler eject or staple fault Clear the paper jam Switch off the machine then switch on the machine GP 14 Perform 11 005 110 11 006 110 11 310 110 11 311 110 RAP for 2K LCSS 11 007 110 11 008 110 11 312 110 11 313 110 11 319 110 RAP for 2K LCSS 11 024 110 11 025 110 RAP for 2K LCSS 11 005 120 11 006 120 11 310 120 11 311 120 RAP for 1K LCSS 11 007 120 ...

Page 649: ... the paper jam Switch off the machine then switch on the machine GP 14 Perform 11 005 110 11 006 110 11 310 110 11 311 110 RAP for 2K LCSS 11 007 110 11 008 110 11 312 110 11 313 110 11 319 110 RAP for 2K LCSS 11 024 110 11 025 110 RAP for 2K LCSS 11 005 120 11 006 120 11 310 120 11 311 120 RAP for 1K LCSS 11 007 120 11 008 120 11 312 120 11 313 120 11 319 120 RAP for 1K LCSS 11 024 120 11 025 120...

Page 650: ...10 11 5XX to 9XX Status codes Status Code UI Message Reason for Message Reference Action 11 917 Clear the paper jam in the Finisher Sheet over HVF BM compiler paper present sensor Clear the HFV BM paper present sensor area Perform 11 172 171 RAP 11 918 Sheet over tri folder assist sen sor Perform 11 185 171 to 11 187 171 RAP 11 919 Sheet over tri folder exit sensor Perform 11 185 171 to 11 187 171...

Page 651: ...e out Warning Timer expiry Wait for machine to pause then press button on pop up screen Follow the instruc tions If necessary perform 11H 171 Table 10 11 5XX to 9XX Status codes Status Code UI Message Reason for Message Reference Action 11 943 Booklet Making and Tri folding are unavailable Check for obstructions Booklet making or tri folding capability degraded Check for obstruc tions in the HVF B...

Page 652: ... not in index position Perform 12 301 RAP Table 10 11 5XX to 9XX Status codes Status Code UI Message Reason for Message Reference Action Table 12 14 5XX Status codes Status Code UI Message Reason for Message Reference Action 14 508 System error scanner is unavailable Status active when start is selected but scan service is unable to acquire resources Switch off the machine then switch on the machi...

Page 653: ...e UI Message Reason for Message Reference Action 16 509 Some network services unavailable Please notify the machine administrator Insufficient memory for internet fax Machine restart initi ated 16 510 Some network services unavailable Please notify the machine administrator E mail process failed Machine restart initi ated 16 511 Some network services unavailable Please notify the machine administr...

Page 654: ...tus codes Status Code UI Message Reason for Message Reference Action 16 539 Cannot connect to prime or backup authentication server Could not communicate with primary or alternate authentica tion server Verify authentication server setup at web UI verify server is online check network connectivity Can con figure authentication to use guest mode 16 540 Incomplete Network Inter face window Death of ...

Page 655: ...fy machine administrator Network controller BOOTP failure configuration of IP will use stored IPdata Connectivity fix and switch off the machine then switch on the machine GP 14 Table 13 16 5XX to 7XX Status codes Status Code UI Message Reason for Message Reference Action 16 560 Some network services unavailable Please notify machine administrator Some processes on the net work controller have fai...

Page 656: ... controller counters document manager process has stopped Switch off the machine then switch on the machine GP 14 Table 13 16 5XX to 7XX Status codes Status Code UI Message Reason for Message Reference Action 16 585 Incomplete system infor mation Please contact the Machine Administrator The network controller counters remote configuration synchroni zation process has stopped Switch off the machine...

Page 657: ... address 17 514 IP interface error Please notify system administra tor External Accounting Device Communication Failure Contact SA Table 13 16 5XX to 7XX Status codes Status Code UI Message Reason for Message Reference Action 17 518 Some network controller services are not available Please notify the machine administrator WSD discovery failure Switch off the machine then switch on the machine GP 1...

Page 658: ...ait Basic Fax card restarts User clears or time out W O TAG X 001 Install a new compact flash PL 20 10 Item 3 20 545 Fax job could not be sent at this time please try again Error with image processing fax command User clears or times out 7 seconds 20 546 Not enough memory to use fax services Contact your system administrator This status code becomes active when fault 20 324 is raised Cleared when ...

Page 659: ...erence Action 22 512 All the paper trays have been disabled for Auto Selection Auto Paper can not be used with these set tings It is recommended that at least one tray be enabled for Auto Selection All trays direct select only Enable one tray for auto select 22 513 Media required for held job is not available Queued Job being held due to lack of for resources Add paper to the tray being used to cl...

Page 660: ...curred The device clock has been adjusted 03 600 Daylight saving time has been automatically changed No action A fax memory error has occurred Contact your sys tem administrator 20 558 When fault 20 322 is raised When fault 20 322 is cleared Perform 20 322 RAP A fax service error has occurred Fax line 2 is unavailable Fax line 1is still available Contact your system administrator 20 550 Extended c...

Page 661: ...until the accounting SA can purge and reload the authorization data base Additional memory required to support fax Please notify machine administra tor 16 555 Network controller not enough physical memory is configured on the platform to support lan fax Add memory Table 1 Status messages A to F UI Message Status Code Reason for Message Reference Action Additional memory required Please call for as...

Page 662: ... out for sheet 08 171 08 181 08 182 Perform 08 171 RAP 08 181 RAP 08 182 RAP Annotation error 22 557 Annotation Bates number over flow Set by the system on the next page after the Bates num ber reaches the maximum of 999999999 Cleared by the single board controller PWB 7 seconds after raised Table 1 Status messages A to F UI Message Status Code Reason for Message Reference Action Auto Configuratio...

Page 663: ...tus messages A to F UI Message Status Code Reason for Message Reference Action Check the settings for Tray 07 501 Tray 1 closed or size change from power on Attributes confirmed or tray opened Check the settings for Tray 07 502 Tray 2 closed or size change from power on Attributes confirmed or tray opened Check the settings for Tray 07 592 Tray 2 closed or size change from power on Attributes conf...

Page 664: ...p cover 11 502 Output module top cover opened in standby Perform 11 300 110 11 302 110 11 303 110 RAP for 2K LCSS 11 300 120 11 302 120 11 303 120 for 1K LCSS 11 300 171 11 302 171 11 303 171 RAP for HVF Close front door 01 510 Front door open Perform 01 300 RAP Close left hand door 01 512 Left hand door open Perform 01 305 RAP Close the output module top tray 11 501 Output module entry gate opene...

Page 665: ...nctions are not available Please notify machine administrator 16 591 Network controller Ethernet TCP IP port connectivity pro cess failed Connectivity fix and switch off the machine then switch on the machine GP 14 Table 1 Status messages A to F UI Message Status Code Reason for Message Reference Action Empty chad bin 11 549 Hole punch chad bin is full and needs emptying Perform 11 364 110 RAP for...

Page 666: ... unavail able 11 552 There are too many pages for the punch to operate Instruct customer to use fewer pages in the set max 50 sheets Hole punching is unavail able Check for obstruc tions in the hole puncher 11 908 Punch head motor fails Clear the paper jam Perform 11 043 110 11 350 110 RAP for 2K LCSS 11 044 171 to 11 047 171 RAP for HVF Image disk offline Jobs may take longer than nor mal 19 511 ...

Page 667: ...7 The network controller TIFF interpreter failed Switch off the machine then switch on the machine GP 14 Incomplete system infor mation Please contact the Machine Administrator 16 585 The network controller counters remote configuration synchroni zation process has stopped Switch off the machine then switch on the machine GP 14 Incomplete system infor mation Please notify machine administrator 16 ...

Page 668: ...Discard output Try flattening the docu ment and either re scan it through the document feeder or scan it from the document glass 05 507 Fault 05 331 is raised Perform 05 330 05 331 RAP Table 2 Status messages G to N UI Message Status Code Reason for Message Reference Action Local interface problem detected Please switch the machine off and on again 02 531 Faults declared UI running in degraded mod...

Page 669: ...en switch on the machine GP 14 Network scanning commu nication error Please notify machine administrator 16 545 Network controller unrecover able scan to file communication error Machine restart initi ated Resubmit job Table 2 Status messages G to N UI Message Status Code Reason for Message Reference Action Network scanning error Please notify machine administrator 16 548 Network controller scan t...

Page 670: ...pen document feeder top cover 05 526 DADH sheet near CVT sensor in duplex path 05 352 fault is raised Reset when DADH top cover closed after jam cleared Perform 05 350 05 352 RAP Open output device door 11 510 Sheet detected over entry sen sor Perform 11 100 110 RAP for 2K LCSS 11 100 120 for 2K LCSS 11 100 171 11 101 171 RAP for HVF Open output device door 11 511 Sheet near entry sensor at shutdo...

Page 671: ...Table 3 Status messages O to R UI Message Status Code Reason for Message Reference Action Open front door 10 513 Sheet near IOT exit sensor Jam clearance Per form 10 107 10 108 10 109 10 110 RAP Open left hand door 08 550 Sheet over wait sensor Jam clearance Per form 08 100 RAP Open left hand door 08 551 Tray 1 feed sensor detects paper in feed area on power on or in standby 08 101 Jam clearance P...

Page 672: ...l at 100 ms cycle communi cation no response 03 360 Perform 03 360 03 408 to 03 410 03 418 RAP Table 3 Status messages O to R UI Message Status Code Reason for Message Reference Action Output tray 1 out of service Check for obstructions in output tray 1 11 902 Tamper move or Bin 1 or com piler eject or staple fault Clear the paper jam Switch off the machine then switch on the machine GP 14 Perform...

Page 673: ...1 460 171 to 11 462 171 RAP for HVF Output tray nearly full 11 575 Bin 2 90 full sensor made Perform 11C 171 RAP Output Trays out of service Remove all paper from Output Trays 11 598 Output trays have reached their capacity Cleared when con firm button pressed Ozone filter near end of life ensure you have a replace ment filter 09 590 Ozone life counter near end of life Order a new ozone fil ter PL...

Page 674: ...rform 11 063 171 11 411 171 RAP for staple unit 1 and 11 403 171 11 413 171 11 414 171 RAP for staple unit 2 Table 3 Status messages O to R UI Message Status Code Reason for Message Reference Action Please delete the job No tray is configured with the required paper size Press the Job Status button Then select the Delete Button 22 504 No tray configured for media Configure one tray for this stock ...

Page 675: ...nal size and press Start 05 546 On pre feed the DADH fails to recognize the size of the docu ment Reload originals or select size Perform 05C RAP Table 3 Status messages O to R UI Message Status Code Reason for Message Reference Action Remove documents from the paper tray and close the cover 05 502 Document present in DADH tray with DADH cover open Lower the document handler to scan your documents...

Page 676: ...d cov ers cycled and switch cleared and normal job or build job Resume job com mand is given with documents replaced in input tray if required or cancel job command is given Table 3 Status messages O to R UI Message Status Code Reason for Message Reference Action Restoring configuration set ting Please wait System will reboot when com pleted 03 526 Software upgrade configura tion reset When the Im...

Page 677: ...or HVF Some network controller services are not available Contact system administra tor 17 570 Communication with NNTP server failed Switch off the machine then switch on the machine GP 14 Some network services unavailable Please notify machine administrator 16 560 Some processes on the net work controller have failed Switch off the machine then switch on the machine GP 14 Some network services un...

Page 678: ...vices are not available Please notify the machine administrator 16 525 The network controller s Scan to Distribution service process has stopped Machine restart initi ated Table 4 Status messages S to X UI Message Status Code Reason for Message Reference Action Some Network Controller services are not available Please notify the machine administrator 16 527 The network controller s SMB service pro...

Page 679: ...form 19 401 19 402 19 403 RAP Table 4 Status messages S to X UI Message Status Code Reason for Message Reference Action System memory is full etc 19 515 This status code becomes active when fault 19 403 is raised Cleared when the cur rent job completes or when the job is deleted Perform 19 401 19 402 19 403 RAP System memory is full etc 19 516 EPC memory is full The status code is cleared when eit...

Page 680: ... is wait ing for in the registry do not appear even though the Image processing UI sync occurred Perform 02 390 02 391 02 704 02 706 RAP Table 4 Status messages S to X UI Message Status Code Reason for Message Reference Action There is a problem with at least one machine service Please switch the machine off then on again If this does not solve the problem switch the machine off and call for assis...

Page 681: ...ns in Tray 5 07 564 Tray 5 lowering has stopped Perform 07 374 Try turning the machine off and on Please call for assistance if the problem persists 03 591 The single board controller PWB reports that its stored machine model ID differs from that stored in the IOT Switch the machine off and on GP 14 If necessary reload the software GP 4 then re run the install wiz ard refer to GP 15 Try turning th...

Page 682: ...1 026 171 11 392 171 to 11 395 171 11 396 171 to 11 399 171 RAP for HVF Unexpected Stock Size in the Finisher 11 950 A shorter than expected sheet has been fed from the inserter Follow the message text Check the size of the paper in the inserter Unsupported scanner detected 03 505 Scanner software no longer supported Switch off machine and switch on machine GP 14 Check software sta tus and upgrade...

Page 683: ...gram 12 PL 3 24 Check the hard disk drive 03C Hard Disk Failure RAP If the problem occurs while entering or exiting sleep mode go to 01K Sleep Mode RAP Procedure WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury WARNING On...

Page 684: ...3 24 Item 12 Check that the contacts of the memory module s are clean If necessary clean the contacts using a lint free wiper PL 26 10 Item 13 Install the memory module s fully into the socket s Switch on the machine GP 14 2 Switch off the machine GP 14 Remove the software module PL 3 24 Item 8 Check that the contacts of the software module are clean If necessary clean the contacts using a lint fr...

Page 685: ...air from the rear of the machine and blows it into the power supply The fan is hard wired into the power supply Refer to PL 1 10 Item 1 Single Board Controller Cooling Fan This fan is located within the single board controller PWB module This fan draws air into the single board controller PWB module and blows the air onto the single board controller PWB Refer to the information that follows Single...

Page 686: ...dure 7 Enter dC131 location 09 069 TCSensorCtrlVoltage Record the value on the NVM sheet stored in the wallet on the rear cover 8 Enter dC131 location 09 271 Developer Age Check that the value for the developer age is correct reset the value if required 9 Perform SCP 6 Final Actions IOT PWB Voltage Check 1 On the IOT PWB check that the voltage present LEDs that follow are on Figure 1 CR12 Indicate...

Page 687: ... multi feeds For tray 1 and tray 2 check the following Check that the paper tray side guides are set to the correct paper size The paper tray drops when the tray is pulled out and the tray elevates when pushed in Check the paper feed assembly REP 8 1 Check the paper feed rolls REP 8 35 Install new components as necessary PL 8 26 The paper trays for worn broken or missing components Install new com...

Page 688: ...of Life RAP Use this RAP if the fuser module has reached its end of life 400 000 prints prematurely Initial Actions WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Enter dC131 location 09 064 FRU Total Count then check t...

Page 689: ...s that cause the fault to occur e g using the input or output module or making reduced images Enter faults mode and check the active messages and the event log If a fault code is raised when the failure occurs then go to the appropriate RAP Make copies and observe where the paper stops and which components are switched on or off when the failure occurs Check if there is a repetitive pattern to the...

Page 690: ...uring continuity Check that all the PWB and in line connections are good refer to PJ Locations Check the continuity of the ground connections to the copy cartridge fuser module and input and output modules Refer to the 01A Ground Distribution RAP Check that all the input and output module static eliminators are connected correctly and in good condition refer to the relevant input or output module ...

Page 691: ...ght Electrostatic Discharge Checkout Perform the following If the fault only occurs when feeding from a specific paper tray go to Paper Trays 1 to 5 Checkout If the fault only occurs when only making duplex copies go to Duplex Transport Assembly Checkout Check that all EPROMs and the NVM are seated correctly and that the connectors are not damaged Refer to REP 3 4 Single Board Controller and Power...

Page 692: ...forming tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Waste toner is being deposited in the waste toner bottle Y N Remove the waste toner bottle and waste toner door REP 9 1 Place a sheet of paper in the bottom of the aperture from where the waste toner bottle was removed to collect fallen toner Enter...

Page 693: ...ter then the CRUM data is cor rupted Procedure Perform the following 1 Refer to Wiring Diagram 6 Check the wiring harness at PJ144 Repair the wiring as nec essary REP 1 2 2 Check for damage to the xerographic module CRUM connector 35 55 ppm PL 4 10 Item 4 or 65 90 ppm PL 4 12 Item 4 If necessary install a new drives module 35 55 ppm PL 4 15 Item 1 or 65 90 ppm PL 4 10 Item 1 3 Check for damage to ...

Page 694: ...tlet The voltage measured is within the power requirements GP 22 Y N If the voltages are 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 Install a new convenience stapler PL 25 10 Item 1 Figure 1 Component location OF14 Extensible Interface Platform RAP Use this RAP when experi...

Page 695: ...nality when Secure Access is installed Perform the steps that follow Check the connection between the Card Reader and the Secure Access Authentication Device Check which LED s are on or blinking on the Secure Access Authentication Device If the LEDs on the Secure Access Authentication Device are not operating go to Secure Access Authentication Device Failure Check for the LED s are on or blinking ...

Page 696: ...UI remains locked after a card is swiped re orient the card and re swipe Try a known good card in the reader If the other card is working on the problem Card Reader Ask customer to make sure the card corresponds to a valid Secure Access Account Try the card in a known good reader If the card is working on a known good Card Reader it may be a problem with the Secure Access Authentication Device Che...

Page 697: ...ass and Scanner RAP 3 19 IQ8 Skew RAP 3 20 IQ9 Unacceptable Received Facsimile Image Quality RAP 3 22 IQ10 Image Quality Improvement RAP 3 23 IQ11 Light Copies RAP 3 24 IQ12 Barber Pole Deletions Developer Leakage RAP 3 29 IQ13 Cockle Deletion RAP 3 32 Image Quality Specifications IQS 1 Solid Area Density 3 33 IQS 2 Background 3 34 IQS 3 Fusing 3 35 IQS 4 Resolution 3 35 IQS 5 Skew 3 36 IQS 6 Copy...

Page 698: ...May 2013 3 2 Xerox WorkCentre 5790 Family Image Quality ...

Page 699: ...ect 2 Sided Press Start Test The printed images of the internal test pattern are good Y N Go to IQ2 Defects RAP Check the prints for damage The prints are not damaged Y N Go to the IQ5 Print Damage RAP If a facsimile card is installed send a test facsimile to the machine The facsimile image quality is good Y N Compare the facsimile print with an internal test pattern print The facsimile print and ...

Page 700: ...o cess direction See also the description displaced and frag mented image 2 5 8 Magnification At 100 magnification the printed image differs from the size of the image on the original document Refer to IQS 8 Magni fication 11 19 Marks Dark marks in the non image areas of the print 1 2 Misregistration The image on the paper is Misregistration Refer to IQS 7 Registration 16 Narrow Bands Bands across...

Page 701: ...e 7 Reserved for engineering investigations Stress test pattern Will not be defect free 10 Parallel lines 8 on 56 off Figure 6 Lines that run LE to TE 11 Combined grey scales Figure 8 This test pattern is for engineering develop ment and used in the light copies RAP 12 Perpendicular bands 25 mm 1 inch on and 25 mm 1 inch off black Fig ure 9 Solid area reproducibility For checking fus ing stripper ...

Page 702: ...May 2013 3 6 Xerox WorkCentre 5790 Family IQ1 Image Quality Figure 4 Test patterns 5 6 and 7 Figure 5 Test pattern 8 Figure 6 Test pattern 9 Figure 7 Test pattern 10 ...

Page 703: ...May 2013 3 7 Xerox WorkCentre 5790 Family IQ1 Image Quality Figure 8 Test pattern 11 Figure 9 Test pattern 12 Figure 10 Test pattern 13 ...

Page 704: ...May 2013 3 8 Xerox WorkCentre 5790 Family IQ1 Image Quality Figure 11 Test pattern 14 Figure 12 Test pattern 15 Figure 13 Test pattern 16 ...

Page 705: ...May 2013 3 9 Xerox WorkCentre 5790 Family IQ1 Image Quality Figure 14 Test pattern 17 Figure 15 Test pattern 18 ...

Page 706: ... pole deletions A series of finger print deletions that form a pattern like a barber pole or auger marks The deletions are repeated at proximately 7 cm and are approxi mately 30 degrees to the lead edge throughout a grey or dark dusting Go to IQ12 Barber Pole Deletions Developer Leakage RAP Beads on print Clean the following Developer beads hanging from the developer roll and the lower lip Figure ...

Page 707: ... 9 22 Item 2 or 40 90 ppm PL 9 20 Item 2 b Perform dC132 NVM Initialisation and select the All Copier MVN routine Do not save restore NVM to from the machine resident diskette because this may restore corrupted NVM However if the NVM on the machine resident diskette was saved from a time when the machine did not have the fault then and NVM restore should be performed c If the problem continues Ins...

Page 708: ...intervals for the pressure roll are 110 mm for 35 55 ppm and 126 mm for 65 90 ppm machine due to the different size of the pressure roll Perform the following Check that the fuser roll is cleaned and lubricated by the fuser web Go to IQ4 Fuser Module RAP Check the fuser web motor refer to the 10A Fuser Web Motor RAP Part images and missing images Go to 05C Document Size Sensor Failure RAP Print da...

Page 709: ...gistration nip assembly PL 8 15 Item 5 Tray 1 and tray 2 Lower bias guide PL 8 15 Item 22 3 Perform ADJ 9 3 Developer Magnetic Seal Brush Adjustment 4 Copy test pattern 82E2020 and print internal test patterns 11 and 15 Go to IQ11 Light Copies RAP and asses the image quality 5 If required Perform IQ10 Image Quality Improvement RAP to optimize the image quality If the problem persists go to the IQ3...

Page 710: ... Failure RAP Perform ADJ 9 4 Xerographics Cleaning Check the registration developer bias harness connection 35 55 ppm PL 9 17 Item 6 or 65 90 ppm PL 9 15 Item 6 Figure 1 Check that the corotron lead connections to the HVPS are secure PL 1 10 Item 5 If nec essary refer to 09 060 HVPS Faults RAP Check for loose ground connections Go to the 01A Ground Distribution RAP Make prints If the image quality...

Page 711: ... module and view the rear end Check the toner reclaim drive cou pling is free to rotate in a clockwise direction If the black drive coupling does not rotate freely install a new xerographic module 35 ppm PL 9 22 Item 2 or 40 90 ppm PL 9 20 Item 2 Check that the surface of the photoreceptor is not chipped scored or scratched The damage can be caused by the covers on the end blocks of the transfer d...

Page 712: ...9 only changes the fuser temperature when card stock is selected Some 200 gsm papers do not fuse correctly Check that the customer is using tray 1 and tray 2 for alternative quality paper or heavy weight paper Refer to IQS 3 Fusing Check the following for wear and contamination Stripper fingers If possible remove the contamination If the stripper fingers are damaged or worn install a new fuser str...

Page 713: ... positioned ADJ 9 1 Corotron Cleaning Check that the fuser roll stripper fingers are clean If the prints are creased or wrinkled after the fuser module then install a new fuser mod ule 35 55 ppm PL 10 8 Item 1 or 65 90 ppm PL 10 10 Item 1 Ensure that paper path sensor actuators move freely GP 7 If the paper is corrugated after passing through the fuser module install a new tri roll shaft assembly ...

Page 714: ...IQ5 Image Quality Figure 1 Curl height measurement Figure 2 Paper path Place the print on a flat surface Measure the curl within 5 seconds Maximum allowable curl for any paper size in any direction 13mm 0 5inch Tray 1 Tray 2 Tray 4 Tray 3 Tray 5 ...

Page 715: ...ng tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Perform the following DADH Checkout Document Glass Checkout Scanner Checkout W O TAG 150 Scanner Checkout W TAG 150 DADH Checkout Perform the following Clean the underside of the DADH area around the CVT roll PL 5 25 Clean the top surface of the CVT gla...

Page 716: ...4 703B to 14 706B 712B 714B 718B Failure To Calibrate RAP W TAG 150 and perform the Exposure Lamp Check Check the mirrors and exposure lamp for contamination Refer to ADJ 14 2 Optics Clean ing Procedure W TAG 150 IQ8 Skew RAP Use this RAP to determine the source of skew Ensure IQ1 Image Quality Entry RAP is performed before starting this RAP Initial Actions WARNING Ensure that the electricity to t...

Page 717: ...per in each tray Check that the paper weight and type is within the specification Refer to GP 20 Paper and Media Size Specifications Check that the paper size guides are set correctly Check the separator strips on the paper tray for wear Refer to OF8 Multifeed RAP Check that the bypass tray width guides are set correctly Check the bypass tray pre reg nip rolls If necessary install a skew bypass tr...

Page 718: ...ossible establish voice contact using the same telecommunication link as used to receive the document The line is free of interference sounds and the normal voice can be heard clearly Y N Perform the following W O TAG X 001 Go 20H Embedded Fax PWB Voltage Checkout W TAG X 001 Check the machine ground connections refer to the 01A Ground Distribution RAP If the machine ground connections are good re...

Page 719: ... 9 2 Image Quality Adjustment Routine If the image quality routine does not correct the image quality defect Enter dC131 and reset location 09 321 and 09 322 to the default value and continue with the procedure Procedure Make a copy of the customers document with different image quality setups until the image quality has been improved Use different combinations of the image quality options that ar...

Page 720: ...rum is discolored or hazy install a new module 35 ppm PL 9 22 Item 2 or 40 90 ppm PL 9 20 Item 2 Check the opera tion of the photoreceptor and ozone fans refer to OF6 Ozone and Air Systems RAP Clean the charge corotron ADJ 9 4 Clean the transfer detack corotron ADJ 9 1 Clean the erase lamp ADJ 9 4 Clean the ROS window ADJ 6 1 With the xerographic module in the machine remove the fuser module Reach...

Page 721: ... on machines that have had new parts or have had NVM val ues changed Also perform this part of the procedure when copies have failed to meet the specification in Part 1 Make the following copies and prints With normal copy quality settings make one DADH and one platen copy of test pattern 82E2010 A4 or 82E2020 8 5x11 inches Then run one each of Internal Test Patterns 11 and 15 dC606 Mark these STA...

Page 722: ...e is consistently above 2 8V the toner dispenser is not operating cor rectly Install a new toner dispenser module 35 55 ppm PL 9 17 Item 1 or 65 90 ppm PL 9 15 Item 1 If the voltage is below 1 5V install a new developer module 35 55 ppm PL 9 17 Item 2 or 65 90 ppm PL 9 15 Item 2 Enter diagnostics dC131 location 09 069 Increase the value by 200 or to the maximum value of 1200 if an increase of 200 ...

Page 723: ...ese prints and copies Save these documents in the machine for future reference Run sample customer documents If necessary use the image quality options sharp ness contrast lighter darker on the UI to customize the look of the customer s copies as detailed in IQ10 Run dC604 Registration Setup Routine Restore the customer s auditron data using the PWS Auditron Save and Restore Tool Record any image ...

Page 724: ...nternal test print 15 Figure 5 Internal test print 11 1 2 3 4 5 6 7 8 1 Bands 7 and 8 should merge or nearly merge and should be evenly black 2 Bands 1 to 6 should all be distinct 3 Bands 1 can be white or light grey These three areas should be grey They should not be white ...

Page 725: ...ut the housing at the inboard and outboard ends Remove the xerographics module and examine the drum surface for chips scores and scratches It is important to note that the drum is usually scored at the inboard or outboard end in the non image area Scores in these areas are as serious as in the image area The drum surface is good Y N Install a new xerographic module 35 ppm PL 9 22 Item 2 or 40 90 P...

Page 726: ...May 2013 3 30 Xerox WorkCentre 5790 Family IQ12 Image Quality Figure 1 Example of barber pole deletions Figure 2 Developer trickle tube Trickle tube ...

Page 727: ...kCentre 5790 Family IQ12 Image Quality Figure 3 Developer trickle door and rear locating holes Figure 4 Developer module locating pins Locating hole Locating hole Trickle door REAR VIEW Front locating pins Rear locating pins ...

Page 728: ...leads poor image transfer The known causes of paper buckle are Worn damaged components within the duplex transport assembly worn damaged components within the registration transport assembly Remove the duplex transport assembly REP 8 7 then inspect the assembly for damage GP 7 The duplex transport assembly is in good condition Y N Install a new duplex transport assembly 35 55 ppm PL 8 22 Item 1 or...

Page 729: ... darker than the 1 3 reference but less than 1 5 The 3 0 3 3 and 3 4 text areas should all be visible The 4 1 line pair should be visible The 2 0 2 2 and 2 4 squares should be darker than the original document The bullseye targets should be clearly reproduced Compare a print of the internal test pattern 12 Figure 2 with the solid area density scale 82E8230 SIR 542 00 The density of the solid areas...

Page 730: ... made from the doc ument glass with the visual scale 82P448 The background of the copies must not be darker than the reference area B Compare a print of the internal test pattern 1 Figure 2 with the visual scale 82P448 The background of the print must not be darker than the reference area B Corrective Action If the background specification is not met then go to the IQ1 Image Quality Entry RAP Figu...

Page 731: ...rface of the paper When checking the fusing on heavy weight paper 200gsm rub the image with a finger Images fused on the smooth side have a greater resistance to rubbing than images fused on the rough side Do not attempt to fold heavy weight paper as this breaks the fibres Figure 1 Test pattern IQS 4 Resolution Documents Test patterns 82E2000 A3 and 11X17 82E2010 A4 82E2020 8 5X11 Specification Ma...

Page 732: ...istance between area A and area B is 250mm 10 inches Use internal test prints 16 or 17 to check printer skew Corrective Action Refer to IQ1 Image Quality Entry RAP Figure 1 Skew measurement Table 1 Skew measurement Source of paper DADH Document glass Printer All trays lead edge registration 3mm 1 8 inch 1 3mm 1 16 inch 1mm 1 32 inch Bypass tray 3mm 1 8 inch 1 3mm 1 16 inch 1mm 1 32 inch Duplex 3mm...

Page 733: ...e ladder scale A Use one of the test patterns 82E2000 A3 and 11X17 82E2010 A4 82E2020 8 5X11 Refer to Table 3 to assess image disturbances Paper wrinkle Paper wrinkles which result in the loss of information are unacceptable at any level In any mode copy prints containing wrinkles or creases which do not result in the loss of information may occur less frequently than 1 in 500 consecutive copies p...

Page 734: ...nce between measurements at A and B of a DADH copy are greater than 3 mm refer to IQS 5 Skew NOTE If a difference between measurements at A and B of a document glass copy are greater than 1 3 mm refer to IQS 5 Skew Corrective Action Refer to ADJ 3 1 Registration Setup Figure 1 Registration measurement Table 1 Registration measurement Source of paper DADH Document glass Printer reference only All t...

Page 735: ... the unfolded test pattern Compare the dimensions Figure 1 Corrective action Refer to ADJ 3 2 Magnification Adjustment NOTE There are no across process direction adjustments Figure 1 Magnification check Table 1 Specifications Source of image In process direction Across process direction Printer In ambient conditions using 80gsm 20lb A4 letter LEF equal to and less than 0 4 equal to and less than 0...

Page 736: ...May 2013 3 40 Xerox WorkCentre 5790 Family IQS 8 Image Quality ...

Page 737: ...REP 5 16 Document Width Sensor 4 69 REP 5 17 Input Tray Static Eliminator 4 70 REP 5 18 Exit Roll Idler 4 71 REP 5 19 DADH Removal 4 73 REP 5 20 Mylar Guide Strip 4 74 REPs 6 ROS REP 6 1 ROS 4 75 REPs 7 Paper Supply REP 7 1 Tray 1 and Tray 2 Removal 4 77 REP 7 2 Tray 3 and Tray 4 Removal W O TAG 151 4 78 REP 7 3 Tray 3 and Tray 4 Elevator Motor W O TAG 151 4 79 REP 7 4 Tray 3 and Tray 4 Elevator C...

Page 738: ...Sensor W TAG 151 4 173 REP 8 50 Tray 3 Feed Sensor W TAG 151 4 174 REP 8 51 Tray 4 Stack Height Sensor W TAG 151 4 175 REP 8 52 Tray 4 Empty Sensor W TAG 151 4 175 REP 8 53 Tray 4 Feed Sensor W TAG 151 4 176 REP 8 54 Tray 3 and Tray 4 Feed Assembly Feed Rolls W TAG 151 4 177 REP 8 55 Tray 3 Paper Guide W TAG 151 4 183 REP 8 56 Tray 4 Paper Guide W TAG 151 4 185 REP 8 57 Tray 3 Transport Clutch Dri...

Page 739: ...mbly 4 325 REP 11 34 171 Inserter Jam Clearance Guide Assembly 4 326 REP 11 35 171 Diverter Exit Gate 4 327 REP 11 36 171 Crease Blade Assembly 4 328 REP 11 37 171 Stacker Driving Shaft Bearings 4 330 REP 11 38 171 HVF Stacker Bin 1 Main Drive Belts 4 331 REP 11 39 171 HVF BM Diverter Gate 4 332 REP 11 40 171 HVF Input Roll 4 333 REP 11 41 171 HVF Inserter Guide Roll 4 335 REP 11 42 171 HVF Buffer...

Page 740: ...ADJs 5 DADH ADJ 5 1 DADH Drive Belt Adjustment 4 437 ADJ 5 2 DADH Height Adjustment 4 438 ADJ 5 3 DADH Skew Adjustment 4 440 ADJ 5 4 DADH Cleaning Procedure 4 441 ADJ 5 5 DADH Registration Adjustment 4 442 ADJ 5 6 DADH Document Pad 4 442 ADJs 6 ROS ADJ 6 1 ROS Window Cleaning Procedure 4 443 ADJ 6 2 ROS Cleaning Procedure 4 444 ADJs 7 Paper Trays ADJ 7 1 Tray 3 and Tray 4 Paper Tray Guide Setting ...

Page 741: ...airs Adjustments ADJ 11 13 171 HVF Performance Improvement W TAG V 006 4 496 ADJ 11 14 171 BM Diverter Solenoid Position 4 501 ADJs 14 Scanner ADJ 14 1 Optics Cleaning Procedure W O TAG 150 4 503 ADJ 14 2 Optics Cleaning Procedure W TAG 150 4 503 ...

Page 742: ...May 2013 4 6 Xerox WorkCentre 5790 Family Repairs Adjustments ...

Page 743: ... IOT PWB NOTE 2 Before starting this procedure read and record the dC131 NVM values in location 09 271 Developer age and 09 069 TC sensor control voltage After installing the new IOT PWB perform an NVM restore GP 5 and write the values recorded from the old IOT PWB into NVM locations 09 271 and 09 069 Load software if required GP 4 In diagnostics on the Ser vice Info screen select the serial numbe...

Page 744: ...igure 3 Remove the cable ties Figure 3 Cable tie and ground connection 7 Figure 4 Remove the securing screw from the power and control assembly Figure 4 Power and control assembly Remove cable tie Cut cable tie 1 Remove screw 2 Move the power and control assembly to the left ...

Page 745: ...all of the HT leads on the HVPS PWB Figure 5 HVPS PWB 9 Figure 6 Disconnect all the PJs on the IOT PWB except PJ14 Figure 6 IOT PWB 10 Figure 7 Disconnect all of the PJs from the LVPS Figure 7 LVPS 11 Remove the power and control assembly 1 Disconnect PJ24 2 Disconnect all the HT leads on the HVPS PWB ...

Page 746: ...he bracket Figure 8 Bypass tray cable 2 Refer to Figure 8 Check that PJ148 has not been disconnected on the Main Drive PWB 3 Figure 9 Ensure that the nut on the ground connection is tightened to secure the ground terminals 4 Figure 9 Use a digital multimeter set to a resistance range Verify that there is continuity between the ground pin on PJ21 and the frame ground connection Figure 9 Ground chec...

Page 747: ...tem 9 Single board controller PWB scanner driver PWB CCD PWB harness W OTAG 150 PL 3 24 Item 7 Single board controller PWB DADH comms scanner power harness W TAG 150 PL 3 24 Item 7 3 The following connectors can be repaired by removing the faulty terminals and installing new terminals Molex SL connectors REP 1 3 Male Hirose DF1B connectors REP 1 4 AMP EI connectors REP 1 5 Hirose DF11 connectors R...

Page 748: ...l into the appropriate position of the crimp tool then close the tool just enough to hold the terminal Figure 3 Crimping the terminal 3 Insert the wire fully into the terminal so that the stripped portion of the wire is within the inner grip of the terminal Close the crimp tool fully to make the crimp 4 Figure 4 Insert the crimped terminal into the appropriate position of the crimp tool and close ...

Page 749: ...rd from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Figure 1 Remove the damaged terminal from the housing Figure 1 Remove the terminal 2 Cut off the damaged terminal then strip 3mm of insulation from the end of the wire Replacement CAUTION There are different terminals for large gauge and small gauge ...

Page 750: ... 2 Crimping the terminal 3 Insert the wire fully into the terminal so that the stripped portion of the wire is within the longer grip of the terminal and the insulation of the wire is within the cable grip of the ter minal Close the crimp tool fully to make the crimp check that the wire is firmly crimped in the terminal 4 Figure 3 Insert the crimped terminal into the appropriate position of the cr...

Page 751: ...asks that do not need electricity Electricity can cause death or injury Moving parts can cause injury NOTE The male housings contain socket terminals and the female housings contain pin ter minals 1 Use the extractor tool to release the terminal from the housing Refer to Figure 1 to iden tify the male housing and terminal type Refer to Figure 2 to identify the female housing and the terminal type ...

Page 752: ...rminal Figure 3 Crimping the terminal 3 Insert the wire completely into the terminal so that the stripped portion of the wire is in the longer grip of the terminal The insulation of the wire is within the cable grip of the termi nal Close the crimp tool completely to make the crimp Check that the wire is crimped firmly in the terminal 4 Figure 4 Insert the crimped terminal into the appropriate pos...

Page 753: ... injury Moving parts can cause injury NOTE The male housing contains female terminals that cannot be crimped in the field if a ter minal is damaged install a new terminal with flying lead 1 Figure 1 Remove the damaged terminal from the connector housing Figure 1 Terminal removed 2 Cut the damaged terminal off the wire Replacement 1 Insert the replacement terminal with flying lead into the connecto...

Page 754: ...nnector splicing blocks removal steps 4 and 5 The replacement procedure is only applicable to crimp terminal connectors 1 Identify the terminal type Go to step 2 for a housing containing crimp terminals or go to step 4 for a housing containing insulation displacement IDC terminals 2 Figure 1 Remove the damaged crimp terminal from the connector housing Figure 1 Terminal removal 3 Cut the damaged cr...

Page 755: ...njury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Pull the fuser module out a short way 2 Figure 1 Release the door interlock switch Figure 1 Releasing switch 3 Figure 2 Remove the interlock switch Figure 2 Removing switch Replacement Reverse the removal procedure to replace the door interlock switch 1 Insert a steel rule or feeler gauge Push to relea...

Page 756: ...injury Figure 1 ESD Symbol 1 Remove the power and control assembly REP 1 1 2 Remove the HVPS 2 screws and the IOT PWB 8 screws from the old LVPS and base module 3 Remove the insulating sheet from behind the HVPS 4 Figure 2 As necessary remove the output device harness and tray 5 harness from the LVPS and base module Figure 2 Remove the output device harness and tray 5 harness Replacement CAUTION D...

Page 757: ...mer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury Figure 1 ESD Symbol 1 Remove the rear cover PL 8 10 Item 1 2 Figure 2 Remove the HVPS Figure 2 Remove the HVPS 1 Disconnect 6 HT connectors 3 Remove 2 screws 2 Disconnect PJ55 4 Re...

Page 758: ...correctly under the locating tabs and over the two metal studs Figure 3 HVPS insulator and push clips 3 Figure 4 Use a digital multimeter set to a resistance range Verify that there is continuity between the ground pin on PJ21 and the frame ground connection Figure 4 Ground connection check HVPS PWB locating tabs Metal studs Frame ground connection 35 55 ppm only Ground pin on PJ21 65 90 ppm only ...

Page 759: ...ure 2 Remove the terminal from the housing using the Molex Mini Fit extractor tool Figure 2 Removing the terminal 2 Cut off the damaged terminal then strip 4mm of insulation from the end of the wire Replacement 1 Select the correct terminal type 2 Figure 3 Insert the terminal into the appropriate position of the crimp tool and close the tool just enough to hold the terminal Figure 3 Crimping the t...

Page 760: ... tool and close the crimp tool to fasten the wire insulation in the outer grip of the terminal Figure 4 Crimping the insulation grip 5 Figure 5 Check that the crimp is correctly made Figure 5 Inspecting the finished crimp 6 Insert the replacement terminal into the connector housing Correct Incorrect Wire exposed Insulation in crimp Loose strands of wire ...

Page 761: ...ymbol CAUTION Ensure that E S D procedures are observed during the removal and installation of the user interface assembly 1 Open the front door PL 8 10 Item 10 2 Remove the user interface assembly Figure 2 Figure 2 UI assembly removal Replacement 1 The replacement is the reverse of the removal procedure Refer to GP 6 before the screws are installed 2 If prompted reload the software set GP 4 The s...

Page 762: ...en PWB 1 Remove the user interface assembly REP 2 1 2 Put the user interface assembly on a flat surface CAUTION The cable clamps are very fragile and only need to be moved slightly to release the ribbon cables 3 Remove the user interface touch screen clamp assembly Figure 2 Figure 2 Remove the clamp assembly 4 Carefully release the UI control panel PWB from the screen clamp Replacement The replace...

Page 763: ...that E S D procedures are observed during the removal and installation of the user interface control PWB 1 Remove the user interface assembly REP 2 1 2 Put the user interface assembly on a flat surface CAUTION The cable clamps are very fragile and only need to be moved slightly to release the ribbon cables 3 Remove the user interface control PWB Figure 2 Figure 2 UI control PWB removal Replacement...

Page 764: ...observed during the removal and installation of the user interface touch screen 1 Remove the user interface assembly REP 2 1 2 Put the user interface assembly on a flat surface 3 Remove the user interface screen clamp assembly refer to REP 2 2 4 Remove the user interface touch screen Figure 2 Figure 2 UI control PWB removal Replacement 1 The replacement is the reverse of the removal procedure Refe...

Page 765: ...tall the new IOT PWB Ensure the IOT PWB ground contact screw is tight on the IOT PWB Figure 3 Ensure the contact faces are clean Ensure the screw is bright plated and not black Perform 1 below Perform the following 1 Reconnect the power cord and switch on the machine GP 14 If necessary reload the software set GP 4 The machine will automatically upgrade or downgrade the software when the machine is...

Page 766: ... need electricity Electricity can cause death or injury Moving parts can cause injury Figure 1 ESD Symbol CAUTION Ensure that E S D procedures are observed during the removal and installation of the disk drive 1 Pull out the single board controller PWB module PL 3 24 Item 1 2 Remove the hard disk drive Figure 2 and Figure 3 Figure 2 Hard disk drive removal 2 Disconnect the data cable 1 Disconnect ...

Page 767: ...file is available from the Office Black White and ColorQube GSN library number 10231 Be aware that the file on the faulty software module may be corrupt NOTE If the machine does not behave as expected during this procedure switch off the machine GP 14 then switch on the machine 1 Switch off the machine GP 14 2 Pull out the single board controller PWB module PL 3 24 Item 1 3 If installed remove the...

Page 768: ...n NVM restore GP 5 NOTE The following warning may be displayed The NVM you are trying to restore has been generated from a different version set number Select Yes to continue 6 When the restore is complete close the NVM save and restore tool The UI should now display Ready to scan Switch off then switch on the machine GP 14 NOTE This will load the SCD on to the new software module and upgrade the ...

Page 769: ...PWB NOTE Record the location of the memory module s before removal NOTE Remove the memory module s and the software module by pressing the side catches downwards When reinstalling the memory and software modules press each end of the modules down firmly and the catches will return to their original position 3 Remove the memory module PL 3 24 Item 12 from the single board controller PWB 4 Remove th...

Page 770: ... PWB 6 Remove the riser PWB See NOTE 4 Remove 1 screw then the embedded fax module from the riser PWB 9 Remove 12 screws then the Single Board Controller PWB 3 Slide the fax clip away from the embedded fax module 8 Remove 4 screws 10 Remove 6 screws then the Power Distribution PWB 1 Loosen 1 screw 2 Release the corner of the embedded fax module from the fax clip Memory modules PJ203 7 W TAG 150 On...

Page 771: ... Power distribution PWB harness from PJ152 at the rear of the SIP tray is not routed under the single board controller PWB It must be routed away from the PWB to the right 1 Ensure the first memory module is installed in PJ203 on the single board controller PWB Refer to Figure 2 2 Install the software module REP 3 3 3 Connect the power cord and switch on the machine GP 14 4 Reload the software GP ...

Page 772: ...May 2013 4 34 Xerox WorkCentre 5790 Family REP 3 4 Repairs Adjustments ...

Page 773: ...u begin this repair procedure ensure that the new Main Drive Module is the correct part number for your machine speed and model 1 Pull out fuser module approximately 100mm 4 inches PL 10 8 Item 1 2 Drop down the short paper path assembly PL 10 25 Item 1 3 Remove the xerographic module PL 9 20 Item 2 and place in a black bag 4 Remove the left hand cover PL 8 10 Item 3 5 Disconnect PJ93 and the bias...

Page 774: ...ke care when removing PJ1 on the IOT PWB the pins can be easily damaged 12 Disconnect PJs on the power and control assembly 35 ppm Figure 3 40 55 ppm Fig ure 4 Figure 3 Power and control assembly 1 Remove screw 2 Disconnect PJ24 3 Move Power supply to the rear Disconnect PJ35 Disconnect PJ1 Disconnect PJ25 Disconnect HT lead C and G Disconnect PJ18 Disconnect PJ2 ...

Page 775: ...te toner full sensor REP 9 4 15 Unclip the wiring harness from the retaining clip and move the harness away from the drives module Figure 5 16 Disconnect PJ57 on the waste toner door switch Figure 5 Figure 5 Harness and door switch Disconnect HT lead C and G Disconnect PJ35 and PJ64 Disconnect PJ25 Disconnect PJ18 Disconnect PJ2 Disconnect PJ1 2 Disconnect PJ57 1 Remove harness from the retaining ...

Page 776: ...nnecting PJ1 on the IOT PWB the pins can easily be damaged Perform the following 1 It is important that the short paper path assembly is held in the up position before install ing the main drives module Figure 7 Figure 7 Short paper path assembly 2 If a new main drives module is installed check that the drive speed is correct The 35 ppm modules have black drive gears Figure 8 The 40 55 ppm modules...

Page 777: ...ve motor to engage the drive between the drives plate and the inverter transport before tightening up the seven mounting screws Figure 6 5 Take care when connecting PJ1 on the IOT PWB make sure to align the pins correctly 6 If a new drives module or developer drive gear is installed reset the developer count to zero in the HFSI feature screen Refer to GP 17 High Frequency service Items Lubricate t...

Page 778: ...se death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the rear cover PL 8 10 Item 1 2 Remove the flywheel 3 short screws Figure 1 Figure 1 Remove the flywheel 3 Remove the main drive PWB Figure 2 Figure 2 Main drive PWB Replacement Replacement is the reverse of the removal procedure 1 Remove 3 short screws...

Page 779: ...njury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the main drive module REP 4 1 2 To remove the main drive belt 35 ppm refer to Figure 1 To remove the main drive belt 40 55 ppm refer to Figure 2 Figure 1 Main drive belt 35 ppm Figure 2 Main drive belt 40 55 ppm 3 Remove the drive belt 1 Remove the circlip and intermediate drive gear 2 Slip the ...

Page 780: ...ARNING 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove rear cover PL 8 10 Item 1 CAUTION When the drive gear is removed from the sh...

Page 781: ...stomer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury CAUTION The 35 ppm 45 55 ppm and 65 90 ppm main drive modules are not interchangeable Before this procedure is begun ensure that the new main drive module is the correct part nu...

Page 782: ...per module REP 9 2 7 Pull the developer module out approximately 100mm 4 inches 8 Remove the rear cover PL 8 10 Item 1 9 Remove the waste toner bottle door assembly REP 9 1 10 Remove the ozone filter and duct PL 9 25 Item 2 11 Move the power and control assembly to the rear Figure 2 Figure 2 Power supply Disconnect bias lead Disconnect PJ93 1 Remove the screw 2 Disconnect PJ24 3 Move Power supply ...

Page 783: ... ground wire refer to the 01A Ground Distribution RAP 14 Remove the waste toner full sensor REP 9 4 15 Unclip the wiring harness from the retaining clip and move the harness away from the drives module Figure 4 16 Disconnect PJ57 on the waste toner door switch Figure 4 Figure 4 Harness and door switch Disconnect PJ35 and PJ64 Disconnect PJ1 Disconnect PJ25 Disconnect HT lead C and G Disconnect PJ1...

Page 784: ...ap the harnesses when the main drives module is located onto the dowels Take care when reconnecting PJ1 on the IOT PWB the pins can easily be damaged Perform the following 1 It is important that the short paper path assembly is held in the up position before install ing the main drives module Figure 6 Figure 6 Short paper path assembly 2 Remove 7 silver screws marked A 3 Slide the assembly off the...

Page 785: ...ting PJ1 on the IOT PWB make sure to align the pins correctly 6 If a new drives module or developer drive gear is installed reset the developer count to zero in the HFSI feature screen Refer to GP 17 High Frequency service Items REP 4 6 Main Drive PWB 65 90 ppm Parts List on PL 4 10 Removal WARNING Switch off the electricity to the machine GP 14 Disconnect the power cord from the customer supply w...

Page 786: ...in drive PWB Figure 3 Drives support bracket Replacement Replacement is the reverse of the removal procedure CAUTION The belt tensioners are of the floating type and are spring loaded They should not be locked down 1 Ensure that the drives bracket is located in the tabs on the drives plate Figure 4 Then secure the main drive PWB to the drives plate Remove 4 screws 1 Remove 6 screws 2 Remove the su...

Page 787: ...l 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the main drive module REP 4 5 2 Remove the drives support bracket Figure ...

Page 788: ...e collar Figure 4 Figure 4 Main drive module support bracket 2 Turn the drive gears by hand to position the drive belts correctly on the drive gears and tensioner rolls 3 If a new developer drive gear is installed reset the developer count to zero in the HFSI feature screen Refer to GP 17 High Frequency service Items 1 Remove circlip and intermediate drive gear 2 Remove drive belt 2 Remove the cir...

Page 789: ...ing parts can cause injury 1 Open the DADH top cover 2 Remove the DADH top cover assembly Figure 1 Figure 1 Top cover Replacement CAUTION Be careful when the self tapping screw is installed into a plastic component refer to GP 6 The replacement is the reverse of the removal procedure Make sure the latch pins are installed correctly refer to Figure 1 1 Disengage the hinges 2 Remove the screw and th...

Page 790: ...0 Item 1 3 Remove the DADH top cover assembly REP 5 1 4 Remove the DADH top access cover assembly Figure 1 Figure 1 Top access cover assembly Replacement CAUTION Be careful when the self tapping screw is installed into a plastic component refer to GP 6 The replacement is the reverse of the removal procedure Make sure that the 2 springs on the idler roll are in the correct position Figure 2 Then in...

Page 791: ...cover 2 Remove the DADH rear cover PL 5 10 Item 1 3 Remove the feed roll assembly REP 5 14 4 Remove the feed assembly Figure 1 NOTE 40 90 ppm machines have an in line connector between PJ184 and the document present sensor Disconnect the in line connector before removing the feed assembly Figure 1 Feed assembly Replacement CAUTION Be careful when the self tapping screw is installed into a plastic ...

Page 792: ...emove the feed assembly REP 5 3 NOTE To release the tension of the drive belts refer to ADJ 5 1 3 Remove the input tray assembly Figure 1 Figure 1 Input tray assembly Replacement CAUTION Be careful when the self tapping screw is installed into a plastic component refer to GP 6 1 The replacement is the reverse of the removal procedure 2 Perform the feed motor and the CVT motor belt tension adjustme...

Page 793: ... the baffle assembly Figure 1 Figure 1 Preparation CAUTION When the top access cover assembly feed assembly input tray assembly and CVT roll are removed the DADH structure is weak Do not lower the DADH in this configuration 7 Carefully install the DADH frame on the machine Secure the DADH with the two thumb screws CAUTION Be careful to prevent damage to the document pad when the document pad is re...

Page 794: ...he self tapping screw is installed into a plastic component refer to GP 6 The replacement is the reverse of the removal procedure Make sure that the torsion springs and harness are in the correct position Figure 4 Figure 4 Torsion springs and harness 2 Disengage the hinge pin 4 Remove the baffle assembly Solenoid link arm 1 Feed the harness and ground harness through the frame 3 Slide the tab thro...

Page 795: ...care during this procedure Sharp edges may be present that can cause injury 1 Remove the feed assembly REP 5 3 2 Remove the takeaway roll assembly Figure 1 NOTE To release the tension of the drive belt on the feed motor refer to ADJ 5 1 Figure 1 Takeaway roll assembly Replacement The replacement is the reverse of the removal procedure Make sure the spacers and E clips are installed correctly refer...

Page 796: ...RNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the DADH rear cover PL 5 10 Item 1 2 Prepare to remove the drive assembly Figure 1 Figure 1 Drives assembly NOTE To release the tension on the drive belts refer to ADJ 5 1 3 Remove the drive assembly Figure 2 Figure 2 Drives assembly 2 Remove 3 self tapping screws marked A 4 Release the harnesses 3 Disc...

Page 797: ...akeaway and CVT Sensor Parts List on PL 5 20 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the DADH top cover ass...

Page 798: ...4 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 1 Remove the input tray assembly REP 5 4 CAUTION Disconnect the ground harness from the static eliminator before the input tray assembly lower cover is removed refer to Figure 1 2 Turn the input tray assembly upside down Remove...

Page 799: ...RNING 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 1 Remove the DADH top cover assembly REP 5 1 2 Remove the registration sensor Figure 1 Figure 1 Registration sensor 1 Remove 2 screws 2 Carefully release the torsion spring 3 ...

Page 800: ...g is installed correctly Figure 2 Figure 2 Torsion spring REP 5 11 Exit Sensor Parts List on PL 5 30 Removal 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 1 Raise the DADH CAUTION Be careful to prevent damage to the doc...

Page 801: ... 2 Exit sensor Replacement CAUTION Take care when installing self tapping screw into plastic components refer to GP 6 The replacement is the reverse of the removal procedure 1 Carefully remove the left hand end of the document pad from the baffle assembly 2 Remove 2 screws 3 Disengage the lugs in the lower cover 4 Remove the lower cover 1 Disconnect PJ196 Remove the exit sensor ...

Page 802: ...emove the DADH REP 5 19 2 Put the DADH upside down on a solid flat surface NOTE The counterbalances are different The removal procedure for the two counterbalances is same 3 Remove the relevant counterbalance right PL 5 10 Item 2 4 screws or left PL 5 10 Item 4 4 screws Replacement CAUTION Be careful when the self tapping screw is installed into a plastic component refer to GP 6 1 The replacement ...

Page 803: ...e static eliminator before the input tray assembly lower cover is removed refer to Figure 1 3 Turn the input tray assembly upside down Remove the relevant cover 35 ppm Input tray assembly lower cover PL 5 35 Item 21 40 90 ppm Lower cover right PL 5 35 Item 9 and Lower cover left PL 5 35 Item 20 4 Remove the exit roll assembly Figure 1 Figure 1 Exit roll assembly Replacement CAUTION Take care when ...

Page 804: ...placement is the reverse of the removal procedure When the feed rolls are installed make sure the lowest roll retard roll is positioned as shown in Figure 2 2 If a new feed roll assembly is installed select dC131 chain 5 location 05 001 and reset the copy count to zero 3 If a new feed roll assembly is installed reset the DADH feed count to zero in the HFSI fea ture screen Refer to GP 17 High Frequ...

Page 805: ... Electricity can cause death or injury Moving parts can cause injury 1 Remove the feed assembly REP 5 3 2 Remove the input tray assembly REP 5 4 3 Remove the DADF drive assembly refer to REP 5 7 4 Remove the duplex gate Figure 1 Figure 1 Duplex gate CAUTION When the top access cover assembly feed assembly input tray assembly and CVT roll are removed the DADH structure is weak Do not lower the DADH...

Page 806: ...roll bearing Figure 2 Figure 2 Bearing 7 Release the front CVT roll bearing PL 5 25 Item 4 Remove the CVT roll and CVT motor drive belt Figure 3 Figure 3 CVT roll 1 Compress the two ends of the bearing together 2 Push the bearing to disengage 1 Remove the CVT roll 2 Remove the CVT motor drive belt ...

Page 807: ...isconnect 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 1 Remove the feed assembly REP 5 3 2 Remove the input tray assembly REP 5 4 CAUTION Disconnect the ground harness from the static eliminator before the input tray assembly lower cover is removed refer to Figure 1 3 Turn the input ...

Page 808: ... from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the input tray assembly REP 5 4 CAUTION Disconnect the ground harness from the static eliminator before the input tray assembly lower cover is removed refer to Figure 1 2 Turn the input tray assembly upside down Remove the relevant cover 35 ppm ...

Page 809: ...tch 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 1 Remove the baffle assembly lower cover PL 5 30 Item 1 2 Remove the baffle assembly REP 5 5 3 Prepare to remove the exit roll idlers Figure 1 Figure 1 Preparation 1 Release the link a...

Page 810: ...ing screws into plastic components refer to GP 6 The replacement is the reverse of the removal procedure Make sure that the torsion spring and document finger are installed correctly refer to Figure 3 Figure 3 Torsion spring and document finger 1 Carefully remove the torsion spring and the document finger 2 Lift out the exit roll idlers 3 Remove the 2 bearings Torsion spring Document finger ...

Page 811: ... 1 Disconnect the communication power cable PL 5 10 Item 6 and the DADH ground har ness PL 5 10 Item 11 2 Raise the DADH WARNING Use safe handling procedures when removing the module GP 16 The module is heavy NOTE The DADH weight is 13Kg 29lb 3 Remove the DADH from the machine Figure 1 Figure 1 DADH removal Replacement 1 The replacement is the reverse of the removal procedure 2 If a new DADH is in...

Page 812: ...oving parts can cause injury 1 Raise the DADH 2 Open the baffle assembly PL 5 30 Item 5 3 Remove the old mylar guide strip PL 5 30 Item 14 4 Use cleaning fluid to remove any contamination from the baffle assembly Replacement 1 Remove the 3 backing strips from the pressure sensitive adhesive tape on the mylar guide 2 Adhere the mylar guide to the baffle assembly Figure 1 Figure 1 Mylar guide 1 Bias...

Page 813: ...e during this procedure Sharp edges may be present that can cause injury WARNING Avoid exposure to laser beam Invisible laser radiation Figure 1 Laser Beam Symbol Figure 2 ESD Symbol 1 Remove the scanner REP 14 1 CAUTION Take care not to damage the wiring at the rear of the ROS 2 Figure 3 remove the ROS Figure 3 ROS removal 1 Remove screw 2 Slide the ROS to the rear to align cut out Lift the rear ...

Page 814: ...re that the ROS is the correct one for the machine speed Check that the part number is correct PL 6 10 Item 4 The part number and the machine speed are labelled on the underside of the ROS as shown in Figure 4 2 Figure 4 Ensure that the harness is routed correctly Figure 4 ROS harness routing 3 Go to dC604 Registration Setup check adjust the registration 4 Perform ADJ 9 2 Image Quality Adjustment ...

Page 815: ...y be present that can cause injury CAUTION Do not stack the trays one on top of the other tray The top tray can damage the bottom tray which can cause misfeeds or paper jams 1 Remove tray 1 or tray 2 Figure 1 NOTE The removal procedure for tray 1 and tray 2 is the same Figure 1 Tray 1 and tray 2 removal Replacement The replacement is the reverse of the removal procedure Make sure that the left tra...

Page 816: ...y 4 front covers Figure 1 Figure 1 Tray 3 and tray 4 front covers removal NOTE If tray 4 needs to be removed then remove tray 3 first NOTE If only tray 3 is to be removed then do not remove the left hand stop 4 Remove the stops Figure 2 Figure 2 Rail stops removal 5 Lift and pull to remove the tray complete with the guide rails Replacement The replacement is the reverse of the removal procedure Re...

Page 817: ...tomer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Pull out tray 3 and tray 4 2 Remove the rear cover from the HCF PL 7 25 Item 1 3 Disconnect PJ395 or PJ397 elevator motor harness from the HCF control PWB 4 Disconnect the harn...

Page 818: ... need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury NOTE The elevator drives at the front and at the rear are similar for both trays 1 Remove tray 3 W O TAG 151 or tray 4 W O TAG 151 REP 7 2 2 Release the cables from the appropriate front drive pulley Figure 1 Figure 1 Front e...

Page 819: ...ppropriate rear elevator cable Tray 3 Figure 3 Tray 4 Figure 4 Figure 3 Tray 3 rear cable removal Tray 4 drive shaft Tray 3 drive shaft Tray 4 pulley carriers Tray 3 pulley carriers 2 Remove the cables through the base of the tray 1 Remove the 2 pulley carriers from the appropriate tray 1 Remove the E clip 5 Remove the cable from the drive pulley 4 Remove the drive dog and end cap 6 Pass cable thr...

Page 820: ...eft Hand Door Assembly Parts List on PL 7 30 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove rear cover PL 8 10 Ite...

Page 821: ...REP 7 6 Tray 1 and Tray 2 Paper Guides Parts List on PL 7 10 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury NOTE The remova...

Page 822: ...he 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the required paper feed assembly Tray 3 paper feed assembly W O TAG 151 REP 8 2 Tray 4 paper fe...

Page 823: ...asks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove tray 1 and tray 2 REP 7 1 2 Remove tray 3 W O TAG 151 REP 7 2 3 Perform the following Remove the tray 3 stack limiter and bracket Figure 1 Remove the tray 4 stack limiter and bracket Figure 2 Figure 1...

Page 824: ...that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury The removal procedure is the same for tray 3 and tray 4 1 Pull out tray 3 or tray 4 2 Remove the rear cover PL 7 25 Item 1 3 Remove the tray home switch and holder Figure 1 Figure 1 Switch and holder removal 2 Slid...

Page 825: ... on PL 7 20 Removal 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 Figure 1 ESD Symbol CAUTION Ensure that E S D procedures are observed during the removal and installation of the HCF Control PWB 1 Remove the rear cover ...

Page 826: ...emoval 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove tray 3 W O TAG 151 or tray 4 W O TAG 151 REP 7 2 2 Remove the damper...

Page 827: ...Gears removal Replacement 1 The replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 2 Ensure the gears are correctly aligned Figure 4 Figure 4 Gears installation 1 Remove the screw 2 Lift and remove the damper 1 Pinch the two sections of the shaft together and pull off the gears 1 Align the two gears as shown and then push the gears onto the shaft ...

Page 828: ... cause injury 1 Remove the output device 2 Remove the right hand cover PL 8 10 Item 9 3 Remove tray 1 or tray 2 leaf spring Figure 1 Figure 1 Leaf springs removal 4 Remove the cams for tray 1 or tray 2 Figure 2 NOTE The cams are the same for tray 1 and for tray 2 The small cam is for the tray home position and the larger cams are for the paper size position Figure 2 Cams removal Replacement The re...

Page 829: ...ent that can cause injury 1 Remove the top cover PL 7 60 Item 10 2 Prepare to remove the tray 5 empty sensor Figure 1 Figure 1 Preparation 3 Remove tray 5 empty sensor Figure 2 Figure 2 Tray 5 empty sensor removal Replacement 1 The replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 2 Make sure that the spring on the paper feed assembly is in the correct p...

Page 830: ...fer to Figure 1 REP 7 14 Tray 5 Stack Height Sensor Parts List on PL 8 45 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 ...

Page 831: ... PL 7 68 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the rear cover PL 7 60 Item 9 2 Remove the tray 5 down sen...

Page 832: ...et Figure 2 Figure 2 Encoder sensor removal Replacement 1 To help with the installing of a new elevator motor support the paper tray on two reams of paper 2 Make sure that the encoder sensor is positioned on the elevator motor assembly Figure 2 3 The replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 4 Check that the harness is routed in the channel on th...

Page 833: ...chine 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the rear cover PL 7 60 Item 9 2 Remove the tray 5 upper limit switch Figure 1 Figure 1 Upper limit switch removal Repla...

Page 834: ...oned in the middle of its travel If the tray must be repositioned refer to REP 7 16 Disengage the elevator motor from the tray and move the tray to the required position Re engage the elevator motor to hold the tray 2 Remove the tray lift top cover Figure 1 Figure 1 Paper tray release 3 Remove the tray 5 down limit switch Figure 2 Figure 2 Remove tray 5 down limit switch Replacement 1 The replacem...

Page 835: ...harp edges may be present that can cause injury WARNING Take care not to topple Tray 5 Tray 5 is unstable when undocked from the machine Do not show the customer how to undock Tray 5 1 Remove the paper from the tray 2 Engage the transit lock Figure 1 Figure 1 Transit lock engage 3 Pull the tray 5 module away from the machine until the transit lock engages 4 At the rear of the machine release the d...

Page 836: ...ule docking 3 Release the transit lock and push the tray 5 module into the working position against the machine Figure 4 Figure 4 Transit lock release 4 Perform ADJ 7 3 Machine to Tray 5 Alignment 1 Align the tray 5 module with the docking plate on the machine Push the module to dock and lock the tray 5 module to the machine 2 Lift the latch and move it to the rear to release the lock 3 Close the ...

Page 837: ...e a note of the position of the two screws on the gear assembly for replace ment purposes 3 Raise the paper lift plate Raise the paper tray lift arm to its fullest extent and slide it towards the rear of the tray This releases the pin from the quadrant as shown in Figure 1 Figure 1 Lift gear removal Replacement The existing gears are snap fitted to the shafts and can be removed to allow the new ge...

Page 838: ...inge pins PL 7 60 Item 3 then remove the front door assem bly PL 7 60 Item 1 4 Remove the top cover PL 7 60 Item 10 front cover PL 7 60 Item 8 and rear cover PL 7 60 Item 9 5 Remove the tray 5 elevator motor assembly REP 7 16 6 Remove the frame top brace PL 7 68 Item 3 7 Remove the crash bar PL 7 68 Item 2 8 Disconnect the tray 5 transport motor PL 8 40 Item 2 9 Disconnect the feed motor PL 8 40 I...

Page 839: ...ck has a clearance cut out to accommodate the front door interlock switch Figure 4 Figure 4 Front elevator rack 3 After the front and rear drive gears are re installed ensure that the tray assembly is re installed in the same horizontal plane as the base of the tray 5 module Figure 5 Figure 5 Tray alignment check 1 Raise the tray assembly until the rear tray level drive gear clip and the elevator ...

Page 840: ...he 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the paper from the two trays 2 Remove the right hand cover PL 7 25 Item 7 3 Remove the tray 3 and tray 4 front cov...

Page 841: ... reverse of the removal procedure Refer to GP 6 when refitting the screws to secure tray 3 and tray 4 front covers NOTE When installing tray 3 or tray 4 ensure that the tray rails are located correctly in the base of the HCF Figure 3 Figure 3 Location of the tray rails 3 Remove the screw and the left stop tray 4 1 Remove the screw and the right stop tray 3 2 Remove the screw and the centre stop Tr...

Page 842: ... be present that can cause injury 1 Pull out tray 3 and tray 4 2 Remove the rear cover from the HCF PL 7 25 Item 1 3 Disconnect PJ395 or PJ397 elevator motor harness from the HCF control PWB 4 Disconnect the harness from the low paper sensor on the elevator motor 5 Remove the tray 3 or tray 4 elevator motor Figure 1 Figure 1 Elevator motor removal Replacement The replacement is the reverse of the ...

Page 843: ...emove tray 3 or tray 4 REP 7 2 2 Release the cables from the appropriate front drive pulley Figure 1 Figure 1 Front elevator cables release 3 Remove the appropriate front elevator cables Figure 2 NOTE The short cable is located over the outer pulley and the long cable is located over the inner pulley Figure 2 Front elevator cables removal 4 Release the appropriate paper tray guide refer to ADJ 7 5...

Page 844: ...ley 2 Thread the long cable over the outer groove on the pulley 1 Remove the E clip 4 Remove the cable from the drive pulley through the cable slot 3 Remove the drive dog to expose the cable slot 5 Pass the cable through the base of the tray to remove 2 Remove the screw press the legs and remove the pulley carrier 1 Remove the E clip 3 Remove the cable from the drive pulley through the cable slot ...

Page 845: ...ver the outer groove on the pulley REP 7 25 Tray 3 and Tray 4 Stack Height Sensor W TAG 151 Parts List on PL 8 32 PL 8 33 Removal 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 WARNING Take care during this procedure Sha...

Page 846: ... do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury The removal procedure is the same for tray 3 and tray 4 1 Pull out tray 3 or tray 4 2 Remove the rear cover PL 7 25 Item 1 3 Pull out the relevant tray by approximately 50mm 2 inches 4 Remove the tray home sensor and h...

Page 847: ... cause death or injury Moving parts can cause injury Figure 1 ESD Symbol CAUTION Ensure that E S D procedures are observed during the removal and installation of the HCF Control PWB 1 Remove the rear cover PL 7 25 Item 1 2 Remove the HCF control PWB Figure 2 Figure 2 HCF control PWB removal Replacement 1 Replacement is the reverse of the removal procedure 2 After completing the replacement procedu...

Page 848: ...ving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove tray 3 or tray 4 REP 7 2 2 Remove the damper from tray 3 Figure 1 Figure 1 Tray 3 damper removal 3 Remove the damper from tray 4 Figure 2 Figure 2 Tray 4 damper removal Replacement 1 The replacement is the reverse of the removal procedure Refer to GP 6 before refitting the ...

Page 849: ...rom the tray 5 module refer to REP 7 21 and perform steps 1 to 11 2 Remove the infill plate assembly Figure 1 Figure 1 Infill plate assembly removal 3 Separate the lift plate from the tray lift top cover Figure 2 Figure 2 Tray separation 4 Remove the tray 5 elevator harness Figure 3 Figure 3 Harness removal 5 Remove the elevator tray guides Figure 4 1 Retain the spring using a thumb or finger 2 Re...

Page 850: ... removal procedure refer to REP 7 21 and perform the replacement procedure 1 Remove the screw then remove the rear elevator tray guide 2 Remove the screw then remove the front elevator tray guide 1 Compress the spring into the cavity and retain the spring using a thumb or finger 2 Position the infill plate in the tray assembly 3 Position the fix ing plate over the actuator arm and place the tongue...

Page 851: ...1 or tray 2 feeds count to zero in the HFSI feature screen Refer to GP 17 High Frequency service Items REP 8 2 Tray 3 Paper Feed Assembly W O TAG 151 Parts List on PL 8 30 Removal 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 ...

Page 852: ...ion of the spacer 3 Make sure that the feed assembly locates in the stack limiter bracket Figure 3 Figure 3 Locate the paper feeder assembly 4 Install the paper feed assembly and push the tray in slowly NOTE Check that the tray does not touch the feed assembly 5 Connect the ribbon cable and the PJs Figure 1 6 If a new feed roll assembly is installed reset the tray 3 feed count to zero in the HFSI ...

Page 853: ...arts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Pull out tray 4 2 Remove the rear cover PL 7 25 Item 1 3 Remove the mounting bracket Figure 1 Figure 1 Mounting bracket removal 4 Remove the paper feed assembly Figure 2 NOTE Note the position of the blue flash on the ribbon cable when connected into PJ391 Figure 2 Tray 4 feed assembly ...

Page 854: ...o zero in the HFSI feature screen Refer to GP 17 High Frequency service Items REP 8 4 Registration Transport Parts List on PL 8 15 Removal 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 WARNING Take care during this proc...

Page 855: ... Figure 1 Figure 1 Preparation 8 Remove the registration transport Figure 2 Figure 2 Transport removal 1 Disconnect the harness 3 Disconnect the bias lead 2 Remove 2 screws and the retainer bracket Temperature Humidity PWB Ground wire 1 Move the frame to the front and lift to unlock the transport from the base 2 Remove the registration transport through the front of the machine ...

Page 856: ...acement is the reverse of the removal procedure Refer to GP 6 before refitting the screw to the retaining bracket CAUTION Ensure that the transport foot is correctly located into the base 2 Locate the transport foot into the base Figure 4 Figure 4 Transport foot location 1 Release the clip 2 Lift the cover and slide off the shaft Shaft Transport foot Location hole in the base ...

Page 857: ...stalled reset the Bias Foam count to zero in the HFSI feature screen Refer to GP 17 High Frequency service Items REP 8 5 Registration Clutch Parts List on 35 55 ppm PL 8 15 65 90 ppm PL 8 17 Removal 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 Movi...

Page 858: ...rt assembly Fig ure 3 2 The clutch harness is correctly routed and secure Figure 1 3 Turn the jam clearance knob 4c to rotate the drive shaft Ensure that the drive plate on the clutch rotates without binding on the clutch body Figure 3 4 After completing the replacement procedure perform the dC604 Registration Setup Figure 3 Clutch location 1 Remove E clip on the gear 2 Remove the E clip 3 Remove ...

Page 859: ...Parts List on 35 55 ppm PL 8 22 65 90 ppm PL 8 20 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury WARNING Take care during t...

Page 860: ...r cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury WARNING Take care during this procedure Motors will become hot during normal operation 1 Remove the duplex transport REP 8 7 NOTE The duct on the duplex transp...

Page 861: ... the back of the solenoid 2 Remove the bypass feed solenoid Figure 1 Figure 1 Solenoid removal Replacement Replacement is the reverse of the removal procedure REP 8 10 Tray 3 and Tray 4 Transport Motor W O TAG 151 Parts List on PL 8 30 Removal 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 electrici...

Page 862: ...1 Parts List on PL 8 30 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the rear cover PL 7 25 Item 1 2 Remove the ...

Page 863: ...n be damaged during removal replacement Care must be taken when removing replacing the drive gear onto the take away drive shaft 1 Install the transport drive belt Figure 2 Figure 2 Drive belt installation 1 Remove 2 screws 2 Remove the bracket with the drive gear and the drive belt Transport drive belt 1 Position the belt over the tray 3 transport drive coupling pulley 2 Slide the belt onto the d...

Page 864: ...ricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove rear cover PL 8 10 Item 1 2 Remove waste toner bottle PL 9 10 Item 1 3 Remove the tray 1 and tray 2 transport drive belt Figure 1 Figure 1 Drive belt removal Replacement 1 Reverse the removal procedure to replace the transport ...

Page 865: ...CAUTION Take care when removing tray 3 support bracket from its snap in mounting 1 Remove tray 3 and tray 4 front covers Figure 1 Figure 1 Front covers removal CAUTION Take care to avoid damage to the tray 3 feed sensor flag at the rear of the tray PL 7 15 Item 9 2 Remove tray 3 transport assembly Figure 2 Figure 2 Transport assembly removal Replacement Replacement is the reverse of the removal pr...

Page 866: ...he actuator spring it can be easily deformed or broken REP 8 15 Registration Sensor 65 90 ppm Parts List on PL 8 17 Removal 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 WARNING Take care during this procedure Sharp edg...

Page 867: ...gistration sensor and support bracket Figure 2 Figure 2 Sensor and bracket removal 5 Remove the sensor from the support bracket Figure 3 Figure 3 Sensor removal 1 Loosen two screws 2 Remove the sensor and support bracket 1 Disconnect the harness 2 Remove the sensor from the support bracket ...

Page 868: ... bracket on the machine frame and tightened the screws Figure 4 Figure 4 Support bracket position 3 Ensure that the mylar guide is located correctly Figure 5 Figure 5 Mylar guide position 4 After completing the replacement procedure perform the dC604 Registration Setup 1 Locate the tab on the bracket in the hole in the frame 2 Tighten two screws 1 Position the mylar guide above the machine frame ...

Page 869: ...the drive shaft and bearings Figure 1 NOTE The drive pulleys have a built in one way clutch Before the drive pulley is removed mark the pulley to indicate its installed position The drive shaft rotates when the pulley is turned in a counter clockwise direction The removal procedure is the same for the tray 1 and tray 2 transport rolls Remove the front bearing when the shaft has been removed Figure...

Page 870: ... while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the left hand door REP 7 5 2 Prepare to remove the door cover Figure 1 Figure 1 Preparation 3 Remove the door cover Figure 2 Figure 2 Door cover removal 1 Remove 3 screws 1 Remove t...

Page 871: ...nsor Figure 3 Wait sensor location 5 Remove the wait sensor Figure 4 Figure 4 Wait sensor removal Replacement 1 Replacement is the reverse of the removal procedure 2 Ensure that the cover is located correctly on the left hand door assembly Figure 5 1 Wait sensor 1 Disconnect the harness 2 Un clip and remove the sensor ...

Page 872: ...r supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the rear cover PL 8 10 Item 1 2 Remove the waste toner bottle and door REP 9 1 3 Remove tray 1 and tray 2 4 Prepare to remove the transport roll drives motor Figure 1 Figure...

Page 873: ...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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove left hand cover PL 8 10 Item 3 CAUTION Take care not to lose the small spring on the back of the solenoid 2 Open left hand door and...

Page 874: ...ver from the feed head Figure 2 Figure 2 Feed head cover removal 4 Release the ribbon cable from the feed head Figure 3 Figure 3 Ribbon cable release 1 Use a small screw driver to release the cover 1 Disconnect the PJ from the tray empty sensor 2 Release the ribbon cable from the retainers ...

Page 875: ...head is replaced ensure that the bypass tray empty sensor actuator is positioned in the slot in the lift plate Refer to Figure 5 4 Manually rotate the drive gear until the tab on the drive gear is engaged with the armature on the bypass tray feed solenoid Figure 5 Component alignment 1 Press the tabs and lift the feed head Repeat the action at the rear 2 Remove the feed head Position of the flat o...

Page 876: ...cedure Sharp edges may be present that can cause injury 1 Remove the bypass tray feed head REP 8 19 2 Remove the bypass tray drive gear Figure 1 Figure 1 Drive gear removal Replacement 1 Replacement is the reverse of the removal procedure 2 Before replacement of the feed head ensure that feed roll pressure plate cam and drive gear are correctly aligned Figure 2 Figure 2 Component alignment 1 Lift ...

Page 877: ...ve the bypass tray feed roll Figure 1 Figure 1 Remove the feed roll Replacement 1 Replacement is the reverse of the removal procedure 2 Ensure that the bearings at both ends of the shaft are correctly located 3 Check the feed head to ensure that the feed roll pressure plate cam and drive gear are correctly aligned Figure 2 Figure 2 Component alignment 4 If a new feed roll is installed reset the By...

Page 878: ... this procedure Sharp edges may be present that can cause injury 1 Remove the bypass tray feed head REP 8 19 2 Prepare to remove the retard pad Figure 1 Figure 1 Preparation 3 Remove the retard pad Figure 2 Figure 2 Remove the retard pad Replacement 1 Replacement is the reverse of the removal procedure 2 If a new retard pad is installed reset the Bypass feeds count to zero in the HFSI feature scre...

Page 879: ...pty sensor Figure 1 Figure 1 Tray empty sensor Replacement Replacement is the reverse of the removal procedure REP 8 24 Tray 1 or Tray 2 Feed Sensor Parts List on PL 7 30 Removal 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 i...

Page 880: ...cover from the left hand door assembly Figure 2 Figure 2 Remove the cover 4 Figure 3 shows the location of tray 1 and tray 2 feed sensors Figure 3 Feed sensor locations 1 Remove the cover from the left hand door assembly Tray 2 feed sensor Tray 1 feed sensor Wait sensor harness 65 90 ppm ...

Page 881: ...r to GP 6 before refitting the screws 2 65 90 ppm Only Before refitting the left hand door cover ensure that the wait sensor harness is correctly located Refer to Figure 3 3 Ensure that the cover is located correctly on the left hand door assembly Figure 5 Figure 5 Cover location 1 Disconnect the harness 2 Remove 1 screw then the sensor 1 The lug on the cover must locate in the door aperture 2 Doo...

Page 882: ...p edges may be present that can cause injury 1 Remove the top cover PL 7 60 Item 10 2 Prepare to remove the tray 5 feed sensor Figure 1 Figure 1 Preparation 3 Remove tray 5 feed sensor Figure 2 Figure 2 Feed sensor removal Replacement 1 The replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 2 Make sure that the spring on the paper feed assembly is in the ...

Page 883: ...26 Registration Drive Roll Assembly Parts List on PL 8 15 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the regis...

Page 884: ...3 Preparation 6 Remove the registration drive roll assembly Figure 4 Figure 4 Drive roll removal Replacement 1 Replacement is the reverse of the removal procedure 2 Ensure that the ground strap is located between the frame and the bearing Figure 5 Figure 5 Ground strap location 1 Remove 2 screws 2 Remove the bias guide 1 Remove the E clip and bearing 2 Remove the E clip spring washer and bearing 1...

Page 885: ...ure 1 Drive belt removal Replacement Replacement is the reverse of the removal procedure REP 8 28 Tray 3 Feed Sensor W O TAG 151 Parts List on PL 8 30 Removal 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 WARNING Take c...

Page 886: ...d from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove tray 3 transport assembly REP 8 13 2 Remove the jam clearance door Figure 1 Figure 1 Door removal 1 Lift the jam clearance door 2 Push the tab to release t...

Page 887: ... the transport roll assembly Figure 2 Figure 2 Preparation 4 Remove the takeaway roll assembly Figure 3 Figure 3 Takeaway shaft removal 1 Remove the E clip 2 Remove the drive gear and belt 2 Remove the E clip 1 Remove the E clip 3 Press the tabs and push the bearing out 4 Remove the takeaway shaft ...

Page 888: ...ssembly W O TAG 151 Parts List on PL 8 35 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove tray 3 transport assembly...

Page 889: ...ing Figure 1 Figure 1 Door and coupling removal 3 Prepare to remove the transport roll assembly Figure 2 Figure 2 Preparation 1 Remove the drive coupling 3 Push the tab to release the door hinge then remove the door 2 Lift the jam clearance door 1 Remove the E clip 2 Remove the coupling 3 Remove the belt and drive pulley ...

Page 890: ...eed electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove tray 3 and tray 4 transport motor REP 8 10 2 Remove Tray 3 and tray 4 transport drive gear REP 8 11 3 Remove the left cover PL 7 25 Item 2 4 Remove paper tray 2 REP 7 1 5 35 55 ppm Only Remove the ground plate Figure 1...

Page 891: ...removal 8 Remove tray 3 and tray 4 transport roll Figure 3 Figure 3 Remove the transport roll 1 Remove the springs 2 Remove the idler rolls shaft and bearings 1 Press the rolls and slide the shaft to the rear until it is released from the front bearing 2 Slide the shaft to the front until it is released from the rear bearing then remove ...

Page 892: ...witch 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury WARNING Take care during this procedure Motors will become hot during normal operation 1 Remo...

Page 893: ...n the HFSI fea ture screen Refer to GP 17 High Frequency service Items 3 65 90 ppm Check that the tension spring is located correctly on the upper transport guide Install the duct on the duplex transport Check that the sensor wires pass through the cut out in the duct and are not caught under the duct Figure 3 Figure 3 Duplex transport duct 2 Remove the screw to release the bracket then remove the...

Page 894: ...edges may be present that can cause injury 1 Remove the rear cover PL 7 60 Item 9 2 Prepare to remove the drive belt Figure 1 Figure 1 Preparation 3 Remove the transport drive belt Figure 2 Figure 2 Drive belt removal Replacement 1 Replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 2 Allow the tension idler to tension the belt and then tighten the screw F...

Page 895: ... machine and remove the retard roll Figure 1 Figure 1 Feed rolls removal Replacement NOTE The feed retard and nudger rolls W O TAG P 002 are no longer available as spare parts If new rolls are required the only option is to install the feed roll retrofit kit W TAG P 002 PL 8 45 Item 22 1 The replacement is the reverse of the removal procedure 2 Ensure that the tabs on the feed roll are located in ...

Page 896: ...d nudger rolls are the same diameter but the retard roll has a larger diameter Figure 1 Feed rolls removal Replacement 1 The replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 2 Make sure that the tabs on the feed roll are located in the drive shaft 3 Check that the tray empty sensor is located in the cover and that the cover is located cor rectly and sec...

Page 897: ... the reverse of the removal procedure Refer to GP 6 before refitting the screws REP 8 37 Tray 5 Transport motor Parts List on PL 8 40 Removal 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 WARNING Take care during this p...

Page 898: ... on PL 8 45 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the rear cover PL 7 60 Item 9 2 Remove the top cover PL...

Page 899: ...oller removal Replacement 1 The replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 2 Check that the cable routing is correct Figure 1 1 Lift the upper feed assembly 2 Remove the lower feed assembly 3 Remove the E clip and bearing 2 Remove the one way pulley clutch 1 Remove the E clip 4 Remove the E clip and bearing 1 Move the take away roller to the rear ...

Page 900: ...that can cause injury 1 Remove the retard roll REP 8 35 2 Remove the clutch coupling PL 8 26 Item 13 3 Remove the friction clutch PL 8 26 Item 2 Replacement 1 The replacement is the reverse of the removal procedure REP 8 40 Tray 3 Paper Feed Assembly W TAG 151 Parts List on PL 8 32 Removal WARNING Switch off the electricity to the machine GP 14 Disconnect the power cord from the customer supply wh...

Page 901: ...placement 1 Ensure the support bracket is present on the tray 3 paper feed assembly Figure 2 Figure 2 Support bracket 2 Install the paper feed assembly Figure 3 1 Disconnect PJ1 PJ4 PJ10 and the connector on the tray 3 home sensor 3 Carefully slide out the paper feed assembly ensuring that harnesses are not damaged 2 Remove 2 screws Support bracket ...

Page 902: ...efer to GP 17 High Frequency Service Items REP 8 41 Tray 4 Paper Feed Assembly W TAG 151 Parts List on PL 8 33 Removal 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 WARNING Take care during this procedure Sharp edges ma...

Page 903: ... paper guide REP 8 55 4 Install the tray 4 paper guide REP 8 56 5 Install the paper feed assembly Figure 3 Figure 3 Feed assembly installation 6 Push tray 4 in slowly and check that the tray does not foul the paper feed assembly 7 Connect the four PJs refer to Figure 1 8 The remainder of the replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 9 If a new pa...

Page 904: ...electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove HCF rear cover PL 7 25 Item 1 2 Remove the HCF transport motor Figure 1 Figure 1 Transport motor removal Replacement 1 Replacement is the reverse of the removal procedure Ensure the at the ground wire is installed between ...

Page 905: ...s may be present that can cause injury 1 Remove the rear cover PL 7 25 Item 1 2 Remove the HCF transport motor W TAG 151 REP 8 42 3 Remove the tray 3 transport gear pulley Figure 1 Figure 1 Transport gear removal Replacement 1 Install the tray 3 and tray 4 transport gear pulley Figure 2 Figure 2 Drive belt installation 2 The remainder of the replacement is the reverse of the removal procedure 1 Re...

Page 906: ...rocedure Refer to GP 6 before refitting the screws REP 8 45 Tray 3 Exit Sensor W TAG 151 Parts List on PL 8 32 Removal 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 WARNING Take care during this procedure Sharp edges ma...

Page 907: ...ury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove tray 3 transport assembly REP 8 44 2 Remove the jam clearance door Figure 1 Figure 1 jam clearance door removal 3 Remove the takeaway roll assembly Figure 2 Figure 2 Takeaway roll removal 1 Lift the jam clearance door 2 Push the tab to release the door hinge 3 Remove the door 3 Remove the drive co...

Page 908: ...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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the left cover PL 7 25 Item 2 2 Remove tray 3 and tray 4 REP 7 22 3 Remove the HCF transport motor W TAG 151 REP 8 42 4 Remove the idler shaft ass...

Page 909: ...e the tray 3 and tray 4 transport roll Figure 3 Figure 3 Transport roll removal 1 Remove the KL clip and front bearing 3 Remove the KL clip 2 Remove the gear 1 Remove the KL clip 4 Slide the bearing out of the frame 5 Slide the transport roll to the rear to release the roll from the front of the frame 6 Slide the transport roll to the front and remove Transport roll ...

Page 910: ...igh Frequency service Items REP 8 48 Tray 3 Stack Height Sensor W TAG 151 Parts List on PL 8 32 Removal 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 WARNING Take care during this procedure Sharp edges may be present th...

Page 911: ...city can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the tray 3 paper feed assembly REP 8 40 2 Release the sensor mounting Figure 1 Figure 1 Sensor mounting release 3 Remove tray 3 empty sensor Figure 2 Figure 2 Sensor removal Replacement Replacement is the reverse of the removal procedure 1 P...

Page 912: ...y can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the tray 3 paper feed assembly REP 8 40 2 Release the sensor mounting Figure 1 Figure 1 Sensor mounting release 3 Remove the tray 3 feed sensor Figure 2 Figure 2 Sensor removal Replacement Replacement is the reverse of the removal procedure 1 P...

Page 913: ...Replacement Replacement is the reverse of the removal procedure Install a new sensor shim to lock the sensor in place REP 8 52 Tray 4 Empty Sensor W TAG 151 Parts List on PL 8 33 Removal 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...

Page 914: ... 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the tray 4 paper feed assembly REP 8 41 2 Release the sensor mounting Figure 1 Figure 1 Sensor mounting release ...

Page 915: ... the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the relevant paper feed assembly Tray 3 paper feed assembly REP 8 40 Tray 4 paper feed assembly REP 8 41 NOTE This procedure illustrates a tray 3 feed assembly t...

Page 916: ...feed motor with the bracket Figure 1 Figure 1 Motor and bracket removal 4 Release the rear fixings Figure 2 Figure 2 Rear fixings 2 Remove 3 screws 3 Remove the motor and bracket 1 Remove screw 4 Disconnect he harness 4 Remove the screw 1 Remove the KL clip 2 Remove the gear 3 Remove 2 bearings ...

Page 917: ...ase the front fixings Figure 3 Figure 3 Front fixings 6 Separate the upper and lower frames Figure 4 Figure 4 Frame separation 1 Remove 2 screws 1 Use a small flat bladed screwdriver to separate the frames 3 Remove the lower frame 2 Ensure the plastic legs disengage from the holes ...

Page 918: ...r removal 8 Remove the nudger roll and feed roll assembly Figure 6 Figure 6 Nudger and feed roll removal 1 Press the fixing to release the cover 1 Remove the KL clip and slide the bearing out of the frame 2 Remove the KL clip and slide the bearing out of the frame 3 Lift the roll assembly out of the frame slots and remove ...

Page 919: ...rd roll components Figure 8 Exploded view of the retard assembly 3 Check that the number of weights on the new nudger roll and feed roll assembly is the same as on the old assembly if necessary correct the number of weights refer to ADJ 8 4 1 Remove the KL clip 2 Use a small screwdriver to push the shaft through the roller but leave the shaft engaged in the pulley and frame 3 Separate the retard r...

Page 920: ...Figure 10 Frame assembly 7 Align and secure the frame halves Figure 11 1 Position the roll assembly above the slots in the frame and align the dog clutch teeth 2 Ensure the tang of the feed roll assembly is positioned under the lift arm then lower the feed roll assembly into position 3 Push the bearing into position and secure with the KL clip 4 Push the bearing into position and secure with the K...

Page 921: ...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 1 Remove the tray 3 paper feed assembly REP 8 40 2 Ensure the 3 protrusions are in the slots 3 Tighten the screw 1 Ensure the plastic legs are through the holes 6 Ensure the 2 protrusions are in the slots 7 Tighten the taptite sc...

Page 922: ... screw 3 Slide the guide to the rear to release the two short pins from the front frame 4 Release the central fixing from the keyhole slot in the frame 5 Pivot the guide so it is clear of the frame at the front and remove 2 Loosen the screw by about 3 turns to allow the frame to spring open Short pin Short pin 1 Locate the two long pins in the frame rear 2 Align the guide so that the central fixin...

Page 923: ...eed electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the tray 4 paper feed assembly REP 8 41 2 Remove the tray 4 paper guide Figure 1 Figure 1 Paper guide removal 1 Remove the screw 3 Slide the guide to the rear to release the two short pins 4 Release the central fixing from the frame 5 Pivot the guide so it is clear of the frame at the front and remove 2 Lo...

Page 924: ...y 1 Remove tray 3 and tray 4 REP 7 22 2 Remove the tray 3 transport gear pulley W TAG 151 REP 8 43 3 Remove the tray 3 transport clutch drive assembly Figure 1 Figure 1 Clutch drive removal Replacement Replacement is the reverse of the removal procedure NOTE The E clip is very small use a small magnetised screwdriver to position the E clip whilst pressing the clutch drive against the spring to exp...

Page 925: ...ing parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the rear cover PL 8 10 Item 1 2 Remove the waste toner bottle and the waste toner door Figure 1 Figure 1 Waste toner door Replacement Replacement is the reverse of the removal procedure 1 Open the waste toner door 2 Screw the cap onto the bottle 4 Press the ends of the strap...

Page 926: ...ocedure 2 When installing a new developer module perform the following NOTE When replacing the original developer perform step C only a Follow the developer spares pack instruction sheet to prepare the developer module b 65 90 ppm only Perform ADJ 9 3 Developer Magnetic Seal Brush Adjustment c Lubricate the developer module support pins ADJ 4 1 d 35 55 ppm only Ensure that the washer and stepped w...

Page 927: ...se injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove rear cover PL 8 10 Item 1 2 Remove the waste toner bottle REP 9 1 3 Remove ozone filter and duct PL 9 25 Item 2 CAUTION When the drive gear is removed the drive pin may fall onto the IOT PWB or LVPS 4 Remove the ozone fan Figure 1 Figure 1 Remove the ozone fan Machine frame Washer Stepped wa...

Page 928: ... Toner Full Sensor Parts List on PL 9 10 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the rear cover PL...

Page 929: ... tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the developer assembly REP 9 2 2 Remove the toner cartridge 3 Disconnect the harness PJ97 and PJ75 on the toner dispense module Figure 1 Figure 1 Disconnect the harness 4 Remove the securing screws ...

Page 930: ... dispenser sump Once the toner in the sump reaches the level of the low toner sensor the toner bottle will stop turning The toner must then be manually run from the toner sump into the developer module To run the toner into the Developer Module a Remove the top left cover to access the left side of the Developer Module and moni tor the toner concentration sensor voltage output at PJ93 pin 8 red wi...

Page 931: ...ath or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the scanner REP 14 1 2 Remove the developer assembly REP 9 2 3 Refer to REP 6 1 and move the ROS to the side Figure 1 Figure 1 Position the ROS 4 Remove the pivot plate to release the developer paddle Figure 2 NOTE Observe where the spring is located on the ...

Page 932: ...0 Item 8 to the internal diameter of the bush on the frame i e the hole the pin fits into prior to insertion 3 Refer to Figure 4 Check the following a The latch pin is correctly lined up with the flats on the latch plate b The latch handle and the latch pin are correctly lined up c When reinstalling the developer paddle into the pivot plate check that the spring is correctly located on the tie bar...

Page 933: ... removal procedure REP 9 8 Transfer Detack Harness Parts List on 35 ppm PL 9 22 40 90 ppm PL 9 20 Removal 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 WARNING Take care during this procedure Sharp edges may be...

Page 934: ...that can cause injury 1 Remove the fuser module PL 10 10 Item 1 2 Remove the xerographic module PL 9 20 Item 2 3 Remove the erase lamp support Figure 1 Figure 1 Erase lamp support 4 Remove the erase lamp Figure 2 Figure 2 Remove the erase lamp Replacement 1 Replacement is the reverse of the removal procedure 2 Check that the location posts on the erase lamp Figure 2 locate in the holes in the fram...

Page 935: ...e present that can cause injury 1 Cam off the developer module 2 Remove the xerographic module PL 9 20 Item 2 3 Remove the waste toner from the auger system at the front of the machine Figure 1 Figure 1 Auger system at the front 4 Remove the waste toner bottle assembly REP 9 1 5 Remove the waste toner from the shutter auger tube at the rear of the machine Figure 2 Figure 2 Shutter and waste toner ...

Page 936: ...nts 8 Remove the shutter assembly and the support bracket Figure 3 Figure 3 Remove shutter assembly 9 Remove the auger damper Figure 4 Figure 4 Remove the auger damper 1 Remove 4 screws 2 Disconnect PJ97 3 Remove the shutter assembly and bracket Pull out the auger damper ...

Page 937: ... spring Figure 5 Installing the insert 3 Ensure that the shutter assembly is positioned correctly on the support bracket 4 Support the auger tube when locating the shutter assembly and bracket onto the auger tube Figure 6 Figure 6 Shutter and bracket position 1 Push and twist the auger damper until it stops at the end of the auger tube 1 Support the auger tube 2 Ensure that the shutter is position...

Page 938: ...May 2013 4 200 Xerox WorkCentre 5790 Family REP 9 10 Repairs Adjustments ...

Page 939: ...moval procedure depicts the W O TAG 114 short paper path assembly However this procedure is also common to the W TAG 114 short paper path assembly 1 Remove the fuser assembly 35 55 ppm PL 10 8 Item 1 65 90 ppm PL 10 10 Item 1 2 Remove the duplex transport REP 8 7 3 Remove the xerographic module and place in a black bag 35 ppm PL 9 22 Item 2 40 90 ppm PL 9 20 Item 2 4 Remove the transfer detack cor...

Page 940: ...re the transport hinge is located correctly First install the left hand screw with the ground lead then the right hand screw 2 Check that the detack wire with the plastic sleeve is routed correctly on the transport hinge Figure 3 Figure 3 Spiral wrap location 3 Position the ground wire terminal in the left hand screw location on the hinge bracket and position the HT leads Figure 4 4 When locating ...

Page 941: ...ine 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury WARNING Take care during this procedure Motors will become hot during normal operation 1 Remove the fuser assembly 35 55 ...

Page 942: ... machines W TAG 120 the thermistor connection PJ76 is not used Refer to Figure 3 Figure 3 Tie bar 1 Remove the screw 2 Rotate the inverter decurler retaining ring to align both cutouts then remove 3 Remove the adjuster 1 Remove 4 screws marked A 3 Disconnect the harness on inverter motor driver PWB 2 Disconnect harness at PJ49 and PJ76 4 Remove the tie bar ...

Page 943: ...rough the right hand side of the machine Figure 5 Figure 5 Remove inverter assembly 2 Lift the frame out of the base 3 Move the inverter assembly 1 Remove the support bracket 1 screw W TAG 046 W TAG 047 and W TAG 148 machines only 4 Rotate the inverter and then slide the assembly clear of the machine 1 Ensure the idler shafts at the rear are clear before turning the inverter 2 Remove the inverter ...

Page 944: ...een the inverter frame and the base Figure 3 2 The solenoid harness connector is located at the rear of the inverter frame Figure 6 Figure 6 Solenoid harness connector 3 The nip roll guide is correctly located in the cut out at the front and rear of the inverter frame Figure 7 Figure 7 Nip roll guide 4 Make sure that the baffle guide PL 10 13 Item 3 and upper baffle PL 10 12 Item 14 are linked cor...

Page 945: ... W TAG 046 W TAG 047 or W TAG 148 Perform ADJ 10 1 Inverter Decurler Adjust ment REP 10 3 Inverter Motor Parts List on PL 10 11 Removal 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 WARNING Take care during thi...

Page 946: ...nector is located at the rear of the inverter frame as in Figure 1 3 Make sure that the link arm is connected to the solenoid armature Manually operate the solenoid armature and check that the inverter gate operates correctly REP 10 5 Inverter Nip Solenoid Parts List on PL 10 11 Removal WARNING Switch off the electricity to the machine Refer to GP 14 Disconnect the power cord from the customer sup...

Page 947: ...are during this procedure Sharp edges may be present that can cause injury 1 Remove the output device and the right hand cover PL 8 10 Item 9 2 Remove the rear cover PL 8 10 Item 1 3 Remove the tie bar Figure 1 Figure 1 Remove tie bar 4 Remove the nip roll guide Figure 2 Figure 2 Nip roll guide 5 Remove the following components from the nip roll guide as required IOT exit sensor Single exit nip ro...

Page 948: ...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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the inverter assembly REP 10 2 2 Remove the upper baffle assembly 35 55 ppm Complete the procedure in Figure 1 65 90 ppm Remove ...

Page 949: ... 10 8 Nip Split Shaft Assembly Parts List on PL 10 11 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the ...

Page 950: ...erse of the removal procedure Refer to GP 6 before refitting the screws 2 Check that both springs are positioned correctly Figure 3 Figure 3 Location of the spring 3 If a nip slit shaft assembly is installed reset the nip split shaft count to zero in the HFSI feature screen Refer to GP 17 High Frequency service Items 1 Release both springs 2 Remove nip split shaft assembly Spring position ...

Page 951: ...ry Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the inverter assembly REP 10 2 2 Remove the inverter nip solenoid REP 10 5 3 Remove the shaft actuator Figure 1 Figure 1 Shaft actuator Replacement 1 Replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 2 Check that both springs...

Page 952: ... during this procedure Sharp edges may be present that can cause injury 1 Remove the DADH REP 5 19 2 Remove the scanner REP 14 1 3 Refer to REP 6 1 and move the ROS to the side Figure 1 Figure 1 Move the ROS WARNING Take care when removing the latch The latch contains a compressed spring which can cause injury when released 4 Hold the fuser latch pin in position with a screw driver and remove the ...

Page 953: ...omer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the inverter path solenoid REP 10 4 2 Remove the jam clearance lever 3a Figure 1 NOTE To remove the inverter gate remove two nuts Figure 2 and flex the bracket If the rep...

Page 954: ... assembly Figure 2 Figure 2 Inverter assembly bracket 4 Remove the inverter path solenoid link Figure 3 NOTE When the link arm has been removed a new link arm must be installed PL 10 11 Item 1 Figure 3 Inverter path solenoid link 1 Remove 2 nuts 2 Use a screwdriver to unlatch the clip on the inverter assembly bracket from the tie bar Inverter assembly bracket 1 Use a screwdriver to remove the link...

Page 955: ...l 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the inverter gate REP 10 11 2 Remove the tri roll jam clearance ...

Page 956: ...0 13 Figure 2 Preparation 4 Remove the securing screw and tri roll drive gear Figure 3 Figure 3 Tri roll drive gear 1 Remove the E clip and bearing 3 Remove the E clip 4 Remove the bearing from the tri roll shaft 6 Remove the E clip and bearing on post fuser exit roll 5 Remove 2 screws 2 Remove screw 1 Remove the screw 2 Raise the tang to remove the tri roll gear 3 Remove the bearing behind the ge...

Page 957: ...Replacement Refer to GP 6 before refitting the screws 1 Re install the following components a Tri roll shaft Figure 5 b Tri roll guide The guide locates on the tri roll shaft in front of the bearing Locate the post on the tri roll guide into the location holes in the front and rear frame Figure 6 2 To remove the tri roll guide lift and twist the guide 1 Pull the side plate to release the tri roll ...

Page 958: ...ost Fuser count to zero in the HFSI feature screen Refer to GP 17 High Frequency service Items REP 10 13 Fuser Web Motor Assembly Parts List on 35 55 ppm PL 4 17 65 90 ppm PL 4 12 Removal 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...

Page 959: ...65 90 ppm 3 Remove the fuser connector assembly from the fuser web motor assembly Figure 3 Figure 3 Fuser web motor assembly Replacement The replacement is the reverse of the removal procedure 1 Remove 3 screws 2 Remove the fuser web assembly 1 Remove 2 screws 2 Remove the fuser connector assembly ...

Page 960: ... can cause injury 1 Remove the inverter assembly REP 10 2 2 Remove the exit shaft assembly 35 55 ppm Figure 1 65 90 ppm Figure 2 Figure 1 Exit shaft assembly 35 55 ppm Figure 2 Exit shaft assembly 65 90 ppm Replacement 1 Replacement is the reverse of the removal procedure 2 Ensure that the bearings locate into the baffle guide and that the baffle guide is linked with the upper baffle Both baffles ...

Page 961: ...d electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the short paper path assembly REP 10 1 2 Release the transfer detack corotron harness from the supports Figure 1 Figure 1 Transfer detack corotron harness 3 Remove the securing screw to release the drives assembly Figure...

Page 962: ...the vacuum fan Figure 3 Figure 3 Remove vacuum fan 5 Remove the intermediate drive assembly Figure 4 Figure 4 Remove the drive assembly 1 Remove 2 screws 2 Remove the vacuum fan 1 Lift the drive gear assembly 2 Move the drive gear assembly to release the catch and remove the assembly ...

Page 963: ...0 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury WARNING Do not touch the fuser while it is hot 1 Remove the fuser...

Page 964: ...per paper guide assembly Figure 2 Figure 2 Upper guide removal 4 Release the harness and remove the fuser exit switch Figure 3 Figure 3 Fuser exit switch removal 2 Remove 2 screws 1 Disconnect the harness 3 Remove the upper guide 1 Remove the screw 2 Release the harness 3 Remove the switch ...

Page 965: ...s are damaged install a new fuser module REP 10 17 IOT Exit Sensor Parts List on PL 10 11 Removal 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 WARNING Take care during this procedure Sharp edges may be present...

Page 966: ...elease the nip roll guide Figure 2 Figure 2 Release the nip roll guide 5 Remove the IOT exit sensor Figure 3 Figure 3 Remove the IOT sensor 1 Remove two screws 2 Lift the guide to release the nip roll guide 1 Disconnect the harness 2 Press the lugs down to release the IOT sensor ...

Page 967: ...ly Parts List on PL 10 11 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the inverter assembly REP 10 2 2...

Page 968: ...of the removal procedure Refer to GP 6 before refitting the screws CAUTION Check that the inverter path solenoid harness is not caught between the nip roll guide and the support bracket Figure 3 Figure 3 Inverter path solenoid harness 2 Remove two screws 1 Remove two screws 3 Flex the side plates to release the output guide Nip roll guide Support bracket Inverter path solenoid harness ...

Page 969: ...jury 1 Remove the inverter assembly REP 10 2 2 Remove the tri roll nip split solenoid Figure 1 Figure 1 Remove the solenoid Replacement 1 The replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 2 Before the inverter is installed manually operate the solenoid and check that the nip rolls operate correctly 3 Check that the wires to the solenoid are free to m...

Page 970: ...cedure Sharp edges may be present that can cause injury 1 Remove the inverter assembly REP 10 2 2 Remove the inverter sensor Figure 1 Figure 1 Remove the inverter sensor Replacement 1 The replacement is the reverse of the removal procedure Refer to GP 6 before refitting the screws 2 Route the harness under the tab on the upper baffle Figure 1 3 Make sure that the upper baffle and the inverter asse...

Page 971: ...or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the covers Figure 1 NOTE Removing the top cover first will allow easy removal of the front and rear covers Figure 1 Removing the covers Replacement Reverse the removal procedure to replace the covers 1 Open the exit cover remove two screws 5 Remove two screws 3 ...

Page 972: ...this procedure Sharp edges may be present that can cause injury 1 Remove the 2K LCSS rear cover REP 11 1 110 2 Remove the motor and drive belt Figure 1 Figure 1 Removing the drive belt Replacement 1 Place the belt around the pulleys 2 Install the motor screws but do not tighten 3 Install the spring 4 Rotate the shaft by hand to ensure the belt runs smoothly over the pulleys and allow the spring to...

Page 973: ...e during this procedure Sharp edges may be present that can cause injury 1 Remove the 2K LCSS rear cover REP 11 1 110 2 Remove the intermediate paper drive belt Figure 1 Figure 1 Removing the drive belt Replacement 1 Lubricate the belt tensioner refer to ADJ 4 1 2 Install the belt over the pulleys ensuring that the belt is on all five pulleys NOTE Two of the pulleys are free to slide along the sha...

Page 974: ...he 2K LCSS rear cover REP 11 1 110 2 Remove the intermediate drive belt REP 11 3 110 3 Remove the output drive belt and motor Figure 1 Figure 1 Removing the drive belt Replacement 1 Install the belt over the pulleys 2 Install the motor pivot shouldered screw and fully tighten 3 Install the two motor mounting bracket securing screws but do not tighten them 4 Install the belt tensioner spring 5 Rota...

Page 975: ...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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the 2K LCSS front and rear covers REP 11 1 110 2 Remove the bin 1 drive belt rear Figure 1 ...

Page 976: ...and upper pulley 2 Remove E clip and bearing 6 Remove 3 screws and release the lower and middle PWB standoffs leaving the PWB attached by only the top standoff 12 Remove 2 screws lower pulley and drive belt 1 Disconnect PJ318 3 Remove 3 screws remove bracket with motor 4 Fully lower bin 1 11 Remove screw and remove the belt clamp 5 Release the tensioner spring 10 Disconnect PJ316 and release the b...

Page 977: ...procedure to replace the bin 1 drive belts NOTE The bin 1 level can critically affect the overall stack registration Refer to ADJ 11 1 110 if adjustment is necessary 2 Install the front and rear covers REP 11 1 110 1 If not already lowered fully lower bin 1 refer to figure 1 2 Release the tensioner spring 3 Remove two screws and lower pulley 5 Remove 2 screws upper pulley and drive belt 4 Remove s...

Page 978: ...Remove the tamper assembly Figure 2 Figure 2 Removing the tamper assembly Replacement Reverse the removal procedure to replace the tamper assembly NOTE Ensure that The slots in the tamper assembly locate correctly in the 2K LCSS frame The sensors are correctly located in the tamper assembly they are easily mis located when being re connected to the harnesses All connectors in the harness over the ...

Page 979: ... 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the 2K LCSS covers REP 11 1 110 2 Remove and empty the chad bin PL 11 6 Item 4 3 Remove the hole punch unit motor assembly and ...

Page 980: ...sses and remove the bracket assembly Press the tabs together to remove the punch head home and punch head present sensors 3 Disconnect the motor harness and remove the hole punch motor assembly 2 Remove 2 screws 6 Remove screw and slide out the bracket 5 Disconnect the PJ 7 Remove 2 screws remove sensors and disconnect the harnesses 1 Remove the thumb screw and slide out the punch unit ...

Page 981: ...ricity 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury WARNING Take care not to topple the 2K LCSS The 2K LCSS is unstable when un docked from the machine Do ...

Page 982: ...Reverse the removal procedure to replace the stapling unit REP 11 9 110 Staple Head Unit Parts List on PL 11 20 Removal 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 WARNING Take care during this procedure Shar...

Page 983: ...eed electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury WARNING Take care not to topple the 2K LCSS The 2K LCSS is unstable when un docked from the machine Do not show the customer how to un dock the 2K LCSS 1 Disconnect the two harnesses between the 2K LCSS and the machine 2 Un doc...

Page 984: ...n installing the ejector assembly onto the 2K LCSS ensure that the ejector fingers do not damage the wiring to the staple head unit Reverse the removal procedure to replace the eject assembly or sensors 2 Remove 3 screws 1 Disconnect 2 bulkhead connectors 3 Lower the ejector assembly disengage the dowels from the mounting blocks and remove Ejector home sensor Q11 320 Ejector out sensor Q11 322 Eje...

Page 985: ...ty can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the ejector assembly REP 11 10 110 2 Remove the stacker level sensors Figure 1 Figure 1 Removing the stacker level sensors Replacement Reverse the removal procedures to replace the bin 1 level sensors 2 Disconnect 2 connectors 1 Remove two scr...

Page 986: ...o not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the stapler traverse assembly REP 11 8 110 2 Remove the tamper assembly REP 11 6 110 3 Remove bin 1 PL 11 2 Item 10 4 Remove the paddle motor assembly Figure 1 Figure 1 Paddle motor assembly 2 Release the harnes...

Page 987: ...ure 3 Figure 3 Front preparation 7 Ensure that the compiler ejector is in the home position fully to the left 1 Remove the E clip and flag 2 Remove the gear assembly 3 Remove the E clip and bearing 4 Remove 3 screws 1 Remove the E clip 2 Release the spring and remove the switch actuator 5 Remove 2 screws 4 Remove the screw and remove the switch bracket 3 Disconnect the harness ...

Page 988: ...5 Install the gear assembly ensuring that it locates onto the large D flat Figure 2 6 Install the flag and E clip ensuring that the flag locates on the small D flat Figure 2 7 Ensure the paddles and flag are correctly aligned Figure 5 Install the motor assembly Figure 1 Figure 5 Paddle alignment 8 Test the operation of the paddle roll enter dC330 output code 11 025 When the code is cancelled the p...

Page 989: ... Sharp edges may be present that can cause injury WARNING Take care not to topple the 2K LCSS The 2K LCSS is unstable when un docked from the machine Do not show the customer how to un dock the 2K LCSS 1 If necessary disconnect the harnesses between the 2K LCSS and the machine 2 Open the 2K LCSS front door 3 Release the 2K LCSS link bracket assembly Figure 1 Figure 1 2K LCSS link bracket assembly ...

Page 990: ...the 2K LCSS rear cover assembly perform 11F 110 2K LCSS PWB DIP Switch Settings RAP Reverse the removal procedure to replace the 2K LCSS PWB REP 11 15 110 Entry Guide Cover Parts List on PL 11 24 Removal 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 ...

Page 991: ...aper guide must be a minimum of 1mm Refer to Figure 2 NOTE If the clearance is less than 1mm then install a new entry guide cover Figure 2 Entry guide cover clearance 3 Run copies through the output device if possible use heavy weight paper or labels Check for marks on the print and for damage to the paper If there are no marks or dam age then install the covers 1 Remove 2 screws 2 Remove 2 screws...

Page 992: ...LCSS is unstable when un docked from the machine Do not show the customer how to un dock the 2K LCSS 1 Remove the front and rear covers REP 11 1 110 2 Un dock the 2K LCSS REP 11 13 110 3 Prepare to remove the docking latch assembly Figure 1 Figure 1 Prepare to remove the latch 4 Remove the docking latch assembly Figure 2 Figure 2 Latch assembly removal Replacement Reverse the removal procedure to ...

Page 993: ...Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the ejector assembly refer to REP 11 10 110 2 Remove the ejector belt Figure 1 Figure 1 Remove the ejector belt Replacement 1 The replacement is the reverse of the removal procedure 2 Ensure that the ejector belt is correctly engaged with the belt grip on the ejector asse...

Page 994: ...May 2013 4 256 Xerox WorkCentre 5790 Family REP 11 17 110 Repairs Adjustments ...

Page 995: ...se death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the covers Figure 1 NOTE Removing the top cover first will allow easy removal of the front and rear covers Figure 1 Removing the covers Replacement Reverse the removal procedure to replace the covers 1 Open the exit cover Remove two screws then the top ...

Page 996: ...emove the 1K LCSS rear cover REP 11 1 120 2 Remove transport motor 1 and the input drive belt Figure 1 Figure 1 Removing the drive belt Replacement 1 Place the belt around the pulleys NOTE Ensure that the shoulder screw is installed in the correct position Refer to Figure 1 2 Install the motor screws but do not tighten 3 Install the spring 4 Rotate the shaft by hand to ensure the belt runs smoothl...

Page 997: ...an cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the 1K LCSS REP 11 11 120 2 Remove the stability foot Figure 1 Figure 1 Removal Replacement Align the slots in the stability foot with the locating pins under the machine Firmly push the sta bility foot into position 1 Push down the rear locking t...

Page 998: ... that can cause injury 1 Remove the 1K LCSS top cover and rear cover REP 11 1 120 2 Remove the intermediate drive belt PL 11 118 Item 4 3 Remove the paper output drive belt Figure 1 Figure 1 Removing the paper output drive belt 4 Remove transport motor 2 Figure 2 Figure 2 Removing transport motor 2 Replacement 1 The replacement is the reverse of the removal procedure 2 Manually rotate the paper ou...

Page 999: ...esent that can cause injury 1 Enter dC330 code 11 032 bin 1 elevator motor down Fully lower bin 1 2 Open the 1K LCSS front door PL 11 100 Item 4 3 Switch off the machine 4 Remove the 1K LCSS rear cover and front cover REP 11 1 120 NOTE Keep all of the components removed as a set The set of rear frame components are different from the front frame set 5 Prepare to remove the rear bin 1 drive belt Fi...

Page 1000: ...e removal procedure to replace the bin 1 drive belts NOTE Bin 1 level can critically affect the overall stack registration Refer to ADJ 11 1 120 if adjustment is necessary 2 Remove 3 screws marked A Release 1 standoff 3 Disconnect PJ 1 Remove 2 screws then the lower pulley Standoff 5 Remove 1 screw from the belt clamp Remove the belt 4 Remove 2 screws then the upper pulley 1 Release the tensioner ...

Page 1001: ...remove the tamper assembly Figure 2 Removing the tamper assembly Replacement Reverse the removal procedure to replace the tamper assembly NOTE Ensure that The slots in the tamper assembly locate correctly in the 1K LCSS frame The sensors are correctly located in the tamper assembly they are easily mis located when being disconnected and re connected to the harnesses All connectors in the harness o...

Page 1002: ...e care during this procedure Sharp edges may be present that can cause injury 1 Remove the 1K LCSS covers REP 11 1 120 2 Manually move the ejector PL 11 114 Item 1 fully to the right out position 3 Prepare to remove the staple head unit and mounting bracket Figure 1 Figure 1 Preparation CAUTION When removing and replacing the stapler assembly support the weight of the assembly under neath the stap...

Page 1003: ...n PL 11 114 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 If necessary manually move the ejector to the right o...

Page 1004: ... installing the ejector assembly onto the 1K LCSS ensure that the ejector fingers do not damage the wiring to the staple head unit Reverse the removal procedure to replace the eject assembly or sensors 2 Remove 3 screws 1 Disconnect 2 bulkhead connectors 3 Lower the ejector assembly disengage the dowels from the mounting blocks and remove Ejector home sensor Q11 320 Ejector out sensor Q11 322 Ejec...

Page 1005: ... REP 11 8 120 2 Remove the bin 1 upper level sensor Figure 1 Figure 1 Removing the stacker level sensors Replacement Reverse the removal procedures to replace the bin 1 upper level sensor REP 11 10 120 Paddle Wheel Shaft Assembly Parts List on PL 11 104 Removal WARNING Switch off the electricity to the machine Refer to GP 14 Disconnect the power cord from the customer supply while performing tasks...

Page 1006: ... the paddle motor assembly Figure 1 Figure 1 Paddle motor assembly 3 Prepare the rear components Figure 2 Figure 2 Rear preparation 2 Disconnect PJ 3 Remove 2 screws 4 Remove motor assembly 1 Disconnect PJ14 1 Remove E clip and flag 2 Remove E clip and bearing 3 Remove 3 screws marked A ...

Page 1007: ...ents Figure 3 Figure 3 Front preparation 5 Ensure that the compiler ejector is fully to the left home position 6 Remove the paddle wheel shaft assembly Figure 4 Figure 4 Paddle wheel shaft removal 1 Remove E clip and bearing 2 Remove 3 screws marked A 1 Remove the output cover 2 Remove the shaft assembly ...

Page 1008: ...emoval Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury WARNING Use safe handling procedures when removing the modul...

Page 1009: ...e that the bottom bracket on the 1K LCSS is located over the support pins Line up the 1K LCSS latches to the machine apertures then push the two units firmly together until they latch 1 Remove 2 thumb screws from under neath the 1K LCSS 2 Pull the latch block forward to release both latches 1 Slide the 1K LCSS away from the machine to disengage the latches and bottom bracket 2 Use the lifting hand...

Page 1010: ...from the 1K LCSS PWB 3 Remove the three screws and release the three standoffs securing the 1K LCSS PWB Replacement 1 Reverse the removal procedure to replace the 1K LCSS PWB 2 Before replacing the 1K LCSS rear cover perform the 11F 120 1K LCSS PWB DIP Switch Settings RAP REP 11 13 120 Entry Guide Cover Parts List on PL 11 122 Removal WARNING Switch off the electricity to the machine Refer to GP 1...

Page 1011: ...the paper guide must be a minimum of 1mm Refer to Figure 2 NOTE If the clearance is less than 1mm install a new entry guide cover Figure 2 Entry guide cover clearance 3 Run copies through the output device if possible use heavy weight paper or labels Check for marks on the print and for damage to the paper If there are no marks or dam age then install the covers 2 Remove 2 screws 3 Remove 2 screws...

Page 1012: ... present that can cause injury 1 Remove the 1K LCSS REP 11 11 120 2 Prepare to remove the docking latch assembly Figure 1 Figure 1 Preparation 3 Remove the docking latch assembly Figure 2 Figure 2 Latch assembly removal 4 Remove the sensor cover PL 11 102 Item 1 5 Release the docking interlock switch from the sensor cover Replacement Reverse the removal procedure to replace the docking latch assem...

Page 1013: ...ury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the ejector assembly refer to REP 11 8 120 2 Remove the ejector belt Figure 1 Figure 1 Remove the ejector belt Replacement 1 The replacement is the reverse of the removal procedure 2 Ensure the ejector belt is correctly engaged with the belt grip on the ejector assemb...

Page 1014: ...May 2013 4 276 Xerox WorkCentre 5790 Family REP 11 15 120 Repairs Adjustments ...

Page 1015: ...icity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury NOTE All major HVF covers are dealt with in this procedure only remove the covers listed for the procedure that you are performing Remove the HVF covers as follows 1 Remove the front door Figure 1 If required remove 5 screws to separate the door sup...

Page 1016: ...op cover removal 3 Remove the front cover Figure 3 NOTE The top cover must be removed before removing the front cover Figure 3 Front cover removal 1 Remove the inserter cover or inserter see NOTE 2 Remove 2 screws 3 Lift the top tray 4 Remove 2 screws 5 Remove the top cover 1 Remove 6 screws 2 Lift the cover to disengage the bottom locating tabs form the frame 3 Remove the front cover ...

Page 1017: ...he foot cover in not installed if a tri folder is installed Figure 5 Vent and foot covers removal Replacement 1 Reverse the removal procedure to reinstall the HVF covers 2 Depending on the installed options and the covers removed refit covers in the following sequence a Vent cover b Foot cover if a tri folder is not installed c Rear cover d Front cover e Top cover f Inserter cover if a inserter so...

Page 1018: ...he IOT 2 Remove the HVF front door REP 11 1 171 3 Remove the HVF top cover REP 11 1 171 4 Remove the HVF front cover REP 11 1 171 5 Remove the rear cover REP 11 1 171 6 Figure 1 At the rear of the HVF disconnect three connectors and remove one screw securing the grounding strap Figure 1 Disconnect PJs and remove screw 7 Figure 2 With the power cord disconnected it is possible to reach behind the s...

Page 1019: ...r assembly Replacement NOTE The ejector unit returns to the home position when the HVF is initialized 1 Slide the stapler assembly into the tray taking care not to trap the earth wire at the rear 2 At the HVF rear pull the back stop to the rear and hold it there while turning the back stop latch clockwise Release the back stop which should slide forward until stopped by the latch 3 Reconnect all P...

Page 1020: ...171 2 Remove the top and rear covers REP 11 1 171 3 Disconnect the links from the tray Figure 1 Figure 1 Link disconnection 4 Remove the bias spring and pin Figure 1 5 Remove the shaft front and rear circlips and bushes Lift the top tray from the shaft Figure 2 NOTE Remove the idler pulley to avoid straining the drive belt when removing the shaft drive pulley Figure 2 Shaft drive and support bushe...

Page 1021: ...ply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the E clip and lift bin 1 to release bin 1 from the lift bar Figure 1 Figure 1 Bin 1 removal Replacement Reverse the removal procedures to reinstall bin 1 1 Remove the E clip 2 L...

Page 1022: ...ity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 With the machine powered use the PTU or control code 11 032 to lower Bin 1 2 Remove bin 1 REP 11 4 171 then remove the right side cover Figure 1 3 Remove 6 screws then remove the right side cover Figure 1 Figure 1 Right side cover Replac...

Page 1023: ...can cause injury 1 Remove bin 1 REP 11 4 171 2 Remove the right side cover REP 11 5 171 3 Remove the front door top cover front cover and rear cover REP 11 1 171 4 Remove the front and rear pressing plate fingers REP 11 7 171 5 Remove the front tamper motor assembly REP 11 11 171 6 Remove the front tamper arm PL 11 153 Item 5 7 Remove the ejector front cover Figure 1 Figure 1 Ejector front cover 8...

Page 1024: ... Prepare to remove the ejector module Figure 4 Figure 4 Disconnect the harness 2 Flex the ejector cover from the shaft of the support finger drive gear 1 Remove 2 screws 3 Remove the pressing plate bracket 2 Disconnect the ejector assembly harness 4 connectors 1 Note the routing of the ejector assembly harness REAR VIEW ...

Page 1025: ...stall the ejector assembly 3 When reinstalling the front tamper and the ejector front cover make sure that the correct screws are used and that the screws are not overtightened GP 6 4 When refitting the pressing plate the shaft of the front support finger drive gear must fit into the ejector assembly cover refer to Figure 3 2 Remove the ejector assembly 1 Remove 2 screws and the earth wire 1 Route...

Page 1026: ...sing plate fingers Replacement Reverse the removal procedures to replace the front and rear pressing plate fingers REP 11 8 171 Front and Rear Support Fingers Parts List on PL 11 140 Removal 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 Mov...

Page 1027: ...ont or rear support fingers NOTE Set the front and rear support fingers so that their ends are aligned when extended Refer to Figure 4 2 With the pressing plate installed set the front and rear support finger alignment Figure 4 If the fingers are not aligned the compiler output will be uneven and cause exit jams 1 Remove the screw and clip 2 Rotate the finger to dis engage the pin from the guide s...

Page 1028: ...NG Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the right side cover REP 11 5 171 2 Remove the offset motor and gear assembly Figure 1 Figure 1 Offset motor and gears Replacement Reverse the removal procedures to reinstall the offset motor assembly 1 Remove the rear pressing plate finger 3 Rotate the encoder wheel until the finger ends align 2 Remove th...

Page 1029: ...ts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Lift the top tray 2 Refer to Figure 1 Raise the paper pusher and remove the four stacker idler rolls Figure 1 Paper pusher and idler rolls Replacement 1 Refer to Figure 2 Ensure the sprung brackets are parallel and re install the idler rolls in the sprung brackets Figure 2 Correct spring ...

Page 1030: ...t do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the front door and front cover REP 11 1 171 2 Remove the front tamper motor assembly Figure 1 Figure 1 Front tamper motor assembly 5 Remove the front tamper motor assembly 4 Remove 3 screws 3 Disconnect the m...

Page 1031: ... 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the front and rear covers REP 11 1 171 2 Remove the rear drive belt lower pulley to ...

Page 1032: ...ricity 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury CAUTION Do not show the customer how to un dock the HVF or HVF BM 1 Open the front door 2 Release the d...

Page 1033: ... or HVF BM REP 11 14 171 HVF Top Jam Clearance Guide Assembly Parts List on PL 11 145 Removal 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 WARNING Take care during this procedure Sharp edges may be present tha...

Page 1034: ... the inboard pivot screw Figure 2 Figure 2 Inboard pivot screw 4 Remove the jam clearance assembly Figure 3 Figure 3 Assembly removal Replacement The replacement procedure is the reverse of the removal procedure Remove the inboard pivot screw REAR VIEW Twist the assembly and lift upwards ...

Page 1035: ...amper assembly Figure 1 Figure 1 Rear tamper assembly NOTE To ease the removal of the rear tamper assembly remove the cable clamps that secure the pressing and support encoder sensor harness to the rear tamper assembly Also turn the offset motor gear to move the offset carriage to the rear Replacement CAUTION Check that the Ejector cable harnesses are routed below rear tamper assembly and do not o...

Page 1036: ...o not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the HVF BM front door and fully pull out the BM module 2 Remove the BM flapper bracket assembly Figure 1 Figure 1 Remove the BM flapper bracket 2 Disengage the drive belt 4 Remove the BM flapper bracket assembly 3...

Page 1037: ...G 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the top cover then the rear cover REP 11 1 171 1 Remove the KL clip and ...

Page 1038: ...M PWB 2 The booklet maker PWB is supplied with a label with the customized NVM values for the new BM PWB Enter the values into the machine dC131 NVM Read Write at Finisher DFA Location 12 Check and perform the adjustments that follow ADJ 11 5 171 Booklet Tamping ADJ 11 6 171 Booklet Compiling Position ADJ 11 7 171 Booklet Crease Position ADJ 11 8 171 Booklet Staple Position 1 Disconnect all PJs 3 ...

Page 1039: ...tomer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the HVF BM front door and fully pull out the BM module 2 Remove the crease blade knob 6d PL 11 161 Item 4 3 Remove the crease roll handle 6c PL 11 161 Item 5 4 Remove the ...

Page 1040: ...tor assembly 1 Remove 4 screws 2 Remove the E clip and bearing release the con necting rod 3 Remove the circlip rear crank and bearing 4 Remove E clip and bearing release the connecting rod 5 Removecirclip front crank and bearing 7 Remove the motor assembly from the frame 6 Disconnect the motor harness ...

Page 1041: ...emoval 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the top cover then the rear cover REP 11 1 171 2 Remove 4 s...

Page 1042: ...re PL 11 163 Item 1 Motor damper PL 11 163 Item 3 BM backstop motor PL 11 163 Item 4 BM backstop drive belt PL 11 163 Item 11 Removal 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 WARNING Take care during this ...

Page 1043: ...ing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the booklet maker REP 11 61 171 2 Rotate the crease roll handle 6c fully counter clockwise 3 Remove the crease roll handle 6c PL 11 161 Item 5 4 Remove the crease blade knob 6d PL 11 161 Item 4 5...

Page 1044: ... Figure 2 Figure 2 Belt clamp 8 Use the allen key PL 11 163 Item 9 to remove the 2 screws and remove shaft support PL 11 164 Item 10 9 Prepare to remove the shaft from the frame Figure 3 Figure 3 Preparation 10 Move the backstop assembly to the bottom of the BM assembly Lay down the BM assembly to access the backstop assembly 1 Use a flat blade screwdriver to push out the harness clamp 2 Use a fla...

Page 1045: ...e anti play shoe 3 Ensure that all of the cable ties are installed and that the harnesses are in the correct position 4 Check that all of the PJ connections on the BM PWB are connected 5 Return the allen key to the storage position inside the drive belt tensioner spring PL 11 163 Item 9 6 Go to ADJ 11 9 171 and complete the adjustments 1 Remove the shaft through the bottom of the BM assembly BM ba...

Page 1046: ...can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the HVF BM front door and fully pull out the BM module 2 Remove the crease blade knob 6d PL 11 161 Item 4 3 Remove the crease roll handle 6c PL 11 161 Item 5 4 Remove the BM front cover PL 11 161 Item 3 5 Remove the BM Entry Roll Figure 1 Figure 1 ...

Page 1047: ... while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the HVF BM front door and fully pull out the BM module 2 Remove the crease blade knob 6d PL 11 161 Item 4 3 Remove the crease roll handle 6c PL 11 161 Item 5 4 Remove the BM front cov...

Page 1048: ...ily REP 11 23 171 Repairs Adjustments Figure 1 Sensor removal Replacement Reverse the removal procedure to replace the BM entry sensor 1 Remove 2 screws 3 Disconnect the sensor harness 4 Remove the baffle 2 Remove 2 screws 5 Remove the sensor ...

Page 1049: ...REP 11 25 171 BM Compiler Motor and BM Flapper Motor Parts List on PL 11 166 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cau...

Page 1050: ...eed electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the HVF BM front door and fully pull out the BM module 2 Remove the crease blade knob 6d PL 11 161 Item 4 3 Remove the crease roll handle 6c PL 11 161 Item 5 4 Remove the BM front cover PL 11 161 Item 3 5 Remove the LH f...

Page 1051: ...stop link removal 12 Figure 3 remove the BM backstop idler bracket assembly Figure 3 Idler bracket assembly removal 1 Press down on the link and release the front tensioner link 2 Press down on the link and release the rear tensioner link 3 Remove the link and two springs 1 Remove 2 screws 2 Remove the bracket assembly and belt ...

Page 1052: ...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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Fully pull out the BM module 2 Remove the relevant staple head cover PL 11 168 Item 14 3 Pull the stapler bracket handle PL 11 168 Item 9 Open the st...

Page 1053: ...eplace the BM staple heads 2 Perform ADJ 11 3 171 Stapler Anvil Alignment 1 Remove 2 screws using a 5 5mm socket and ratchet driver 2 Loosen 1 screw using a 5 5mm socket and ratchet driver 3 Using a 5 5mm socket and short extension fully loosen the screw until the staple head is released Leave the socket and extension in position on the screw 4 Disconnect the stapler harness and remove the stapler...

Page 1054: ...ct 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the top cover then the rear cover REP 11 1 171 2 Remove 4 screws securing the BM PWB mounting plate to the frame allow the PWB and mounting...

Page 1055: ...0 Family REP 11 28 171 Repairs Adjustments 10 Figure 2 lower the stapler bracket Figure 2 Lowering stapler bracket 1 Release the rear follower from the slot using a screwdriver 2 Pull the stapler bracket handle to open the staplers fully ...

Page 1056: ... latch shaft Figure 3 Latch shaft removal 1 Remove KL clip and pull shaft forward 50mm 2 inches 3 Compress the spring remove the rear follower and spring 2 Remove 2 E clips and the front follower 4 Push the shaft to the rear to release the latch slide 5 Pull the shaft completely to the rear to remove ...

Page 1057: ...Repairs Adjustments 12 Figure 4 prepare to remove the BM stapler bracket assembly Figure 4 Preparation 1 Remove KL clip 4 Release the spring from the side frame 3 Remove 2 E clips 6 Disconnect harnesses and ground wire 5 Remove E clip 2 Disconnect ground wire ...

Page 1058: ...icity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury NOTE The removal procedure illustrates how to remove the rear conveyor belt The proce dure for the front conveyor belt is similar 1 Remove bin 2 by disconnecting the harness removing the thumb screw then lifting the bin upwards to release 2 Remove t...

Page 1059: ... 6 Figure 2 remove the BM conveyor belt Figure 2 Belt removal Replacement Reverse the removal procedure to replace the BM conveyor belts 1 Remove E clip 2 Push out shaft and remove one bearing 3 Push the other bearing though the frame to remove the idler roller 1 Release belt from the drive pulley 2 Feed the belt through the cut out to remove ...

Page 1060: ...ING 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the HVF BM front door and fully pull out the BM module 2 Remove the crea...

Page 1061: ...ide at the same time Both tamper racks must engage with the BM tamper gear simultaneously To check that the front and rear tampers are correctly aligned perform the following Fully push in the tampers The distance between the end stop on each tamper and the ends of the BM tamper rack guide should be equal Refer to Figure 2 If the distances are different by more than 1mm 0 040 inches Perform again ...

Page 1062: ...t that can cause injury 1 Remove the HVF front door REP 11 1 171 2 Remove the HVF top cover REP 11 1 171 3 Remove the HVF front cover REP 11 1 171 4 Remove the HVF rear cover REP 11 1 171 5 Figure 1 At the rear of the finisher disconnect the two PJs Figure 1 Disconnecting PJs 6 Figure 2 Remove the pivot screw Figure 2 Pivot screw removal 7 Pass the PJs through the cut out in the rear frame 8 Withd...

Page 1063: ...ition the spigot at the guide rear in the hole in the rear frame The rest of the replacement procedure is the reverse of the removal procedure REP 11 33 171 Buffer Pocket Jam Clearance Guide Assembly Parts List on PL 11 153 Removal 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 ...

Page 1064: ...ower cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the HVF front door top cover and front cover REP 11 1 171 2 Figure 1 Remove the pivot screw from the front end of the inserter jam clearance guide ...

Page 1065: ...can cause injury 1 Remove the HVF front door top cover front cover and rear cover REP 11 1 171 2 Figure 1 At the rear of the HVF remove the solenoid arm the K L clip and the bush from the diverter shaft Figure 1 Removal preparation 3 Figure 2 Remove the diverter exit gate Figure 2 Diverter removal Replacement The replacement procedure is the reverse of the removal procedure CAUTION After replaceme...

Page 1066: ... cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the HVF BM front door and fully pull out the BM module 2 Remove the crease blade knob 6d PL 11 161 Item 4 3 Remove the crease roll handle 6c PL 11 161 It...

Page 1067: ...rt Figure 2 Front support removal 7 Figure 3 remove the rear blade support Figure 3 Rear support removal 1 Remove E clip 2 Release the front connecting rod and bearing 3 Remove E clip 4 Remove front blade support 1 Remove E clip 3 Remove E clip 2 Release the rear connecting rod and bearing 4 Remove rear blade support ...

Page 1068: ...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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the front and rear covers REP 11 1 171 2 Remove the stacker motor and gear assembly REP 11 12 171 3 Remove the shaft rear bearing Figure 1 Fig...

Page 1069: ...ct 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury NOTE The removal and replacement procedure for the front and rear stacker driving belts is the same Support the Bin 1 lift bar if removing the front...

Page 1070: ...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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the HVF front door top cover front cover and rear cover REP 11 1 171 2 Remove the rea...

Page 1071: ...hine 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the HVF front door top cover front cover and rear cover REP 11 1 171 2 Figure 1 Remove the black plastic cover ...

Page 1072: ... Figure 3 At the rear of the HVF remove the input roll Figure 3 Input roll removal Replacement The replacement procedure is the reverse of the removal procedure Remove the circlip and bush 1 Remove the circlip 2 Slide the pulley and the bush along the shaft 3 Lift the shaft and remove the belt from the pulley 4 Remove the pulley and the bush 5 Remove the input roll REAR VIEW ...

Page 1073: ... edges may be present that can cause injury 1 Remove the HVF front door top cover front cover and rear cover REP 11 1 171 2 Open guide 8a 3 Figure 1 At the front of the HVF remove the circlip and the bush Figure 1 Circlip and bush removal 4 Figure 2 At the rear of the HVF remove the inserter guide roll Figure 2 Inserter guide roll removal Replacement The replacement procedure is the reverse of the...

Page 1074: ...HVF front door top cover front cover and rear cover REP 11 1 171 2 Remove the punch unit or the punch unit guide as appropriate 3 Figure 1 At the front of the HVF remove the circlip and bush Figure 1 Circlip and bush removal 4 At the rear of the HVF remove the buffer pocket roll The bracket can be moved if neces sary to improve access two screws Figure 2 Figure 2 Buffer pocket roll removal Replace...

Page 1075: ... Sharp edges may be present that can cause injury 1 Remove the HVF front door top cover front cover and rear cover REP 11 1 171 2 Figure 1 Remove the circlip and bush at the outboard end of the roll Figure 1 Circlip and bush removal 3 Figure 2 At the rear of the HVF remove the booklet entrance roll Figure 2 Booklet entrance roll removal Replacement The replacement procedure is the reverse of the r...

Page 1076: ...y be present that can cause injury 1 Remove the HVF front door top cover front cover and rear cover REP 11 1 171 2 Open jam clearance guide 5b 3 Figure 1 Remove the circlip and the bush from the outboard end of the roll Figure 1 Circlip and bush removal 4 Figure 2 At the rear of the HVF remove the buffer lower roll Figure 2 Buffer lower roll removal Replacement The replacement procedure is the rev...

Page 1077: ...e injury 1 Remove the HVF front door top cover front cover and rear cover REP 11 1 171 2 Figure 1 Remove the circlip and the bush Figure 1 Circlip and bush removal 3 Figure 2 Remove the buffer upper roll Figure 2 Buffer upper roll removal Replacement The replacement procedure is the reverse of the removal procedure 1 Remove the circlip and the bush 2 Remove the screw 3 Loosen screw Fixed guide 1 R...

Page 1078: ...rts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the HVF front door top cover front cover and rear cover REP 11 1 171 2 Figure 1 Remove the circlip and bush Figure 1 Circlip and bush removal 3 Figure 2 Remove the stacker exit feed roll Figure 2 Stacker exit feed roll removal Replacement The replacement procedure is the reverse o...

Page 1079: ... injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 If fitted undock the inserter REP 11 82 171 2 Remove the HVF front door top cover front cover and rear cover REP 11 1 171 3 Figure 1 Raise the top tray and lower the plate beneath it Figure 1 Lowering the plate 4 Figure 2 Remove the circlip and bush Remove the front magn...

Page 1080: ...ar component removal 6 Figure 4 Remove the top exit feed roll Figure 4 Top exit feed roll removal Replacement The replacement procedure is the reverse of the removal procedure 1 Remove the circlip 2 Slide the pulley and the bush along the shaft 3 Slip the belt off of the pulley 4 Remove the pulley and the bush 5 Remove 2 screws REAR VIEW 1 Remove the magnet bracket 2 Remove the top exit feed roll ...

Page 1081: ...place the compiler paddle module driving motor assem bly REP 11 49 171 Compiler Paddle Module Parts List on PL 11 145 Removal 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 WARNING Take care during this procedur...

Page 1082: ...ile performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the BM right hand cover REP 11 56 171 2 Remove the upper static eliminator 3 screws PL 11 168 Item 18 3 Figure 1 remove the BM exit sensor Figure 1 Sensor removal Replacement Reverse t...

Page 1083: ...ears Clutch and Bearings Parts List on PL 11 167 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the HVF BM ...

Page 1084: ... the BM crease roll motor using only the top screw 10 Temporarily attach the PWB mounting plate using only the top two screws 11 Fully pull out the BM module 12 Figure 2 prepare to remove the upper crease roll Figure 2 Preparation 1 Remove 2 circlips 2 Remove 2 bearings 1 Remove the circlip 2 Remove the upper crease roll gear 3 Remove the upper crease roll bearing ...

Page 1085: ...ve the lower crease roll and clutch assembly Figure 4 Lower crease roll and clutch assembly 1 Slide the upper crease roll to the rear remove from the front 1 Pull the lower crease roll and clutch assembly to the front to release the bearing 2 Slide the front of the lower crease roll and clutch assem bly out of the slot 3 Remove the lower crease roll and clutch assembly ...

Page 1086: ...identify the lower crease roll gear and clutch assembly compo nents Reassemble the components on the lower crease roll shaft in sequence from 1 to 12 Ensure the following points are followed Components are orientated correctly as shown in Figure 6 The shallow grooves in the bore of the gear face towards the rear and mate with the teeth of the clutch plate installed on the shaft The deep grooves in...

Page 1087: ...1 Repairs Adjustments Figure 6 Clutch components Lower crease roll shaft Bearing Shaft keyed clutch plate Gear keyed clutch plate Shaft keyed clutch plate Gear keyed clutch plate Lower crease roll gear note the orientation Retainer note the orientation Screw ...

Page 1088: ...aft keyed clutch plate does not come off of the shaft during installation Figure 8 Outer gear keyed clutch plate e Tighten the screw on the front end of the shaft until it reaches a hard stop f Check that the lower crease roll gear and clutch assembly is secure on the shaft If necessary repeat steps A to D 3 Install the remainder of the removed components by reversing the removal procedure Tabs Gr...

Page 1089: ...er motor gearbox REP 11 12 171 3 Remove components Figure 1 Figure 1 Components removal 4 Remove the pusher driving motor assembly REP 11 51 171 5 Remove the pusher sensor assembly REP 11 54 171 6 Remove the pusher module Figure 2 The mylar strips and dampers are attached to the pusher module Figure 2 Pusher module removal Replacement Reverse the removal procedures to reinstall the compiler paper ...

Page 1090: ...moval procedures to replace the sensor assembly REP 11 55 171 HVF Power Supply Unit Parts List on PL 11 157 Removal 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 WARNING Take care during this procedure Sharp ed...

Page 1091: ...e performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the top cover then the rear cover REP 11 1 171 2 Open the BM front door and fully pull out the BM module 3 Remove the crease blade knob 6d PL 11 161 Item 4 4 Remove the crease roll handl...

Page 1092: ...WorkCentre 5790 Family REP 11 56 171 Repairs Adjustments 6 Figure 1 Prepare to remove the BM right hand cover Figure 1 Preparation 1 Push the BM fully home 2 Remove 3 screws 3 Fully pull out the BM module 4 Remove 3 screws ...

Page 1093: ...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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the rear cover REP 11 1 171 2 Disconnect the PJs remove 9 screws and remove the PWB assembly Figure 1 Figure 1 HVF main PWB R...

Page 1094: ...ry Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the BM front door and fully pull out the BM 2 Rotate the crease roll handle 6c fully counterclockwise 3 Remove the crease blade knob 6d PL 11 161 Item 4 4 Remove the crease roll handle 6c PL 11 161 Item 5 5 Remove the BM front cover PL 11 161 Item 3 6 Figure 1 remove the...

Page 1095: ... screws securing the BM PWB mounting plate to the frame allow the PWB and mounting plate to hang down giving access to the rear nip spring and linkage 11 Figure 3 remove the rear lower linkage Figure 3 Rear linkage removal 1 Move the spring to the corner cutout 2 Flex the spring slightly and slide out of the hole 1 Remove the KL clip 2 Remove the E clip 3 Slide the linkage from the shafts 4 Releas...

Page 1096: ...uide PL 11 167 Item 16 Crease roll gate PL 11 167 Item 19 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open th...

Page 1097: ... crease roll gate rack drive gear and both crease roll gate rack gears Figure 1 Removing gears 8 Figure 2 remove the front and rear crease roll gate racks Figure 2 Removing the racks 1 Remove the E clip and 2 gears 2 Remove E clip and gear 1 Remove E clip and front rack 2 Remove E clip and rear rack ...

Page 1098: ...ove the crease roll gate Figure 3 Gate removal 10 Figure 4 remove the grease roll gate front guide Figure 4 Front guide removal Twist the gate to allow the shaft to exit the slot then lift out the gate 1 Remove two screws 2 Remove screw 4 Remove the guide 3 Hold the baffle away from the guide ...

Page 1099: ... 11 161 Item 10 Nip shaft PL 11 161 Item 11 NOTE If only new nip components are being installed the BM paper guide assembly does not need to be removed Removal 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 WARN...

Page 1100: ... REP 11 60 171 Repairs Adjustments 6 Figure 1 remove the front bearing Figure 1 Front bearing removal 7 Figure 2 remove the rear bearing Figure 2 Rear bearing removal 1 Remove the E clip 2 Remove the bearing 1 Remove the E clip then the bearing ...

Page 1101: ...ment Reverse the removal procedure to replace the BM paper guide assembly 2 Remove 4 screws Disconnect the ground harness 3 Pivot the BM flapper assembly down to rest on the crease blade 4 Lift out the BM paper guide assembly 1 Pull out the 2 harness supports 1 Release the nip springs to remove the nip shaft and nip rolls 2 Remove E clip and rear latch 3 Remove E clip and front latch 4 Carefully d...

Page 1102: ...he customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury WARNING Do not undock the HVFBM from the machine The machine maintains the stability of the HVFBM 1 Remove the top cover then the rear cover REP 11 1 171 2 Figure 1 disconn...

Page 1103: ...2 Disconnect the harness 4 Figure 3 prepare to remove the BM module Figure 3 Preparation 1 Remove 2 screws 2 Disconnect the harness Secure the harness to the harness retainers 2 Make sure that the top of the paper stack is level with the base of the BM module 1 Align approximately two reams of paper against the edge of the HVF BM ...

Page 1104: ...ure 5 Release the latches Figure 5 Releasing the slides 1 Fully pull out the BM module 2 Disconnect the ground harness Secure the harness to the har ness retainers 1 Pull up the right side latch to release the slide from the rail 3 Push down the left side latch to release the slide from the rail 2 Fully push in the slide 4 Fully push in the slide ...

Page 1105: ...ront cover when the BM module is removed NOTE The BM module weight is 23 Kg 50 6 lb NOTE The BM catch will spring to the rear when the BM module is removed Refer to Figure 7 7 Figure 6 remove the BM module Figure 6 Remove the BM module 1 Carefully remove the BM module One person must lift the BM module by the left side cross member A second person must lift the BM module by the booklet exit slot ...

Page 1106: ...m the new BM module Refer to Figure 5 b Install the new BM module onto the existing rails in the HVF BM 4 Figure 7 prepare to install the BM module Figure 7 Position of the catch 5 Reverse the removal procedure to replace the BM module CAUTION Ensure the BM harness and bin 2 harness are correctly positioned in the harness retainers so that harnesses are not damaged when the BM is moved to the extr...

Page 1107: ...eed electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the BM module REP 11 61 171 2 Remove the BM front cover PL 11 161 Item 3 3 Figure 1 Remove the slide assembly from the HVF BM frame Figure 1 Remove the slide assembly 2 Move the slide to the rear and remove the slide a...

Page 1108: ...ure 2 Remove the bracket and the slide rail 5 Figure 3 Remove the two brackets from the slide rail Figure 3 Remove the bracket from the slide rail 1 Remove four screws 2 Cut the four cable ties to release the harness 3 Remove the bracket and the slide rail 1 Remove screw 2 Remove the bracket from the slide rail 3 Remove screw 4 Remove the bracket from the slide rail ...

Page 1109: ...e the bracket from the slide rail Replacement 1 Reverse the removal procedure to replace the slide assembly 2 Ensure that all of the cable ties are installed and the harness are in the correct position 3 Check that all of the PJ connections are connected 1 Remove four screws 2 Cut the five cable ties to release the harness 3 Remove the bracket and the slide rail 1 Remove screw 2 Remove the bracket...

Page 1110: ...entry feed motor 1 2 Set the belt tension ADJ 11 10 171 REP 11 64 171 Bypass Feed Motor Parts List on PL 11 150 Removal 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 WARNING Take care during this procedure Shar...

Page 1111: ... tension ADJ 11 10 171 Do not tighten the motor bracket screws fully until the belt is tensioned by the spring REP 11 66 171 Exit Feed Motor 2 Parts List on PL 11 150 Removal 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 ca...

Page 1112: ...front cover Figure 1 Figure 1 Tri folder front door and cover 2 Remove the rear cover the top cover and the right side cover as necessary Figure 2 NOTE Open the top cover and remove the rear cover to access to the top cover rear fas teners and the top cover interlock sensor connector Figure 2 Top rear and right side covers Replacement Reverse the removal procedures to reinstall the tri folder cove...

Page 1113: ...an cause injury 1 Remove the HVF rear cover REP 11 1 171 2 Remove the tri folder rear cover REP 11 67 171 3 Remove the tri folder drive assembly Figure 1 Figure 1 Drive assembly 4 If necessary remove the circlip then remove the drive coupler refer to Figure 1 Replacement 1 Detach the coupler alignment tool from the drive unit refer to Figure 1 2 Install the drive assembly Figure 2 Figure 2 Attach ...

Page 1114: ...igure 3 Centralise the alignment tool 4 Prepare to centralise the drive coupler refer to Figure 1 with the HVF BM crease roll encoder disc Figure 3 5 Slacken off the drive unit retaining screws Figure 4 Figure 4 Loosen the drive unit 1 Position the coupler alignment tool onto the crease roll encoder disc 2 Carefully slide the BM towards the drive assembly 1 Loosen 4 screws Drive unit ...

Page 1115: ...the alignment tool onto the drive assembly for future use 9 Carefully slide back the BM and engage the drive unit coupler 10 Check that the harnesses do not obstruct the BM crease roll motor encoder disc 11 Reverse the removal procedures to replace the tri folder 1 Adjust the position of the drive unit 2 Ensure the drive coupler is centralised with the alignment tool Drive coupler Alignment tool 1...

Page 1116: ...ury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the tri folder rear cover REP 11 67 171 NOTE Access is improved if the top cover is removed also 2 Remove the drive coupling assembly bracket Figure 1 Figure 1 Drive coupling assembly 1 Remove the drive belt 2 Remove the driven pulley and gear 3 Remove the feed and the exit roll drive gear then th...

Page 1117: ...t do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Undock the tri folder from the HVF then move the unit to the right to access the left side of the frame refer to REP 11 73 171 2 Remove the drive belt Figure 1 Figure 1 Drive belt removal 3 If necessary remove the f...

Page 1118: ...solenoid Replacement Reverse the removal procedures to replace the assist gate solenoid REP 11 72 171 Crease Roll Springs Parts List on PL 11 197 Removal 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 WARNING Ta...

Page 1119: ...Figure 1 NOTE Control the movement of the torsion spring Figure 1 Top cover removal 3 Remove idler assemblies Figure 2 Figure 2 Idler assembly removal Replacement 1 Reverse the removal procedures to reinstall the idler assembly and top door cover assembly 2 Make sure that the correct self tapping screws are used to replace the cover base Do not overtighten the screws refer to GP 6 3 Replace but do...

Page 1120: ... be present that can cause injury 1 Undock the tri folder assembly from the HVF REP 11 73 171 Position and support the tri folder so that it is safely accessible from the front rear and left side 2 Release the crease roll drive belt tension REP 11 69 171 Disconnect the harness from the diverter and assist gate solenoids 3 Remove the tri folder roller assembly Figure 1 NOTE If not supported the rol...

Page 1121: ... right side of the diverter shaft lever Refer to Figure 2 3 Check that the diverter gate operates correctly before tensioning the crease roll drive belt REP 11 75 171 Bin 1 Limit Switches Parts List on PL 11 135 Removal 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 ...

Page 1122: ... customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the HVF front and rear covers REP 11 1 171 2 Disconnect the connector then remove the transmitter or receiver as necessary Figure 1 Figure 1 Bin 1 upper level sensor...

Page 1123: ...al Replacement Reverse the removal procedures to replace the front door and top cover interlock switches and the top access cover sensor REP 11 78 171 Tri Folder Entry and Assist Gate Sensors Parts List on PL 11 197 Removal 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 Electric...

Page 1124: ...or removal Replacement Reverse the removal procedures to replace the exit sensor REP 11 80 171 Tri Folder Control PWB Parts List on PL 11 193 Removal 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 WARNING Take c...

Page 1125: ...eed electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the tri folder rear cover REP 11 67 171 If removing the tri folder harness remove the HVF rear cover REP 11 1 171 2 Disconnect then remove the relevant harness Figure 1 Figure 1 Harness removal Replacement Reverse the ...

Page 1126: ...re during this procedure Sharp edges may be present that can cause injury CAUTION Place the inserter on a suitable surface Do not damage the inserter locating pins CAUTION Do not show the customer how to undock the inserter 1 Open the HVF front door 2 Undock the inserter Figure 1 Figure 1 Inserter undocking Replacement 1 Reverse the removal procedures to dock the inserter 2 Lock the inserter onto ...

Page 1127: ... the inserter front and rear covers REP 11 84 171 Inserter Motor Parts List on PL 11 181 Removal 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 WARNING Take care during this procedure Sharp edges may be present ...

Page 1128: ...ist on PL 11 179 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the inserter rear cover REP 11 83 171 2 R...

Page 1129: ... REP 11 87 171 Inserter Top Cover Interlock Switch Parts List on PL 11 177 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause...

Page 1130: ...move the rear pivot screw and remove the top cover Figure 1 Figure 1 Switch removal 4 Remove the door latch pins then remove 4 screws holding the top inside cover Figure 1 5 Release the cable harness clips and lift the top inside cover Disconnect the PJs and remove the top left door interlock switch Replacement 1 Reverse the removal procedures to replace the left hand cover interlock switch 2 When...

Page 1131: ...t Reverse the removal procedures to replace the inserter main tray and paper length sensors REP 11 90 171 Bottom Tray and Paper Sensors Parts List on PL 11 175 Removal 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 inj...

Page 1132: ...isconnect 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the inserter front cover REP 11 83 171 2 Remove the top cover pivot screw Move the rear top guide to disengage the pivots then remov...

Page 1133: ...d electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the front and rear covers REP 11 83 171 2 Remove the acceleration sensor Figure 1 Figure 1 Sensor removal Replacement Reverse the removal procedure to replace the inserter top left door and the acceleration sen sor 2 Rem...

Page 1134: ...at can cause injury 1 Remove the inserter front and rear covers REP 11 83 171 2 Remove the inserter motor REP 11 84 171 3 Remove the pickup roll assembly REP 11 95 171 4 Remove the top cover REP 11 91 171 5 Remove the top inside cover refer to REP 11 88 171 6 Remove the relevant sensor Figure 1 Figure 1 Sensor removal Replacement 1 Reverse the removal procedure to replace the LE and TE sensors 2 W...

Page 1135: ...al Replacement Reverse the removal procedure to replace the inserter bottom plate sensor REP 11 95 171 Inserter Pickup Assembly and Reverse Feed Roller Parts List on PL 11 179 Removal 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 par...

Page 1136: ...ctricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury CAUTION Do not remove more than one castor at a time unless the HVF frame is properly supported and stable NOTE The HVF weight is 72 8kg 160lbs the HVF BM weight is 100 3kg 220 6lbs 1 If installed undock the tri folder from the HVF RE...

Page 1137: ...Support the HVF frame Remove the adjustable castor from the frame Figure 2 Figure 2 Adjustable castor removal Replacement Reverse the removal procedure to replace the HVF fixed and adjustable casters 1 Remove 2 screws then the fixed castor 1 Remove the screw and stop plate 2 Rotate the castor adjustment wheel to unscrew the castor from the frame ...

Page 1138: ...emoval Replacement Reverse the removal procedure to replace the pause to unload PWB REP 11 98 171 Inserter Idle Roller Assembly Parts List on PL 11 179 Removal 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 WARN...

Page 1139: ...y 2 Replace the loading bracket screws and check that the front loading lever is at the same angle as the rear loading lever then tension the torsion spring The loading tray will not operate correctly if it is not supported horizontally in the inserter frame 2 Remove 2 circlips then the driven and idler gears 3 Remove 2 screws at the rear of the idle roller assembly 1 Disconnect the connector Uncl...

Page 1140: ...Sharp edges may be present that can cause injury 1 Remove the HVF rear cover REP 11 1 171 2 Remove the tri folder rear cover REP 11 67 171 3 Remove the coupler drive belt REP 11 68 171 4 Open the tri folder front door then remove the front and rear thumb screws Figure 1 Figure 1 Thumb screw removal 5 Disconnect the HVF to tri folder bin 2 tray harness from the tri folder module REP 11 81 171 6 Dis...

Page 1141: ...uring this procedure Sharp edges may be present that can cause injury 1 Rotate the ejector paddle assembly until the two short tabs are visible 2 Remove the ejector paddle assembly Figure 1 Figure 1 Ejector paddle assembly Replacement 1 Rotate the paddle shaft to ensure that the locating tab is uppermost Figure 2 2 Hold the paddle assembly by the two short tabs and clip onto the shaft NOTE Ensure ...

Page 1142: ...e wheels with the paddle module assembly installed If necessary remove the paddle unit assembly before replacing the paddle wheels Refer to REP 11 49 171 1 Rotate the paddle until the two rubber blades are visible CAUTION To ensure that the correct home position of the paddle wheel shaft is maintained install the new paddle wheels one at a time 2 Remove one paddle wheel at a time from the shaft Fi...

Page 1143: ...s on 65 90 ppm machines 1 Remove the OCT PL 12 10 Item 1 2 Remove the right hand cover PL 8 10 Item 4 3 Remove lug 1 and lug 2 from the rear of the right hand cover Figure 1 Figure 1 Lug removal CAUTION Make sure that the OCT fingers are installed in the correct position Each of the three fingers is marked 4 Install three OCT fingers on to the exit shaft assembly Figure 2 Figure 2 Finger install 5...

Page 1144: ... CAUTION When the right cover is installed make sure that the OCT fingers extend through the hole in the right hand cover Refer to Figure 4 7 Install the right hand cover Figure 4 Figure 4 Finger check 8 Remove the piece of paper from the paper path Make sure that the OCT fingers fall freely under their own weight 9 Re install the fuser and then the OCT 1 Release the jam clear ance handle 3d 4d 2 ...

Page 1145: ...135 PJ133 PJ131 PJ132 b Disconnect the following connectors from the single board controller PWB PJ101 PJ102 PJ103 PJ104 PJ105 PJ107 PJ109 PJ113 PJ114 PJ152 connection on the rear of the module to DADH c W TAG 150 disconnect PJ4 and PJ6 from the scanner daughter PWB PL 3 24 Item 20 d Remove the cable clamp PL 3 24 Item 10 e Release the harnesses from the single board controller PWB module f Releas...

Page 1146: ...eceptacle on the base of the scanner is correctly installed onto the tongue on the machine frame Refer to Figure 2 1 Remove 2 screws and 2 spacers 4 Raise the scanner and release the harness from beneath the scanner 3 Push the scanner towards the rear of the machine Tongue Receptacle 2 positions 2 Remove 1 screw and 1 spacer 2 W TAG 150 Only Remove 1 screw and 1 spacer Tongue 5 Remove the scanner ...

Page 1147: ... 1 Inverter and fuse Replacement 1 Reverse the removal procedure to replace the exposure lamp inverter and fuse 2 When re connecting the ribbon cable into PJ463 the blue band printed on the cable must face to the left when viewed as shown in Figure 1 3 Figure 1 ensure the ribbon cable is folded correctly in the cable clamp Engage two of the cable clamp clips in the carriage holes Bend the clamp to...

Page 1148: ... the same as for 1 Replacement Reverse the removal procedure to replace the document size 1 and 2 sensors REP 14 4 DADH Closed Switch Parts List on PL 14 25 W O TAG 150 PL 14 15 W TAG 150 Removal 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 injur...

Page 1149: ...PL 14 20 W O TAG 150 PL 14 10 W TAG 150 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the DADH REP 5 19 ...

Page 1150: ...hat can cause injury 1 Remove the DADH REP 5 19 2 Remove the user interface assembly REP 2 1 3 Remove the scanner top cover PL 14 20 Item 3 W O TAG 150 PL 14 10 Item 3 W TAG 150 CAUTION Do not remove the document glass Do not loosen the two screws securing the setting plate shown in Figure 1 4 Remove the scan carriage home sensor Figure 1 Figure 1 Scan carriage home sensor 1 Remove 2 screws 3 Lift...

Page 1151: ...witch 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the DADH REP 5 19 2 Remove the user interface assembly REP 2 1 3 Remove the...

Page 1152: ... and document glass REP 14 6 2 Manually move the Scan carriage to align with the cut outs in the frame 3 Remove the exposure lamp with the end blocks Figure 1 Figure 1 Releasing lamp fasteners 4 Remove the end blocks from the exposure lamp Figure 2 Figure 2 Removing end blocks Replacement Reverse the removal procedure to replace the exposure lamp 2 Press the catch and slide the mounting block upwa...

Page 1153: ...arefully move the scan carriage to the left side of the scanner module 3 Remove the scan idler pulleys Figure 1 NOTE Figure 1 and Figure 2 show the rear scan idler pulley The procedure for the front scan idler pulley is similar Figure 1 Scan idler pulley removal Replacement 1 Reverse the removal procedure to replace the scan idler pulleys 2 Make sure the scan idler pulleys are installed correctly ...

Page 1154: ...can motor and then remove the weight 35 ppm only Figure 2 Figure 2 Motor removal Replacement 1 Re assemble the motor onto the bracket and fully tighten the screws 2 Replace motor bracket assembly into the optics cavity engage the motor pulley with the drive belt and install the two screws but do not tighten 3 Move the motor bracket assembly to the right until the bracket aligns with the scribe lin...

Page 1155: ...he 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury CAUTION When moving the scan carriages hold them by the metal parts only to avoid damaging the lamp or mirrors 1 Remove the DADH REP 5 19 2 Remove the C...

Page 1156: ...ables Figure 1 Scan cables arrangement Front cable dark cable Rear cable silver cable Anchor ball End ball Scan carriage clamp Half rate scan carriage pulleys Half rate scan carriage pulleys Fixed pulley Fixed pulley Tab to secure the spring to the frame Capstan Capstan Drive shaft Fly wheel weight W O TAG 150 machines only Anchor ball End ball Scan carriage clamp ...

Page 1157: ...eps 7 and 8 for the front cable Replacement NOTE The replacement procedure is made easy by holding the windings on the capstan in place with tape at all times until each cable is fully installed Keep the cable tight to prevent it unwinding 1 Prepare several short lengths of adhesive tape 2 If necessary rotate the capstan to bring the anchor ball recess to the top and slightly to the right Check th...

Page 1158: ...re 4 Figure 4 Cable clamps 14 Hold the carriages fully to the right and tighten the clamps 15 Move the carriages from one end to the other to ensure the windings are straight and even 16 Reinstall the following DADH REP 5 19 Reinstall the CVT glass and document glass REP 14 6 W TAG 150 Document size sensor cover REP 14 20 DADH REP 5 19 CVT glass and document glass REP 14 6 REP 14 13 Scanner Drive ...

Page 1159: ...the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the DADH REP 5 19 2 Remove the user interface assembly REP 2 1 It is not necessary to disconnect the PJ 3 Figure 1 remove the top cover Figure 1 Top cover removal...

Page 1160: ...riage Drive Belts W TAG 150 Parts List on PL 14 15 Removal 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 WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the CVT...

Page 1161: ...ate pulley bracket and scan motor bracket are aligned with the scribed marks 1 Remove the E clip 2 Move the scan carriage drive shaft towards the front 3 Slip the scan carriage drive belt over the scan carriage pulley 5 Remove the E clip and bearing Push the shaft rearwards to release the rear bearing lift the intermediate pulley and shaft remove the drive belts 1 Carefully hold the scan cable on ...

Page 1162: ...procedure Sharp edges may be present that can cause injury 1 Remove the CVT glass REP 14 6 2 Remove the CVT ramp and document glass REP 14 6 3 Release the exposure lamp inverter PWB Figure 1 Figure 1 Release the inverter 4 Remove the exposure lamp inverter Figure 2 Figure 2 Remove the inverter 1 Remove 2 screws 2 Place fingers under the carriage to hold the cable clamp then release the 3 clips fro...

Page 1163: ...y while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the CVT glass REP 14 6 2 Remove the CVT ramp and document glass assembly REP 14 6 3 Remove five screws securing the scanner PWB cover 4 Lift the PWB cover and disconnect PJ923 on t...

Page 1164: ...ectricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Remove the CVT glass REP 14 6 2 Remove the CVT ramp and document glass assembly REP 14 6 3 Remove five screws securing the scanner PWB cover 4 Lift the PWB cover and disconnect PJ923 on the scanner PWB PL 14 15 Item 4 5 Disconnect all of the h...

Page 1165: ...ury 1 Remove the CVT glass REP 14 6 2 Remove the CVT ramp and document glass assembly REP 14 6 3 Remove four screws securing PWB cover 4 Lift the PWB cover and disconnect PJ923 on the scanner PWB PL 14 15 Item 4 5 Remove document size sensor 1 Q14 315 or document size sensor 2 Q14 320 Figure 1 NOTE The removal of document size sensor 1 and document size sensor 2 is identical Figure 1 Remove docume...

Page 1166: ...May 2013 4 428 Xerox WorkCentre 5790 Family REP 14 20 Repairs Adjustments ...

Page 1167: ...ury NOTE There are no across process direction adjustments 1 Select 100 magnification 2 Use the internal registration test pattern 3 Make a copy from the document glass or through the DADH 4 Measure the process direction dimension IQS 8 Magnification 5 Enter dC131 select either W O TAG 150 05 009 DADH Mag copy mode W TAG 150 14 169 DADH Mag 14 027 Scanner Mag Adj NOTE An entry of less than the def...

Page 1168: ...May 2013 4 430 Xerox WorkCentre 5790 Family ADJ 3 1 ADJ 3 2 Repairs Adjustments ...

Page 1169: ...rt Roll Assembly Registration Transport Gears Developer Module Support Pins 1K LCSS Drive Belt Tensioners 1K LCSS Bin 1 Drive Belt Pulleys and Idler 2K LCSS Drive Belt Tensioners 2K LCSS Bin 1 Drive Belt Pulleys and Idler 1K and 2K LCSS Bin 1 Elevator Motor Worm and Gear 1K and 2K LCSS Tamper Assembly HVF BM Support Pin Tray 3 and 4 Transport Roll and Bearings Parts list on PL 8 30 W O TAG 151 PL ...

Page 1170: ...tuator located at the rear left side of the tray and the paper width guides 4 Re install tray 1 and 2 REP 7 1 Tray 3 Takeaway Roll Assembly Parts list on PL 8 35 Item 2 W O TAG 151 PL 8 36 Item 2 W TAG 151 1 Remove the tray 3 takeaway roll assembly REP 8 29 W O TAG 151 or REP 8 46 W TAG 151 2 Use plastislip grease PL 26 10 Item 8 to lubricate the two areas of the shaft normally located within the ...

Page 1171: ...egistration clutch PL 8 15 Item 7 Lubricate the gear teeth only Gear 22T 28T PL 8 15 Item 17 Lubricate the gear teeth only Gear 23T PL 8 15 Item 18 Lubricate the gear teeth and the bore of the gear 3 Re install the removed components REP 8 5 Developer Module Support Pins 1 Remove the developer assembly REP 9 2 2 Figure 4 use plastislip grease PL 26 10 Item 8 to lubricate the developer assembly sup...

Page 1172: ...Remove the 2K LCSS top cover and rear cover REP 11 1 110 2 Remove the relevant belt tensioner Intermediate paper drive belt tensioner PL 11 22 Item 17 Bin 1 drive belt tensioner PL 11 10 Item 13 3 Remove the E clip and pulley from the belt tensioner Apply plastislip grease PL 26 10 Item 8 to the shaft and pulley bore Re assemble the pulley and E clip on the belt ten sioner 4 Clean off the old lubr...

Page 1173: ...to lubricate the tamper assembly NOTE The lubrication procedure is the same for the 1K LCSS and the 2K LCSS Figure 6 Lower vertical slides HVF BM Support Pin 1 Open the BM front door 2 Fully pull out the BM unit 3 Figure 7 use plastislip grease PL 26 10 Item 8 to lubricate the BM support pin Figure 7 Support pin lubrication 4 Fully push in the BM unit and close the HVF BM front door Apply grease t...

Page 1174: ...May 2013 4 436 Xerox WorkCentre 5790 Family ADJ 4 1 Repairs Adjustments ...

Page 1175: ...ake sure all components removed in the repair proce dure are installed correctly NOTE The same adjustment applies to the feed motor and the CVT motor This procedure shows how to adjust the feed motor The green spring applies tension to the feed motor drive belt The silver spring applies tension to the CVT motor drive belt 1 Remove the rear cover PL 5 10 Item 1 2 Adjust the correct motor drive belt...

Page 1176: ...ADH standoffs include the CVT roll bearings PL 5 25 Item 4 and PL 5 25 Item 13 1 Check the height of the DADH The two standoffs touch the CVT glass when the DADH is closed Figure 1 Check that the DADH is parallel to the scanner module Perform the steps that follow Refer to Figure 2 a Put a strip of paper on the CVT glass below the back DADH standoff b Close the DADH c Carefully pull the paper Make...

Page 1177: ...erbalance Adjust the two counterbalances 1 If the height of the DADH is wrong adjust the counterbalances Figure 3 Figure 3 Counterbalances 2 If mis registration is found after the DADH is set to the correct height go to ADJ 5 5 DADH Registration Adjustment CVT glass Back DADH standoff Strip of paper 1 Loosen the lock nut 2 Use an allen key to adjust the setting screw to raise or lower the DADH 3 T...

Page 1178: ...ecessary perform the Adjustment Adjustment WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 1 Raise the DADH 2 Loosen both DADH thumbscrews PL 5 10 Item 12 3 Adjust the setting screw on the right counterbalance to correct...

Page 1179: ...ADH rear cover rotate the takeaway rolls 7 Clean the takeaway rolls PL 5 35 Item 6 with a micro fiber wiper and water CAUTION When the feed rolls are installed make sure the lowest roll retard roll is correctly positioned on the assembly as shown in Figure 1 8 Remove the feed roll assembly REP 5 14 Clean the 3 rolls and the pad PL 5 35 Item 2 with a micro fiber wiper and water Use a brush to clean...

Page 1180: ...ricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury NOTE If a new document pad is installed make sure that the protective paper is removed from the adhesive pads 1 Raise the DADH Put the document pad with the adhesive pads face up on the document glass ...

Page 1181: ...ng parts can cause injury WARNING Do not break the glass Broken glass can cause injury CAUTION The ROS window is secured by 2 clips 1 at the front and 1 at the rear If too much pressure is applied when cleaning the ROS window the glass will flex and may break 1 Remove the xerographic module 35 ppm PL 9 22 Item 2 or 40 90 ppm PL 9 20 Item 2 2 Using a clean dry cotton tip very carefully clean the un...

Page 1182: ...op cover is replaced 1 Remove the ROS REP 6 1 2 Remove the top cover from the ROS 5 torx head screws CAUTION Do not attempt to clean the ROS laser diode 3 Refer to Figure 1 Refer to Cleaning Methods Inspect the inside of the ROS As neces sary clean the inside of the ROS the mirrors the polygon mirror the lens and the surface of all glass components NOTE Carefully rotate the polygon mirror for acce...

Page 1183: ...Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 1 Pull out the tray to be adjusted and remove the paper from the tray 2 Push in the retaining clips and remove the paper tray guide PL 7 15 Item 20 Figure 1 Figure 1 Remove the paper guide 3 To reset the paper tray guide Refer to Figure 2 to set the paper tray guide to A4 paper size and reposition the ret...

Page 1184: ...4 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 1 Open tray 5 door and allow the tray to lower and remove the paper stack 2 Adjust the paper guide to the required paper size Figure 1 To set the paper tray guide to A4 A3 paper size move the paper guide to the outer position To set the paper tray guide to 8 5 x 11 11 x 17 inch paper size move the paper...

Page 1185: ...castor at the left of the tray 5 module to set tray 5 level with the left hand door The measurement between the left hand door and tray 5 should be equal at the front and the rear This is the nominal position for tray 5 and the image registration and hole punching should need little or no correction NOTE Before each adjustment or measurement un dock and re dock the module to reset the tray 5 posit...

Page 1186: ...ure NOTE Perform ADJ 7 3 Tray 5 Module to Machine Alignment before starting this adjustment procedure Use both ADJ 7 3 and this adjustment to achieve correct hole punch alignment Before performing this adjustment return the NVM values for tray 5 to the nominal values Adjustment WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Re...

Page 1187: ...ator 4 Secure the docking pin bracket Figure 4 Figure 4 Secure the docking pin bracket 5 Make sample prints and check the top edge registration 6 Enter dC604 Registration Setup Procedure and set the top edge registration 7 If the top edge registration is still out of range then repeat the adjustment 1 Turn the adjusting screw as necessary 2 The bracket moves Use the scribed indicators to determine...

Page 1188: ...des Refer to Figure 1 and Figure 2 to change the paper tray guides and paper guides from A4 paper size to 8 5x11 inch paper size Refer to Figure 3 and Figure 4 to change the paper tray guides and paper guides from 8 5x11 inch paper size to A4 paper size Figure 1 Paper tray guide re position Figure 2 Paper guides re position 1 Pull out 2 retaining clips 2 Lift the paper tray guide 3 Engage the pape...

Page 1189: ...3 Engage the paper tray guide with the rearward location points top and bottom 4 Push in 2 retaining clips Top location points Bottom location points 1 Release the top fixing from the tray 2 Move the rear paper guide to the front position 3 Press the paper guide into position 4 Release the top fixing from the tray 5 Move the front paper guide to the rear position 6 Press the paper guide into posit...

Page 1190: ... Platform Preparation WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury Special tool required PFP setting tool PL 26 11 Item 6 and Figure 1 1 Remove the following components from the upper feed assembly drive shafts Feed r...

Page 1191: ...ab in the setting tool location slot Figure 3 Figure 3 Tab location 1 Locate the PFP setting tool onto the feed roll shaft so that the nudger roll shaft rests on top of the setting tool flange Nudger roll shaft 1 Ensure that the location slot of the PFP setting tool slides onto and fully locates on the tab of the upper feed assembly Upper feed assembly tab ...

Page 1192: ... the paper strip does not feed between the flange of the PFP setting tool and the retard shield then retard shield is positioned correctly proceed to Stack Height Sensor Check and Adjustment If the paper strip does feed between the flange of the PFP setting tool and the retard shield then the retard shield requires adjustment continue at step 3 Nudger roll shaft Tab in the location slot 1 Attempt ...

Page 1193: ... tool as the retard shield is repositioned Ensure the retard shield remains parallel to the upper feed assembly Figure 7 Retard shield adjustment 5 Re check the position of the retard shield Figure 5 If necessary repeat the adjustment of the retard shield 1 Loosen the retard shield retaining nut Retard shield 1 Raise the retard shield until it just butts against the underside of the PFP setting to...

Page 1194: ...equire adjustment con tinue at step 5 5 Adjust the position of the stack height sensor Figure 9 Figure 9 Sensor adjustment 6 Check the position of the stack height sensor Figure 7 If necessary repeat the adjust ment of the stack height sensor 7 The adjustments are now complete remove the PFP setting tool 8 Install all the removed PFP components refer to Preparation steps 1 and 2 Replacement is the...

Page 1195: ...ns Figure 1 3 If necessary repeat steps 1 and 2 4 Record the new values in the machine log book 5 Check the duplex buckle timing Duplex Buckle Timing Check Go to dC131 select location 08 148 Le Dup Snr To Clh On The value should be set in the region of 10 to 30 below the default value shown in Table 2 Adjustment 1 Adjust the duplex buckle timing NVM value in increments of 10 in accordance with Tab...

Page 1196: ...ds Check Remove the relevant feed head Refer to Figure 1 Check the position of the spring seat Figure 1 Spring seat position Adjustment NOTE The feeders have the spring seat set in the nominal 1mm position during manufac ture Figure 2 1 Figure 2 change the position of the spring seat to adjust the nip pressure of the retard roll Change the spring seat to the 2mm position to increase the retard rol...

Page 1197: ...on Nominal 1mm position 2mm position To release the spring seat from this position press down the pip and slide the spring seat away from the frame hole To locate the spring seat in this position slide the spring seat along the slot until the pip drops into the frame hole Pip To release the spring seat from this position lift up the base of the spring and slide the spring seat away from the spring...

Page 1198: ...hts Figure 2 Weights location 2 Figure 3 change the number of weights to adjust the downward pressure of the nudger roll Figure 3 Spring seat adjustment 3 Install the feed head and check the paper feeding performance Storage position of the spare weights 1 Remove the nut 2 Change the number of weights 3 Install and tighten the nut ...

Page 1199: ...is achieved by running an Image Quality Adjustment routine from within SAKO tools This routine can be performed at any stage of the machine s operational life by the key operator Adjustment The adjustment routine consists of the steps that follow 1 Load A4 8 5x11 inch white paper LEF in the Bypass Tray 2 Turn off or reset to nominal all image enhance features 3 Enter Customer Administration Tools ...

Page 1200: ...ation If either or both above are true continue below 1 Remove the developer module PL 9 15 Item 2 Place the developer module left side down on a suitable surface 2 Check the shutter assembly seal for damage Figure 2 If necessary install a new shutter assembly PL 9 15 Item 20 3 Remove contamination from the following Above and below the developer roll area Registration guide and the halo guide The...

Page 1201: ... Use the curved edge of the magnetic seal repair tool PL 26 10 Item 23 to remove devel oper from the rear of the magnetic roll Figure 3 The correct quantity of toner that should be removed from the magnetic roll is shown in Figure 4 Magnetic seal brush To be effective this must have a uniform profile the full length of the magnet Check the seal for torn fabric broken edges and delamination from th...

Page 1202: ...n 2 Lean the tool toward the bottom of the developer until it is in line with lower lip 3 Keeping the tool at this angle push the tool up the magnetic roll to remove developer 4 When the tool is in line with upper seal lean back then carefully lift the tool Ensure the maximum amount of developer is removed 5 Use the upper seal to keep the material on the tool Correct quantity of developer ...

Page 1203: ...ttle will not form a good seal 4 Use a flat edge of the tool to distribute the developer across the width of the magnetic strip Figure 6 Figure 6 Distributing developer 5 Repeat steps 2 to 4 for the front of the magnetic roll NOTE Two scoops of developer is the optimum amount to form a good seal Do not use more than three scoops 2 Apply the developer evenly to the magnetic strip to form the seal O...

Page 1204: ...clean before re installing the assembly 4 35 ppm Clean the charge scorotron by carefully pulling out the cleaning rod on the front of the xerographic module as far as it will go and then pushing it fully home Repeat nine times 5 40 90 ppm Clean the charge scorotron Perform the following a Press the Log in out key symbol button on the key pad or select Guest on the UI b Enter User Name admin case s...

Page 1205: ...her then the machine has a problem with poor shadows dark greys Go to the Poor Shadows Adjustment If section 1 looks white then the machine has a problem with poor highlights light greys Go to the Poor Highlights Adjustment For 35 ppm machines only Some machines suffer from poor shadows and poor high lights In such cases install the ROS filter and optimize poor shadows first Installation of the RO...

Page 1206: ...tern 15 3 Exit diagnostics GP 1 4 Place the new printed test pattern 15 on the platen glass and make one copy 5 If the copy has poor highlights then go to the next step If the highlights are good then go to the Final Image Quality Check 6 Enter dC131 NVM Location 09 003 Charge Grid and reduce the value by 25 Reduce the value in increments of 25 until good highlights is achieved Do not reduce the v...

Page 1207: ...ab The Device Settings screen will display c Select the Option Enablement d Use the numerical keypad to enter the following code 3386787231 The asterisk must be entered before the number Press Enter e Switch off then switch on the machine GP 14 NOTE To disable the timing patch perform step 3 again but enter 3386787230 at the step d Adjustment 1 Initial calibration of the inverter decurler NOTE The...

Page 1208: ...tion a Reset the position of the retaining ring To increase the down curl on output copies see Figure 3 To decrease the down curl on output copies see Figure 4 Figure 4 Decrease down curl b Run 20 duplex copies of the customers preferred print media or A4 8 5x11 inch paper c Assess the copies for curl refer to IQ5 2 Turn the adjuster 1 increment clockwise to increase down curl or turn the adjuster...

Page 1209: ...evel the tray Lock the clamps 4 Re install the bin 1 motor refer to REP 11 5 110 5 Switch on the machine GP 14 6 Enter dC330 code 11 033 Bin 1 Elevator Motor Cycle Check that bin 1 cycles without giving any fault indications ADJ 11 2 110 Machine to 2K LCSS Alignment Parts List on PL 11 2 Purpose To correctly align the 2K LCSS to achieve reliable transfer of paper from the machine to the 2K LCSS Ad...

Page 1210: ...need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 1 Remove the chad bin and unscrew the thumb screw retaining the hole punch assembly 2 Pull out the hole punch assembly a short distance to access the spacer if installed refer to Figure 2 The following settings can be made NOTE If the spacer cannot be found suitable washers...

Page 1211: ...table motor or tensioning pulley bracket is positioned with fastening screws not tightened fully NOTE For motors with pivoted brackets the pivot screw must be fitted and tightened 4 The tensioning spring is fitted between the bracket and frame locating point Adjustment WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP...

Page 1212: ... Check the belt condition and routing if the tension spring is not extended or the locking screw is at the end of the bracket adjustment slot Figure 1 Drive belt tensioning Typical spring tensioning arrangement Drive belt Bracket Pivot Screw Lock screw Adjustment slot Tension spring ...

Page 1213: ...0 Motor Drive Belt Tensioning Purpose To set the tension of directly or indirectly driven belts that are tensioned by a spring attached to the motor Check 1 The shafts and pulleys are installed and properly located 2 The drive belt is undamaged and correctly routed 3 The adjustable motor or tensioning pulley bracket is positioned with fastening screws not tightened fully NOTE For motors with pivot...

Page 1214: ... Check the belt condition and routing if the tension spring is not extended or the locking screw is at the end of the bracket adjustment slot Figure 1 Drive belt tensioning Typical spring tensioning arrangement Drive belt Bracket Pivot Screw Lock screw Adjustment slot Tension spring ...

Page 1215: ...djustment WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 1 Figure 1 turn both adjustable castors in the same direction to adjust the vertical alignment between the HVF HVF BM and the machine Figure 1 Machine to HVF HVF ...

Page 1216: ...ition 1 Remove the front door PL 11 190 front cover PL 11 190 and the rear cover PL 11 190 Check that the front and rear paper setting adjusters are in position for the appropriate size of paper Figure 1 Figure 1 Tri Folder paper setting 2 Set the front and rear paper setting adjusters to the A4 or 8 5 x 11 inch LTR position Figure 1 NOTE Do not over loosen the adjuster screws The adjusters can de...

Page 1217: ...hed off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 To improve the access to the two clamp screws for the anvil remove the tamper assem bly REP 11 30 171 2 Fully pull out the BM module Remove ...

Page 1218: ...o drop the anvil spacer or clamp plate Figure 3 as they can fall to the bottom of the BM module If parts need to be retrieved from the bottom of the BM module it may be necessary to tilt the whole HVF BM to make the loose parts slide to the centre of the base from where they can be easily removed Loosen 2 clamp screws so that the anvil can move freely see note ...

Page 1219: ...at the two protrusions on the tool engage with the depressions in the anvil Move the anvil if necessary using the two clamp screws 3 Continue to rotate the stapler gear until the anvil is tightly clamped by the alignment tool and the stapler will close no further 4 Tighten the two screws alternately a little at a time while holding the free screw with a finger Ensure that the anvil does not move a...

Page 1220: ...e machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury WARNING Take care during this procedure Sharp edges may be present that can cause injury 1 Open the HVF BM front door and fully pull out the BM module 2 Remove the crease blade knob 6d PL 11 161 Item 4 3 Remove th...

Page 1221: ... 10 Lock the crease gate in the open position Figure 2 Figure 2 Lock the crease gate Crease roll shafts Crease blade setup tool One tool is shown located on the front of the crease rolls Locate the second tool on the rear of the crease rolls in the same manner 1 Lift the gate to the highest position 2 Insert an interlock cheater in the teeth as shown to prevent the gate from falling ...

Page 1222: ... 11 4 171 Repairs Adjustments 11 Loosen the crease blade screws Figure 3 Figure 3 Blade loosening 12 Fully insert the crease blade by positioning the crease blade knob 6d PL 11 161 Item 4 with the arrow in the down position Loosen 10 screws marked A ...

Page 1223: ...arrow in the up position 15 Tighten the six remaining crease blade clamp screws refer to Figure 3 16 Remove both crease blade setup tools and return them to the storage position 17 Install all of the removed components and check the operation of the BM module 1 Push the front of the crease blade forward to contact the setup tool 3 Tighten 2 screws 2 Push the rear of the crease blade forward to con...

Page 1224: ...edge without touching the sheet the NVM value will need to be increased to move the tampers closer together perform the adjustment If the tampers are in the correct position within 0 5mm 0 02 inch of the sheet edge without touching the sheet do the following a Enter dC131 b Select Diagnostic Routines c Select Copier Routines d Select dC131 NVM Read Write e Select 12Finisher DFA f Select 12 006 Boo...

Page 1225: ...e sheet edge without touching the sheet do the following a Enter dC131 b Select Diagnostic Routines c Select Copier Routines d Select dC131 NVM Read Write e Select 12Finisher DFA f Select 12 006 BookMkrTampRdyOff set g Select Read Write and increase the value by 19 h Select Save select OK select Close select Exit Adjustment 1 Do the following a Enter dC131 b Select Diagnostic Routines c Select Cop...

Page 1226: ...d release the jam clearance handle PL 11 161 Item 8 fully open the paper guide PL 11 161 Item 7 3 Enter dC330 code 11 065 BM Backstop Motor select Start allow the backstop to raise to the receive position where it will pause select Stop 4 Insert a single sheet of A4 paper short edge downward into the booklet maker compiling area so that it rests on the backstop and is approximately central front t...

Page 1227: ...ease the jam clearance handle PL 11 161 Item 8 fully open the paper guide PL 11 161 Item 7 3 Do the following a Enter dC131 b Select Diagnostic Routines c Select Copier Routines d Select dC131 NVM Read Write e Select 12Finisher DFA f Select 12 003 BookMkrCompileOff set g Select Read Write and increase the original value by 80 h Select Save select OK select Close select Exit 4 Enter dC330 code 11 0...

Page 1228: ...dC131 NVM Read Write e Select 12Finisher DFA f Select 12 003 BookMkrCompileOff set g Select Read Write and decrease the value by 80 h Select Save select OK select Close select Exit i Re install the BM right hand cover if removed in step 5 4 When the compiling position is correct switch the machine off then on GP 14 ADJ 11 7 171 Booklet Crease Position Purpose To set the crease position of the book...

Page 1229: ...eck to ensure the staple position is correct 4 When the staple position is correct switch the machine off then on GP 14 ADJ 11 9 171 Booklet Maker Skew Purpose To adjust the skew of the booklet crease Check and complete the following adjustments ADJ 11 6 171 Booklet compiling position ADJ 11 8 171 Booklet staple position ADJ 11 7 171 Booklet crease position Check 1 Run a copy job of 3 stapled 4 sh...

Page 1230: ...rackets the pivot screw must be fitted and tightened 4 The tensioning spring is fitted between the bracket and frame locating point Adjustment WARNING Ensure that the electricity to the machine is switched off while performing tasks that do not need electricity Refer to GP 14 Disconnect the power cord Electricity can cause death or injury Moving parts can cause injury 1 Figure 1 shows a typical ar...

Page 1231: ...Idler Drive Belt Tensioning Purpose To set the tension of drive belts that are tensioned by a spring attached to an idler See also ADJ 11 10 171 Motor Drive Belt Tensioning Check 1 The shafts and pulleys are installed and properly located 2 The drive belt is undamaged and correctly routed 3 The tensioning spring is fitted between the idler bracket and frame locating point Typical spring tensioning...

Page 1232: ...rect size of paper ADJ 11 2 171 Tri Folder Paper Size Setting 3 The NVM settings Enter dC131 then check that codes values for 12 009 C folds 12 010 Z folds and 12 011 Tri fold de skew are set in accordance with the values on the HVF BM label Figure 1 If necessary enter dC131 and change the NVM values for codes 12 009 12 010 and 12 011 to match with the values on the HVF BM label 4 Ensure the front...

Page 1233: ... An increase to the NVM value by 30 will decrease the A fold by 1mm A decrease to the NVM value by 30 will increase the A fold by 1mm Use dC131 code 12 009 to make adjustments to C folded copies Use dC131 code 12 010 to make adjustments to Z folded copies B Folds Figure 3 The folds marked B are created within the tri folder module The length of the B fold is determined by the position of the paper...

Page 1234: ...he Lower Paddles 8 Check the Position of the Ejector Assembly 9 Chamfered Staple Cartridge Installation 10 Customer Awareness Instruction on Bin 1 Obstructions 11 BM Diverter Solenoid Position Procedures Hole Punch Blanking Assembly Modification The hole punch blanking assembly heats up as copies pass through The increase in tempera ture causes the hole punch blanking assembly to bow This bowing e...

Page 1235: ... number is before either of the fol lowing install a new set of four paddle wheels PL 11 145 Item 28 to maintain good reliability HVF YFV005294 manufacture date 17th March 2009 HVF BM YFW02881 manufacture date 19th November 2009 1 Figure 4 Check the paddle wheels of the paddle module assembly for wear Figure 4 Paddle module assembly 2 Run 50 sets of 3 documents in A4 or 8 5 x 11 inch LEF simplex a...

Page 1236: ... paper grooves in one or more of the tampers 1 Run 50 sets of 3 documents in A4 or 8 5 x 11 inch LEF simplex and stapled mode 2 Check during the upper paddle operation that the tampers come to a closed position with un buckled paper in between 3 Check for mis compiling in the direction of feed If mis compiling is evident and greater than 1 2mm continue with steps 4 to 6 If there is no mis compilin...

Page 1237: ...jector assembly will cause the top sheet of a stacked set to mis stack mis staple or not staple 1 Figure 8 Check the lower paddle for wear Figure 8 Lower paddle NOTE On W O Tag V 007 machines the lower paddle is not a spared item 2 Perform one of the following If wear on the lower paddle is evident on a W O Tag V 007 machine install a new W Tag V 007 ejector assembly PL 11 14 Item 2 If wear on the...

Page 1238: ...ed Staple Cartridge Installation The surface area of the 100 sheet staple cartridge can protrude slightly where the corner of the output sets are positioned for stapling This raised area can catch the first 5 sheets in a out put set then cause the set to mis compile mis staple and or create dog ears 1 Figure 10 Check the staple cartridge for a raised surface Figure 10 Staple cartridge 2 Check if t...

Page 1239: ...new stacker motor gearbox PL 11 135 Item 10 to maintain good reliability HVF YFV005294 manufacture date 17th March 2009 HVF BM YFW02881 manufacture date 19th November 2009 BM Diverter Solenoid Position The booklet maker diverter gate is susceptible to breakage if the diverter gate solenoid travel is not arrested by the stop washer pressing against the solenoid body but by the diverter gate reachin...

Page 1240: ...vement in the solenoid mounting position to eliminate any gap under the washer install a spacer washer shim between the E clip and rubber washer to eliminate the gap 3 Enter the dC330 output code 11 074 to energize the BM diverter solenoid to check that the rubber washer is now pinched between the E clip and the solenoid body 4 Make prints or copies to both the booklet maker and to bin 1 to ensure...

Page 1241: ...micro fiber wiper PL 26 10 Item 13 4 Re install the remainder of the removed components ADJ 14 2 Optics Cleaning Procedure W TAG 150 Parts List on PL 14 10 Purpose To clean the optical components of the scanner ensuring optimum image quality NOTE This adjustment must only be performed if directed to it from an Image Quality RAP or if the optics cavity was opened to install a new component and cont...

Page 1242: ...May 2013 4 504 Xerox WorkCentre 5790 Family ADJ 14 1 ADJ 14 2 Repairs Adjustments ...

Page 1243: ...pm 5 39 PL 8 17 Registration Transport 65 90 ppm 5 40 PL 8 20 Duplex Transport 65 90 ppm 5 41 PL 8 22 Duplex Transport 35 55 ppm 5 42 PL 8 25 Tray 1 and 2 Paper Feed Assembly 1 of 2 5 43 PL 8 26 Tray 1 and 2 Paper Feed Assembly 2 of 2 5 44 PL 8 30 Tray 3 Paper Feed Assembly W O TAG 151 5 45 PL 8 31 Tray 4 Paper Feed Assembly W O TAG 151 5 46 PL 8 32 Tray 3 Paper Feed Assembly W TAG 151 5 47 PL 8 3...

Page 1244: ... Back Stop assembly 5 109 PL 11 165 HVF BM Crease Blade Motor 5 110 PL 11 166 HVF BM Crease Rolls Motor and PWB 5 111 PL 11 167 HVF BM Crease Rolls and Support Leg 5 112 PL 11 168 HVF BM Stapler Assemblies 5 113 PL 11 169 HVF BM Bin 2 5 114 PL 11 Inserter PL 11 175 Inserter Covers 5 115 PL 11 177 Inserter Main Drives 1 of 3 5 116 PL 11 179 Inserter Main Drives 2 of 3 5 117 PL 11 181 Inserter Main ...

Page 1245: ...5 90 ppm USSG XCL 4 Shield Not Spared 5 105K29563 HVPS 35 ppm REP 1 10 105K29553 HVPS 40 90 ppm 6 Locking screw Not Spared 7 110K14020 Door interlock switch S01 300 NOTE REP 1 8 8 110K14030 On Off switch 9 108E06730 In line fuse 2 5A slow blow 10 Main power cord REF PL 1 15 Item 1 11 Not used 12 962K34760 IOT HVPS harness 35 ppm 962K27020 IOT HVPS harness 40 90 ppm 13 962K49460 IOT Finisher Harnes...

Page 1246: ...5 55 ppm 152S06413 Europe Alternate 35 55 ppm 152S06406 Europe 65 90 ppm 152S06400 USSG XCL 35 55 ppm 152S06401 USSG XCL 65 90 ppm 152S06415 Denmark 35 55 ppm 152S06404 Denmark 65 90 ppm 152S06416 Switzerland 35 55 ppm 152S06420 Switzerland 65 90 ppm 152S06402 Argentina 35 55 ppm 152S06403 Argentina 65 90 ppm 152S06405 South Africa 65 90 ppm 2 117E36280 20A power cord NOTE This power cord can also...

Page 1247: ...0 UI touch screen PWB REP 2 2 7 848K48822 User interface housing USSG XCL 35 55 ppm 848K48812 User interface housing XE 35 55 ppm 848K48842 User interace housing USSG XCL 65 90 ppm 848K48832 User interface housing XE 65 90 ppm 8 Name plate label see below for variants 897E70180 35 ppm 897E70170 40 ppm 897E70160 45 ppm 897E70150 55 ppm 897E70140 65 ppm 897E70130 75 ppm 897E70120 90 ppm 9 UI Interna...

Page 1248: ...rive SATA P O PL 31 13 Item 23 REP 3 2 3 960K72210 Riser PWB REP 3 4 4 960K27451 Foreign device interface PWB 5 962K82620 Foreign device interface harness 6 019E67610 Fax mounting bracket 7 HDD mounting bracket P O PL 31 13 Item 23 8 HDD thumb screw Not Spared 9 813W25205 Locking screw 10 HDD power cable Not Spared 11 HDD data cable Not Spared 12 Foreign device interface kit REF PL 31 14 Item 2 ...

Page 1249: ...le scanner driver PWB CCD PWB harness REF PL 14 25 Item 13 W O TAG 150 Single board controller PWB DADH comms scanner power harness REF PL 14 15 Item 5 W TAG 150 8 960K65035 Software module REP 3 3 9 Single board controller CCD PWB harness REF PL 14 25 Item 5 10 Cable clamp Not Spared 11 Single board controller module user interface harness Not Spared 12 960K52410 Memory module 1Gb 13 813W25205 Lo...

Page 1250: ... PL 4 10 Item 1 NOTE REP 4 6 7 Ozone fan REF PL 9 25 Item 1 8 130E10530 Waste toner door switch S09 380 9 114E18630 Fuser connector assembly 10 Spring P O PL 4 10 Item 1 11 604K24650 Auger damper kit REP 9 10 12 Mounting bracket P O PL 4 10 Item 1 13 055K36090 Shutter assembly REP 9 10 14 Washer P O PL 4 10 Item 1 15 Screw P O PL 4 10 Item 1 16 Waste toner full sensor REF PL 9 10 Item 2 17 Photore...

Page 1251: ...drive belt 2 REP 4 7 10 807E06462 Fuser drive gear pulley assembly REP 4 7 11 Bearing P O PL 4 12 Item 10 12 114E18810 Fuser CRUM connector 13 Screw P O PL 4 10 Item 1 14 Support plate P O PL 4 10 Item 1 15 807E05670 Registration transport drive pulley REP 4 7 16 Bearing P O PL 4 12 Item 17 17 Developer drive gear pulley assembly P O PL 9 15 Item 23 REP 4 7 18 023E25050 Main drive belt 1 REP 4 7 1...

Page 1252: ...nd PWB assembly 35 ppm NOTE REP 4 2 127K55420 Main drive motor and PWB assembly 40 55 ppm NOTE REP 4 2 7 Ozone fan REF PL 9 25 Item 1 8 130E10530 Waste toner door switch S09 380 9 114E18630 Fuser connector assembly 10 Spring P O PL 4 15 Item 1 11 055K36090 Shutter assembly REP 9 10 12 Waste toner full sensor P O PL 9 10 Item 2 13 604K24650 Auger damper kit REP 9 10 14 Washer P O PL 4 15 Item 1 15 ...

Page 1253: ... REP 4 3 8 807E09940 Intermediate drive gear REP 4 3 9 023E30740 Main drive belt REP 4 3 10 007K13202 Fuser drive gear REP 4 3 11 Bearing P O PL 4 17 Item 10 12 114E18810 Fuser CRUM connector 13 Screw P O PL 4 15 Item 1 14 807E05670 Registration transport drive pulley REP 4 3 15 807E05700 Developer drive gear White REP 4 3 807E05680 Developer drive gear Black 16 Scorotron cleaner home sensor Q09 0...

Page 1254: ...7 Harness support P O PL 5 10 Item 9 8 Top cover REF PL 5 20 Item 15 9 084K42640 DADH 35 ppm REP 5 19 ADJ 5 2 ADJ 5 5 084K36766 DADH 40 90 ppm REP 5 19 ADJ 5 2 ADJ 5 5 10 DADH Closed switch magnet Not Spared NOTE 1 11 DADH ground harness P O PL 5 10 Item 9 12 803E13680 Thumbscrew 40 90 ppm 003K20000 Thumbscrew 35 ppm 13 Bracket P O PL 5 10 Item 9 14 CVT Cleaning label Not Spared 15 End stop Not Sp...

Page 1255: ...5 305 12 Document present sensor actuator Not Spared 13 130K73890 Document present sensor Q05 310 14 125E00430 Static eliminator 15 Gear P O PL 5 15 Item 26 16 127K53770 Feed motor MOT05 020 See NOTE 2 ADJ 5 1 17 Feed motor tension spring red P O PL 5 10 Item 9 18 Feed assembly complete Not Spared 19 Shaft P O PL 5 15 Item 26 20 Bracket P O PL 5 15 Item 18 21 Feed roll assembly cover Not Spared 22...

Page 1256: ...8 14 125E00430 Static eliminator 15 Gear P O PL 5 17 Item 26 16 127K53770 Feed motor MOT05 020 See NOTE 2 ADJ 5 1 17 Feed motor tension spring red P O PL 5 10 Item 9 18 Feed assembly complete REF PL 31 11 Item 8 W TAG D 002 TAG D 006 19 Shaft P O PL 5 17 Item 26 20 Bracket P O PL 5 17 Item 18 21 802E87730 Feed roll assembly cover 22 Intermediate feed bearing P O PL 5 17 Item 26 23 013E93370 Bearin...

Page 1257: ...914 Base 7 Spring P O PL 5 20 Item 17 8 Torsion spring silver P O PL 5 20 Item 17 9 029E37810 Latch pin 10 Spring plate P O PL 5 20 Item 17 11 130K73960 Takeaway sensor Q05 335 REP 5 8 12 130K73970 CVT Sensor Q05 350 REP 5 8 13 Sensor support P O PL 5 20 Item 17 14 Shaft securing bracket P O PL 5 20 Item 17 15 802K62453 Top cover 16 Top cover assembly REP 5 1 17 Top access cover assembly REP 5 2 N...

Page 1258: ...m 17 REP 5 15 6 022E25061 Pre scan idler 7 Base P O PL 5 10 Item 9 8 Shaft Not Spared 9 127K53780 CVT Motor MOT05 030 ADJ 5 1 10 CVT Motor tension spring silver P O PL 5 10 Item 9 11 023E25420 CVT Motor drive belt REP 5 15 ADJ 5 1 12 050E14972 Duplex gate REP 5 15 13 013E21094 Rear CVT roll bearing 14 Spacer white P O PL 5 10 Item 9 15 004E22560 CVT Motor bracket 16 Ground harness Not Spared 17 60...

Page 1259: ...id SOL05 050 REP 5 7 5 055K36641 Baffle assembly complete REP 5 5 6 022E25061 Post scan idlers 7 806E19680 Shaft 8 059K50770 Exit roll idlers 35 ppm REP 5 18 059K43910 Exit roll idlers REP 5 18 9 Bearing P O PL 5 30 Item 5 10 Document finger P O PL 5 30 Item 5 11 Torsion spring P O PL 5 30 Item 5 12 Lift bar P O PL 5 30 Item 5 13 Link arm P O PL 5 30 Item 5 14 604K48160 Mylar guide strip REP 5 20 ...

Page 1260: ... 2 Q05 320 See NOTE W TAG D 007 REP 5 9 9 Lower cover right P O PL 5 35 Item 18 40 90 ppm 10 115K02540 Static eliminator large 11 103K01511 Document width sensor Q05 325 REP 5 16 12 Bearing P O PL 5 35 Item 1 13 014E61020 Spacer black 14 Spacer white P O PL 5 35 Item 1 15 Pulley P O PL 5 35 Item 1 16 Sensor bracket P O PL 5 35 Item 1 17 059K43920 Exit roll assembly REP 5 13 18 Not used 19 130E1120...

Page 1261: ...PL 5 40 Item 1 3 Counter balance P O PL 5 40 Item 2 4 Document pad Not Spared 5 Counterbalance support Not Spared 6 Document cover bracket Not Spared 7 803E13680 Thumbscrew 8 LH Adaptor plate P O PL 5 40 Item 1 9 RH Adaptor plate P O PL 5 40 Item 1 10 Platen cover handle P O PL 5 40 Item 1 11 Magnetic interlock P O PL 5 40 Item 2 12 Cover platen P O PL 5 40 Item 2 ...

Page 1262: ...ot Spared 4 604K41020 ROS spares kit 35 ppm 604K34980 ROS spares kit 40 55 ppm 604K34950 ROS spares kit 65 90 ppm 5 962K12184 ROS Power distribution PJ120 PJ18 Communication PJ121 PJ2 PJ122 PJ109 harness 35 55 ppm ROS Power distribution PJ120 PJ18 communication PJ121 PJ2 PJ122 PJ228 harness Not Spared 65 90 ppm 6 Scanner frame securing bracket Not Spared 7 Spacer Not Spared 8 ROS P O PL 6 10 Item ...

Page 1263: ... 7 10 Item 4 13 Tray 1 and 2 paper lift plate P O PL 7 10 Item 26 PL 7 10 Item 27 14 059K59270 Paper stop assembly 15 059K59221 Lift gear kit REP 7 20 16 IOT PFM Harness PJ7 PJ382 Not Spared REP 7 13 17 025E07320 Paper tray 1 2 lift arm 18 Bearing P O PL 7 10 Item 26 PL 7 10 Item 27 19 Quadrant gear 60T P O PL 7 10 Item 15 20 Gear 13T P O PL 7 10 Item 15 21 Not used 22 Lift arm pin P O PL 7 10 Ite...

Page 1264: ...12K05690 Tray 3 elevator cable assembly REP 7 4 11 012K05701 Tray 4 elevator cable assembly REP 7 4 12 849E21140 Pulley carrier 13 Tray 3 feed sensor actuator spring P O PL 7 15 Item 9 14 004K07330 Tray 4 elevate damper assembly REP 7 11 15 004K07320 Tray 3 elevate damper assembly REP 7 11 16 038E30370 Tray lift guide 17 019E73940 Retard pad cork 18 Separation strip 7 off P O PL 7 15 Item 19 19 80...

Page 1265: ... PL 7 17 Item 3 6 604K18182 Tray 3 4 mylar retainer clip kit 7 Retainer clip Wide 6 off P O PL 7 17 Item 6 8 Retainer clip Narrow 2 off P O PL 7 17 Item 6 9 Not used 10 Paper tray guide Not Spared ADJ 7 1 11 Flexure spring Not Spared 12 009K02380 Top edge flexure spring 13 Retaining clips Not Spared 14 019K06030 HCF Tray alignment clip kit 15 Front clip P O PL 7 17 Item 14 16 Rear clip P O PL 7 17...

Page 1266: ... elevator cable tray 3 P O PL 7 18 Item 9 REP 7 24 9 604K84081 Tray 3 elevator cable kit REP 7 24 10 604K84091 Tray 4 elevator cable kit REP 7 24 11 Pulley carrier P O PL 7 18 Item 9 PL 7 18 Item 10 12 004K07622 Tray 4 elevate damper assembly REP 7 28 13 004K07690 Tray 3 elevate damper assembly REP 7 28 14 Retard pad Not Spared 15 868E87140 Tray 3 skew bracket NOTE 1 W TAG 153 16 868E87150 Tray 4 ...

Page 1267: ...3 604K83671 Tray 3 and 4 clamp kit 4 Side clamp 2 off P O PL 7 19 Item 3 5 Centre clamp P O PL 7 19 Item 3 6 Tray 4 paper tray guide P O PL 7 18 Item 2 7 Tray 3 paper tray guide P O PL 7 18 Item 3 8 019E74532 Retaining clips 9 Front clip Not Spared 10 807E47310 Elevator drives gear coupling REP 7 4 11 Tray 4 paper guide P O PL 7 18 Item 2 12 Tray 3 paper guide P O PL 7 18 Item 3 13 815E73163 Separ...

Page 1268: ...otor MOT07 030 Tray 4 elevator motor MOT07 040 REP 7 3 2 960K41522 HCF control PWB REP 7 10 3 019E63410 Switch holder 4 130E10570 Tray 3 home switch S07 303 Tray 4 home switch S07 304 REP 7 9 5 Not used 6 120E25810 Tray 4 stack limiter REP 7 8 7 868E11660 Tray 3 stack limiter bracket 8 120E25800 Tray 3 stack limiter REP 7 8 9 868E11670 Tray 4 stack limiter bracket ...

Page 1269: ...tor motor MOT07 030 Tray 4 elevator motor MOT07 040 REP 7 23 2 960K80940 HCF control PWB REP 7 27 604K95330 HCF control PWB W TAG 158 REP 7 27 NOTE 3 019E87841 Sensor holder REP 7 26 4 130E18220 Tray 3 home sensor Q07 303 Tray 4 home sensor Q07 304 REP 7 26 NOTE Install only when noise reduction is required due to noisy tray 3 and 4 feed motors and HCF motor ...

Page 1270: ...ion 1 802K48781 Rear cover 2 848K12270 Left cover 3 059K77240 Castor locking 4 848E17500 Tray 4 front cover 5 848E17490 Tray 3 front cover 6 826E20970 Screw M6 x 30 7 848E63650 Right cover 8 Cover infill 1 P O PL 7 25 Item 10 9 Cover infill 2 P O PL 7 25 Item 10 10 848E17510 Cover infill kit 11 Castor Not spared ...

Page 1271: ...Part Description 1 848E63675 Rear cover 2 848E63644 Left cover 3 059K77240 Castor locking 4 604K83651 Tray 4 front cover 5 604K83660 Tray 3 front cover 6 Castor Not spared 7 848E63650 Right cover 8 Cover infill 1 P O PL 7 26 Item 10 9 Cover infill 2 P O PL 7 26 Item 10 10 848E17510 Cover infill kit ...

Page 1272: ...r P O PL 7 30 Item 5 15 Feed roll P O PL 7 30 Item 21 REP 8 21 16 Nip roll P O PL 7 30 Item 5 17 Left hand door cover P O PL 7 30 Item 2 18 Retard pad bracket P O PL 7 30 Item 21 19 Retard pad assembly P O PL 7 30 Item 21 20 Retard pad spring P O PL 7 30 Item 21 21 059K39862 Feed roll and retard pad assembly See NOTE 2 REP 8 22 22 Solenoid spring P O PL 7 30 Item 4 23 003E78141 Interlock cover 24 ...

Page 1273: ...door NOTE 3 059K77240 Castor locking 4 848E63650 Right cover 5 802K48781 Rear cover 6 Stand base Not Spared 7 826E20970 Screw M6x30 8 Door hinge pin P O PL 7 40 Item 2 9 Cover infill 1 P O PL 7 40 Item 11 10 Cover infill 2 P O PL 7 40 Item 11 11 848E17510 Cover infill kit 12 848K12270 Left cover NOTE Hinge pins PL 7 40 Item 8 are supplied with the front door ...

Page 1274: ...E20570 Front door interlock switch S07 306 110E07300 Front door interlock switch See Note 7 Interlock switch plate Not Spared 8 848K19110 Front cover 9 802E82351 Rear cover 10 802E82363 Top cover 11 Cable clamp P O PL 7 60 Item 9 12 848E05863 Base knuckle cover 13 Front door interlock harness Not Spared 14 Tamper guide lever P O PL 7 60 Item 1 15 Tamper lever compression spring P O PL 7 60 Item 1 ...

Page 1275: ...ing latch spring P O PL 7 62 Item 16 8 Docking latch bracket P O PL 7 62 Item 16 9 Docking latch main bracket P O PL 7 62 Item 16 10 803E13680 Docking latch thumb screw See NOTE 11 068K54920 Docking plate See NOTE 12 Slide assembly Not Spared 13 Docking guides P O PL 7 62 Item 16 14 Slide assembly locking nut Not Spared 15 Docking plate assembly P O PL 31 11 Item 11 16 003K20681 Latch assembly NOT...

Page 1276: ...Not Spared 3 Latch spacer Not Spared 4 Slide latch Not Spared 5 Spring leaf Not Spared 6 Rear guide P O PL 7 64 Item 12 7 Front guide assembly Not Spared 8 038E34401 Guide strip 9 Adjustment plate P O PL 7 64 Item 13 10 Docking pin P O PL 7 64 Item 13 11 Rear guide assembly spring P O PL 7 64 Item 12 12 038K16403 Rear guide assembly 13 029K04680 Docking pin assembly ...

Page 1277: ... drive gear clip Not Spared 12 110E06961 Upper limit switch S07 412 REP 7 17 13 Rear elevator rack P O PL 7 68 Item 25 REP 7 21 14 Front elevator rack P O PL 7 68 Item 25 REP 7 21 15 Retard roller shield P O PL 8 47 Item 1 16 003K20950 Shipping handle assembly 17 Shipping pin bearing P O PL 7 68 Item 16 18 Shipping pin spring P O PL 7 68 Item 16 19 Shipping pin P O PL 7 68 Item 16 20 Shipping pin ...

Page 1278: ...t Spared 9 Lift plate crash bar actuator 2 Not Spared 10 Lift plate crash bar actuator 1 Not Spared 11 Crash bar actuator spring Not Spared 12 Not Used 13 Infill actuator arm P O PL 7 70 Item 19 14 Infill actuator arm spring P O PL 7 70 Item 19 15 Infill actuator arm pin P O PL 7 70 Item 19 16 Infill plate spring P O PL 7 70 Item 19 17 Lower safety spring Not Spared 18 612W25655 Tray down limit sw...

Page 1279: ...PL 10 20 Item 1 W TAG 046 TAG 047 Right hand cover P O PL 10 21 Item 1 W TAG 148 5 Filter Not Spared 6 Filter cover Not Spared 7 826E49310 Thumbscrew 8 Work shelf P O PL 8 10 Item 11 9 Work shelf bracket P O PL 8 10 Item 11 10 848K48881 Front door assembly 35 55 ppm 848K48893 Front door assembly REF PL 8 11 Item 10 65 90 ppm 11 Work shelf assembly kit 12 014E67571 Stand off cable holder NOTE NOTE ...

Page 1280: ...tem 10 2 Grill P O PL 8 11 Item 10 3 Paper path cooling fan 1 P O PL 8 11 Item 10 4 Cooling duct P O PL 8 11 Item 10 5 Foam seal P O PL 8 11 Item 10 6 Paper path cooling fan 2 P O PL 8 11 Item 10 7 Harness P O PL 8 11 Item 10 8 Front door P O PL 8 11 Item 10 9 Logo badge P O PL 8 11 Item 10 10 848K48893 Front door assembly 11 Door hinge pin P O PL 8 11 Item 10 ...

Page 1281: ... 8 15 Item 1 11 Gear 26T P O PL 8 15 Item 1 12 Spring arm P O PL 8 15 Item 1 13 Torsion spring P O PL 8 15 Item 1 14 Gear 28T P O PL 8 15 Item 1 15 Ring pitch P O PL 8 15 Item 1 16 Black nylon washer P O PL 8 15 Item 1 17 Gear 22G 28T P O PL 8 15 Item 1 ADJ 4 1 18 Gear 23T P O PL 8 15 Item 1 ADJ 4 1 19 Gear 22G 20T P O PL 8 15 Item 1 20 Drive belt P O PL 8 15 Item 1 REP 8 27 21 Spring arm pin P O ...

Page 1282: ...P O PL 8 17 Item 1 11 Gear 26T P O PL 8 17 Item 1 12 Spring arm P O PL 8 17 Item 1 13 Torsion spring P O PL 8 17 Item 1 14 Gear 28T P O PL 8 17 Item 1 15 Ring pitch P O PL 8 17 Item 1 16 Black nylon washer P O PL 8 17 Item 1 17 Gear 22G 28T P O PL 8 17 Item 1 ADJ 4 1 18 Gear 23T P O PL 8 17 Item 1 ADJ 4 1 19 Gear 22G 20T P O PL 8 17 Item 1 20 Drive belt P O PL 8 17 Item 1 REP 8 27 21 Spring arm pi...

Page 1283: ... 20 Item 1 7 Nip roll shaft P O PL 8 20 Item 1 8 127K62340 Duplex motor MOT08 060 REP 8 8 9 960K32880 Duplex motor driver PWB REP 8 8 10 Drive pulley P O PL 8 20 Item 1 11 Lower cover P O PL 8 20 Item 1 12 Duplex duct P O PL 8 20 Item 1 13 Duplex nip roll shaft P O PL 8 20 Item 1 14 059K49400 Nip roll assembly 15 Bearing P O PL 8 20 Item 1 16 Duplex drive roll shaft P O PL 8 20 Item 17 W O TAG 051...

Page 1284: ...0760 Jam clearance latch 6 Spring P O PL 8 22 Item 1 7 Nip roll shaft P O PL 8 22 Item 1 8 127K53190 Duplex motor MOT08 060 REP 8 8 9 960K52720 Duplex motor driver PWB REP 8 8 10 Drive pulley P O PL 8 22 Item 1 11 Lower cover P O PL 8 22 Item 1 12 Duplex nip roll shaft P O PL 8 22 Item 1 13 059K49400 Nip roll assembly 14 Bearing P O PL 8 22 Item 1 15 Duplex drive roll shaft P O PL 8 22 Item 16 W O...

Page 1285: ...t drive belt REP 8 12 3 020E54150 Pulley 4 020E48680 Pulley idler 5 127K61842 Transport roll drives motor MOT08 025 6 013E37480 Rear transport roll bearing REP 8 16 7 013E37490 Front transport roll bearing REP 8 16 8 059K70070 Transport roll NOTE 9 962K64030 Power harness 10 962K64020 Signal harness 11 120E36130 Cable holder 12 962K64040 Connection harness NOTE HFSI To reset the HFSI count refer t...

Page 1286: ...tard roll P O PL 8 26 Item 3 5 Feed Nudger roll assembly P O PL 8 26 Item 3 6 127K61850 Feed elevator motor MOT08 010 MOT08 020 7 130E12770 Tray empty sensor Q07 331 Q07 342 8 130E12790 Tray 1 stack height sensor Q07 336 Tray 2 stack height sensor Q07 337 9 Guide P O PL 8 26 Item 1 10 014E67650 Shim sensor 11 809E84180 Retard roll gate spring 12 Retard roll gate P O PL 8 26 Item 1 13 Clutch coupli...

Page 1287: ... P O PL 8 30 Item 16 12 Spring P O PL 8 30 Item 16 13 Drive coupling P O PL 8 30 Item 16 14 Tray 3 and 4 transport motor bracket Not Spared 15 130E12510 Tray 3 feed sensor Q08 103 See NOTE 1 REP 8 28 16 005E21801 Drive coupling assembly 17 809E94510 Ground plate 35 55 ppm 18 059K58620 Tray 3 and 4 transport roll 35 55 ppm NOTE 2 REP 8 31 ADJ 4 1 059K50120 Tray 3 and 4 transport roll 65 90 ppm REP ...

Page 1288: ...ft P O PL 8 31 Item 11 6 Bearing P O PL 8 31 Item 11 7 Idler roll P O PL 8 31 Item 11 8 Spring P O PL 8 31 Item 11 9 Tray 4 feed sensor bracket P O PL 8 31 Item 12 10 604K48620 Tray 3 and 4 multifeed roll fix kit rough tread rolls W TAG 110 11 006K29490 Idler shaft assembly 12 130K75380 Tray 4 feed sensor assembly Q08 104 13 130E12060 Stack height sensor 14 604K95360 Tray 3 and 4 multifeed roll sp...

Page 1289: ...k height sensor Q07 383 P O PL 31 13 Item 21 REP 8 48 8 110E21540 Tray 3 over elevate switch 9 Tray 3 paper guide P O PL 8 32 Item 1 REP 8 55 10 Tray 3 feed motor MOT08 030 P O PL 8 32 Item 1 11 Feed roll assembly P O PL 31 13 Item 14 See NOTE REP 8 54 12 Nudger roll P O PL 8 32 Item 11 REP 8 54 ADJ 8 4 13 Feed frame assembly P O PL 8 32 Item 1 REP 8 40 14 Earth cable P O PL 8 32 Item 1 15 Support...

Page 1290: ...nsor bracket Not Spared 5 Spring Not Spared 6 Tray 4 stack height sensor Q07 384 P O PL 31 13 Item 21 REP 8 51 7 110E21540 Tray 4 over elevate switch 8 Tray 4 feed motor Q08 040 P O PL 8 33 Item 1 9 Feed roll assembly P O PL 31 13 Item 14 See NOTE REP 8 54 10 Nudger roll P O PL 8 33 Item 9 REP 8 54 ADJ 8 4 11 Tray 4 paper guide P O PL 8 33 Item 1 REP 8 56 12 Sensor mounting P O PL 8 33 Item 1 REP ...

Page 1291: ...2E26620 Transport roll bearing 4 Flange P O PL 8 35 Item 15 5 Pulley P O PL 8 35 Item 15 6 023E24440 Drive belt 7 Drive coupling P O PL 8 30 Item 16 8 022E26630 Transport roll REP 8 30 9 Shaft Not Spared 10 Spring P O PL 8 35 Item 15 REP 8 30 11 059K50110 Transport roll assembly REP 8 30 ADJ 4 1 12 022E26640 Idler roll 13 Spring plate P O PL 8 35 Item 15 14 Base P O PL 8 35 Item 15 15 059K43830 Tr...

Page 1292: ...lt P O PL 8 36 Item 16 REP 8 57 7 Drive coupling P O PL 31 12 Item 16 REP 8 46 8 059K85140 Idler roll assembly metal shaft REP 8 46 Idler roll assembly plastic shaft Not spared REP 8 46 9 Spring P O PL 8 36 Item 11 10 Base P O PL 8 36 Item 11 11 038K23512 Tray 3 transport assembly REP 8 44 12 Transport gear pulley P O PL 8 36 Item 16 REP 8 43 13 HCF transport motor MOT08 045 P O PL 8 36 Item 16 RE...

Page 1293: ...0 Item 3 6 Not used 7 423W09050 Drive belt REP 8 33 8 Upper limit actuator spring Not Spared 9 Upper limit actuator Not Spared 10 Belt tensioner Not Spared 11 Belt tensioner spring Not Spared 12 Not used 13 125E00430 ESD brush 14 Transport motor harness Not Spared 15 Tray 5 upper feeder assembly harness Not Spared 16 962K50475 Elevator motor harness 17 962K63351 IOT to tray 5 harness 18 Not used 1...

Page 1294: ... 22 W TAG P 002 Nudger roll Not Spared W O TAG P 002 11 Upper feed assembly top cover P O PL 8 45 Item 1 12 Feed roll P O PL 8 45 Item 20 PL 8 45 Item 22 W TAG P 002 Feed roll Not Spared W O TAG P 002 13 Clutch P O PL 8 45 Item 20 14 Gear 38T P O PL 8 45 Item 1 15 Roller belt P O PL 8 45 Item 1 16 Washer P O PL 8 45 Item 1 17 Torsion chute spring P O PL 8 45 Item 1 18 Housing spring P O PL 8 45 It...

Page 1295: ...8 47 Item 1 4 One way pulley clutch P O PL 8 47 Item 1 5 Take away roller P O PL 31 13 Item 4 REP 8 38 6 Bearing P O PL 8 47 Item 1 7 Clutch P O PL 8 45 Item 20 W TAG P 002 005E29040 Clutch W O TAG P 002 8 Torsion retard spring P O PL 8 47 Item 1 9 Retard roller shaft P O PL 8 47 Item 1 10 Lower feed assembly base P O PL 8 47 Item 1 11 Clutch coupling P O PL 8 45 Item 20 W TAG P 002 Clutch couplin...

Page 1296: ...6 Waste toner bottle 2 130K74702 Waste toner full sensor Q09 350 REP 9 4 3 802E93283 Waste toner door REP 9 1 4 003E77450 Strap NOTE 5 803E03180 Hinge block 6 Waste toner door switch S09 380 REF PL 4 10 Item 8 PL 4 15 Item 8 7 Sensor cover Not Spared 8 848E96690 Toner cover NOTE Refer to REP 9 1 for the waste toner bottle assembly ...

Page 1297: ...or kit 14 Push on fastener P O PL 9 15 Item 24 15 Spring P O PL 9 15 Item 24 16 Main drive gear P O PL 9 15 Item 23 See NOTE 2 17 Not used 18 Toner dispense module kit REF PL 31 12 Item 21 19 604K24570 Trickle outlet shutter kit 20 Shutter assembly P O PL 9 15 Item 19 21 Shutter spring P O PL 9 15 Item 19 22 Push on fastener P O PL 9 15 Item 19 23 604K24930 Developer Drives interface kit See NOTES...

Page 1298: ...4K16890 Out of toner sensor kit 14 Push on fastener P O PL 9 17 Item 23 15 Spring P O PL 9 17 Item 23 16 Sleeve P O PL 9 17 Item 23 17 Toner cartridge latch P O PL 9 17 Item 23 18 Not used 19 604K24570 Trickle outlet shutter kit 20 Shutter assembly P O PL 9 17 Item 19 21 Shutter spring P O PL 9 17 Item 19 22 Push on fastener P O PL 9 17 Item 19 23 604K30560 Developer latch repair kit 24 Developer ...

Page 1299: ...5E54960 Erase lamp support 7 Xerographic module latch P O PL 9 20 Item 17 REP 9 6 8 504K12320 Transfer Detack corotron NOTE 1 ADJ 9 1 9 113K03330 Transfer Detack harness 10 802E87941 Pivot plate 11 Latch spring P O PL 9 20 Item 17 12 Latch pin P O PL 9 20 Item 17 13 Latch plate Not Spared 14 031E11102 Developer paddle REP 9 7 15 809E69220 Spring 16 Curly clip Not Spared 17 604K41120 Developer latc...

Page 1300: ...port 7 Xerographic module latch P O PL 9 22 Item 18 REP 9 6 8 504K12310 Transfer Detack corotron NOTE 1 ADJ 9 1 9 113K03330 Transfer Detack harness REP 9 8 10 Not used 11 Latch spring P O PL 9 22 Item 18 12 Latch pin P O PL 9 22 Item 18 13 Latch plate Not Spared 14 031E11102 Developer paddle REP 9 7 15 809E69220 Spring 16 802E87941 Pivot plate 17 Curly clip Not Spared 18 604K41120 Developer latch ...

Page 1301: ...an and Photoreceptor Fan Item Part Description 1 127K42790 Ozone fan REP 9 3 2 054E33051 Ozone duct 3 053K04960 Ozone filter 4 Magnet P O PL 9 25 Item 2 5 Photoreceptor duct P O PL 9 25 Item 6 6 127K53200 Photoreceptor fan assembly 7 Fan P O PL 9 25 Item 6 8 054E33001 Lower duct ...

Page 1302: ...P 10 10 6 Fuser latch pin P O PL 10 8 Item 10 7 Spring P O PL 10 8 Item 10 8 Latch stop P O PL 10 8 Item 10 9 Screw P O PL 10 10 Item 10 10 604K35371 Fuser latch pin kit 11 110E20190 Fuser exit switch S10 100 REP 10 16 12 Fuser upper exit guide P O PL 10 8 Item 1 13 Fuser top cover P O PL 10 8 Item 1 14 Lower input guide Not Spared 15 Lamp P O PL 10 8 Item 1 NOTE 1 An ozone filter PL 9 25 Item 3 i...

Page 1303: ... 10 10 6 Fuser latch pin P O PL 10 10 Item 10 7 Spring P O PL 10 10 Item 10 8 Latch stop P O PL 10 10 Item 10 9 Screw P O PL 10 10 Item 10 10 604K35371 Fuser latch pin kit 11 110K20910 Fuser exit switch S10 100 REP 10 16 12 Fuser upper exit guide P O PL 10 10 Item 1 13 Fuser top cover P O PL 10 10 Item 1 14 Lower input guide Not Spared 15 Lamp P O PL 10 10 Item 1 NOTE 1 An ozone filter PL 9 25 Ite...

Page 1304: ...4390 Inverter path solenoid SOL10 045 REP 10 4 15 Not used 16 Not used 17 Inverter nip solenoid bracket P O PL 10 11 Item 25 18 Solenoid link P O PL 10 11 Item 23 19 Bearing P O PL 10 11 Item 25 20 Thermistor assembly Not Spared 65 90 ppm W O TAG 120 21 Inverter locator Not Spared W O TAG 046 TAG 047 22 960K32891 Inverter motor driver PWB 65 90 ppm 960K41881 Inverter motor driver PWB 35 55ppm 23 I...

Page 1305: ...avity gate finger P O PL 10 11 Item 23 W O TAG 005 Rear gravity gate finger P O PL 10 12 Item 25 W TAG 005 14 Upper baffle P O PL 10 12 Item 22 PL 10 12 Item 23 15 Idler roll P O PL 10 12 Item 22 PL 10 12 Item 23 16 Idler roll shaft P O PL 10 12 Item 22 PL 10 12 Item 23 17 Spring P O PL 10 12 Item 22 PL 10 12 Item 23 18 Post fuser jam clearance latch REF PL 10 15 Item 11 19 Inverter sensor P O PL ...

Page 1306: ... 55 ppm P O PL 10 11 Item 23 4 806E41911 Exit shaft assembly W O TAG 046 TAG 047 REP 10 14 Exit shaft assembly W TAG 046 TAG 047 REP 10 14 5 013E36980 Bearing 6 Exit gear REF PL 10 15 Item 1 7 Baffle guide 65 90 ppm P O PL 10 11 Item 23 8 Decurler roll P O PL 10 13 Item 9 NOTE W TAG 046 TAG 047 9 604K55120 Decurler soft roll repair kit NOTE W TAG 046 TAG 047 NOTE The decurler roll is only to be in...

Page 1307: ...r assembly Not Spared 65 90 ppm 3 Nip roller Not Spared 4 Solenoid ramp Not Spared 65 90 ppm 5 Jam clearance knob REF PL 10 15 Item 13 6 Bearing Not Spared 7 Gear 24T REF PL 10 15 Item 9 8 Gear assembly REF PL 10 15 Item 8 9 Upper inverter drive shaft P O PL 10 14 Item 11 W O TAG 051 10 Lower inverter drive shaft P O PL 10 14 Item 11 W O TAG 051 11 604K55570 Drive roll repair kit W TAG 051 ...

Page 1308: ... 807E15790 Idler gear 20T 5 807E15780 Idler gear 19T 6 007K19670 Dog drive assembly 7 807E15770 Post fuser gear 20T 8 807E15820 Gear assembly 9 807E15850 Gear 24T 10 807E15840 Gear 21T 11 003K20990 Post fuser jam clearance latch 12 003E77261 Tri roll knob 13 003E77271 Jam clearance knob 14 003E77251 Latch cam handle 15 Inverter motor gear 35 55 ppm REF PL 10 11 Item 11 Inverter motor gear 65 90 pp...

Page 1309: ...914 Inverter decurler kit 35 55 ppm W TAG 046 REP 10 2 2 Retaining ring P O PL 10 20 Item 1 3 Adjuster P O PL 10 20 Item 1 4 Support bracket P O PL 10 20 Item 1 5 604K60872 Inverter decurler assembly 35 55ppm 6 Screw M4x8 P O PL 10 20 Item 1 604K60802 Inverter decurler assembly 65 90 ppm 7 Shoulder screw M4x12 P O PL 10 20 Item 1 NOTE The inverter decurler soft roll repair kit is shown on PL 10 13...

Page 1310: ...P O PL 10 21 Item 1 6 Shoulder screw M4x12 P O PL 10 21 Item 1 7 Rear inverter bush P O PL 10 21 Item 1 8 Tie bar P O PL 10 21 Item 1 9 Right hand cover P O item 1 WARNING 10 Mounting bracket P O PL 10 21 Item 1 11 OCT transport assembly P O PL 10 21 Item 1 12 OCT tray P O PL 10 21 Item 1 13 962K96240 Inverter jumper harness WARNING Do not use the W TAG 148 right hand cover with an output device o...

Page 1311: ...Intermediate drive assembly P O PL 10 25 Item 1 8 807E15940 Gear Pulley 28T 25G 9 Gear Pulley P O PL 10 25 Item 1 16T 30G 10 Intermediate drive belt P O PL 10 25 Item 1 REP 10 15 11 604K55570 Drive roll repair kit W TAG 051 12 Ozone duct P O PL 10 25 Item 1 13 Push rod P O PL 10 25 Item 1 14 Ground harness P O PL 10 25 Item 1 15 Base P O PL 10 25 Item 1 16 Roll assembly P O PL 10 25 Item 11 17 Cor...

Page 1312: ...castor 6 017K04520 Adjustable castor 7 Output cover Not Spared 8 802K48320 Lower right hand cover 9 050K67380 Bin 0 10 050K68490 Bin 1 W O TAG F 013 ADJ 11 1 110 11 848K06180 Rear cover assembly REP 11 1 110 12 Upper right hand cover Not Spared 13 019K13380 Bin 1 alignment clip 14 2K LCSS front door cover assembly kit REF PL 31 12 Item 10 15 Hole punch assembly cover Not Spared 16 604K48150 Bin 1 ...

Page 1313: ...cking Latch Item Part Description 1 Sensor cover Not Spared 2 110K13980 Docking interlock switch S11 300 3 003K20401 Link bracket assembly 4 Stopper Not Spared 5 Docking latch P O PL 11 4 Item 8 6 Not used 7 120K02590 Docking actuator 8 003K20410 Docking latch assembly REP 11 16 110 ...

Page 1314: ...humb Screw Not Spared 6 Bracket P O PL 11 6 Item 14 7 130E10380 Punch Sensor Q11 110 Chad Bin Full Sensor Q11 348 REP 11 7 110 8 Sensor Bracket Not Spared 9 LCSS Hole Punch Repair Kit REF PL 31 14 Item 7 W TAG F 006 ADJ 11 3 110 604K53830 LCSS Hole Punch Repair Kit W TAG F 014 ADJ 11 3 110 10 Bracket P O PL 11 6 Item 9 W TAG F 014 Bracket P O PL 11 6 Item 9 W TAG F 006 11 Punch Drive Gear P O PL 1...

Page 1315: ...y Not spared W O TAG F 016 REP 11 12 110 006K27952 Paddle wheel shaft assembly W TAG F 016 5 013E25790 Bearing 6 Gear Not Spared 7 Flag Not Spared 8 Cable clamp Not Spared 9 Output cover REF PL 11 2 Item 7 10 127K55881 Paddle motor assembly MOT11 024 11 130E10360 Paddle roll position sensor Q11 326 12 Shaft P O PL 11 8 Item 4 W TAG F 016 13 Paddle P O PL 11 8 Item 4 NOTE W TAG F 016 NOTE Paddles a...

Page 1316: ...er limit switch S11 334 110K13990 Upper limit switch alternate S11 334 4 Sensor bracket Not Spared 5 130E10360 Bin 1 90 full sensor Q11 331 6 Pulley Not Spared 7 013E25810 Bearing 8 127K55890 Bin 1 elevator motor MOT11 030 9 Front belt clamp Not Spared ADJ 11 1 110 10 Motor bracket Not Spared 11 130E12330 Motor encoder sensor Q11 336 12 Pulley assembly Not Spared 13 Belt tensioner Not Spared 14 Sp...

Page 1317: ...12 2K LCSS Bin 1 Control Components 2 of 2 Item Part Description 1 110K13990 Bin 1 lower limit switch S11 335 2 Not used 3 130E10360 Bin 1 Upper level sensor Q11 332 Bin 1 Lower level sensor Q11 333 REP 11 11 110 4 Actuator Not Spared 5 Sensor support assembly Not Spared ...

Page 1318: ...ption 1 023E24340 Input drive belt REP 11 2 110 2 127K55860 Transport motor 1 MOT11 000 REP 11 2 110 3 Spring Not Spared 4 Pulley Not Spared 5 013E25790 Nylon bearing 6 006K27980 Feed roll shaft short 7 013E25800 Bearing 8 Jam clearance guide P O PL 11 24 Item 1 9 006K31670 Feed roll shaft long 10 Thumb wheel Not Spared ...

Page 1319: ...tion 1 068K54280 Tamper assembly REP 11 6 110 2 Tamper unit P O PL 11 16 Item 1 3 130E10360 Front tamper home sensor Q11 310 Rear tamper home sensor Q11 006 Rear tamper home away sensor Q11 319 4 Sensor bracket P O PL 11 16 Item 1 5 Static eliminator stacker REF PL 11 23 Item 7 6 Sensor retainer P O PL 11 16 Item 1 ...

Page 1320: ... Q11 322 Ejector motor encoder sensor REP 11 10 110 4 Pulley Not Spared 5 023E24330 Ejector belt REP 11 17 110 6 Clip P O PL 11 18 Item 1 7 019K13390 Support finger set Qty 4 8 020K21490 Pulley drive gear 9 Washer Not Spared 10 Spring P O PL 11 18 Item 1 11 Shaft P O PL 11 18 Item 1 12 Slide ejector bearing P O PL 11 18 Item 15 13 Wide slide ejector bearing P O PL 11 18 Item 15 14 Cushion washer P...

Page 1321: ...F PL 31 12 Item 9 REP 11 8 110 2 Head traverse unit P O PL 11 20 Item 1 3 130E10360 SU1 Home sensor Q11 370 SU1 Front index sensor Q11 371 4 130E10380 SH1 Paper sensor Q11 361 5 029K04520 Staple head unit REP 11 9 110 6 Stapler cover P O PL 11 20 Item 1 7 Staple cartridge REF PL 26 10 Item 11 8 Not used 9 Sensor cover P O PL 11 20 Item 1 10 Staple head assembly P O PL 11 20 Item 1 ...

Page 1322: ... REP 11 4 110 6 Spring Not Spared 7 115E12830 Static eliminator 8 006K27980 Feed roll shaft short 9 013E25800 Bearing 10 032K04580 Paper guide 11 130E10370 Top exit sensor Q11 130 12 121K45010 Diverter solenoid SOL11 002 13 Shaft diverter assembly P O PL 31 13 Item 6 W TAG F 017 14 023E24340 Paper output drive belt REP 11 4 110 15 006K27970 Drive shaft assembly 16 003K17531 Jam clearance knob 17 B...

Page 1323: ...0 Lower right hand paper guide 3 006K27960 Ejector drive shaft REF PL 11 22 Item 1 4 130E10370 2nd to top exit sensor Q11 140 5 013E25790 Nylon bearing 6 Pulley Not Spared 7 115E11810 Static eliminator stacker 8 Paper output drive belt REF PL 11 22 Item 14 9 Upper right hand paper guide Not Spared 10 013E25800 Bearing 11 Mylar safety cover P O PL 11 23 Item 1 ...

Page 1324: ...Cover Jam Clearance Guide Item Part Description 1 032K04600 Paper entry guide assembly 2 Jam clearance handle P O PL 11 24 Item 1 3 130E10380 Entry sensor Q11 100 4 Sensor bracket Not Spared 5 848K06160 Entry guide cover REP 11 15 110 6 Jam clearance guide P O PL 11 24 Item 1 7 809E78390 Latch ...

Page 1325: ...110 2 105K35842 Power supply module 3 960K34490 Offline staple PWB S11 373 4 962K56951 Cord bracket assembly 5 110K13980 Front door interlock switch S11 303 6 110K13970 Top cover interlock switch S11 302 CAUTION Do not install a new 2K LCSS PWB until the cause of the damage to the old 2K LCSS PWB has been determined Go to the 11G 110 2K LCSS PWB Damage RAP ...

Page 1326: ... 1 120 5 1K LCSS mounting bracket repair kit 6 Thumbscrew Not Spared 7 Output cover Not Spared 8 Not used 9 050K67380 Bin 0 10 050K68490 Bin 1 W O TAG L 013 ADJ 11 1 120 604K48150 Bin 1 tray kit improved stacking W TAG L 013 11 848K06140 Rear cover REP 11 1 120 12 Right hand cover Not Spared 13 019K13380 Bin 1 alignment clip 14 017E11260 Stability foot REP 11 3 120 NOTE W TAG L 013 improves stacki...

Page 1327: ...ion 1 Sensor cover P O PL 11 102 Item 8 2 110K13980 Docking interlock switch S11 300 REP 11 14 120 3 003K20401 Link bracket assembly REP 11 14 120 4 Not used 5 Docking latch P O PL 11 102 Item 8 REP 11 14 120 6 Spring P O PL 11 102 Item 8 7 120K02590 Docking actuator 8 003K20391 Docking latch assembly REP 11 14 120 ...

Page 1328: ...11 NOTE W TAG L 016 3 Not used 4 006K30491 Paddle wheel shaft assembly W O TAG L 016 REP 11 10 120 006K34580 Paddle wheel shaft assembly W TAG L 016 5 013E25790 Bearing 6 Not used 7 Flag Gear Not Spared 8 Not used 9 Output cover REF PL 11 100 Item 7 10 127K55840 Paddle motor assembly MOT11 024 11 130E12330 Paddle roll position sensor Q11 326 NOTE Paddles are also supplied 4 off as a kit PL 31 13 I...

Page 1329: ...Not Spared 5 130E12330 Bin 1 90 full sensor Q11 331 Bin 1 upper level sensor Q11 332 REP 11 9 120 Motor encoder sensor Q11 336 6 Pulley Not Spared 7 013E25810 Bearing 8 127K55890 Bin 1 elevator motor MOT11 030 9 Front belt clamp Not Spared ADJ 11 1 120 10 Motor bracket Not Spared 11 110K13990 Bin 1 lower limit switch S11 335 12 Pulley assembly Not Spared 13 Sensor support Not Spared 14 P clamp Not...

Page 1330: ...on 1 023E30690 Input drive belt REP 11 2 120 2 127K55820 Transport motor 1 MOT11 000 REP 11 2 120 3 Spring Not Spared 4 Pulley Not Spared 5 013E25790 Nylon bearing 6 006K27980 Feed roll shaft short 7 013E25800 Bearing 8 Paper entry guide assembly REF PL 11 122 Item 1 9 006K31670 Feed roll shaft long 10 Thumb wheel Not Spared ...

Page 1331: ...ion 1 068K54270 Tamper assembly REP 11 6 120 2 Tamper unit P O PL 11 112 Item 1 3 130E12330 Front tamper home sensor Q11 310 Rear tamper home sensor Q11 006 Rear tamper home away sensor Q11 319 4 Sensor bracket P O PL 11 112 Item 1 5 Static eliminator stacker REF PL 11 120 Item 7 6 Sensor retainer P O PL 11 112 Item 1 ...

Page 1332: ...0 Ejector assembly REP 11 8 120 2 Ejector base P O PL 11 114 Item 1 3 130E12330 Ejector home sensor Q11 320 Ejector out sensor Q11 322 Ejector motor encoder sensor REP 11 8 120 4 Pulley Not Spared 5 023E24330 Ejector belt REP 11 15 120 6 Clip P O PL 11 114 Item 1 7 020K21490 Pulley drive gear 8 Washer Not Spared 9 KL Clip Not Spared ...

Page 1333: ...1 014K10100 Stapler assembly 2 Mounting bracket P O PL 11 116 Item 1 3 Stapler harness P O PL 11 116 Item 1 4 130E10380 SH1 Paper sensor Q11 361 REP 11 7 120 5 Staple head unit P O PL 11 116 Item 1 6 Stapler cover P O PL 11 116 Item 1 7 Cable clamp P O PL 11 116 Item 1 8 Staple cartridge Not Spared 9 Staple refills Not Spared ...

Page 1334: ... paper drive belt 5 Spring Not Spared 6 Spring Not Spared 7 115E12830 Static eliminator 8 006K27980 Feed roll shaft short 9 013E25800 Bearing 10 032K04550 Paper guide 11 130E11440 Top exit sensor Q11 130 12 121K45290 Diverter solenoid SOL11 002 13 Shaft diverter assembly P O PL 31 13 Item 6 W TAG L 003 14 Belt tensioner Not Spared 15 006K27970 Drive shaft assembly 16 003K17531 Jam clearance knob 1...

Page 1335: ...ve shaft REF PL 11 118 Item 1 4 130E11440 2nd to top exit sensor Q11 140 5 013E25790 Nylon bearing 6 Pulley Not Spared 7 115E11810 Static eliminator stacker 8 023E24340 Paper output drive belt REP 11 4 120 9 Upper right hand paper guide Not Spared 10 013E25800 Bearing 11 Belt tensioner Not Spared 12 Spring Not Spared 13 127K55830 Transport motor 2 MOT 11 001 REP 11 4 120 14 Mylar safety cover P O ...

Page 1336: ...Cover Jam Clearance Guide Item Part Description 1 032K04600 Paper entry guide assembly 2 Jam clearance handle P O PL 11 122 Item 1 3 130E10380 Entry sensor Q11 100 4 Sensor bracket Not Spared 5 848K06160 Entry guide cover REP 11 13 120 6 Jam clearance guide P O PL 11 122 Item 1 7 809E78390 Latch ...

Page 1337: ...assembly 5 110K13980 Front door interlock switch S11 303 6 110K13970 Top cover interlock switch S11 302 7 1K LCSS communication harness P O PL 11 124 Item 4 8 Power cord P O PL 11 124 Item 4 9 Lower bracket P O PL 11 124 Item 4 10 Upper bracket P O PL 11 124 Item 4 11 Screw P O PL 11 124 Item 4 CAUTION Do not install a new 1K LCSS PWB until the cause of the damage to the old LCSS PWB has been dete...

Page 1338: ...EP 11 1 171 6 848K12530 Vent cover REP 11 1 171 7 848E17800 Foot cover REP 11 1 171 8 848E17810 Inserter removable cover REP 11 1 171 9 848K12540 Top tray REP 11 3 171 10 Seal Not Spared 11 017K04830 Fixed castor assembly REP 11 96 171 12 Fixed castor bracket P O PL 11 130 Item 11 13 017K04630 Adjustable castor REP 11 96 171 14 Adjustable castor washer P O PL 11 130 Item 13 15 017K04640 Mounting b...

Page 1339: ...Spared 9 Main belt tensioner Not Spared 10 127K56591 Bin 1 elevator motor assembly REP 11 12 171 11 Bin 1 rear lift bar bracket Not Spared 12 Bin 1 front lift bar bracket Not Spared 13 Bin 1 lift bar Not Spared 14 Front main belt clamp 2 of 2 Not Spared 15 Front main belt clamp 1 of 2 Not Spared 16 050E23670 Bin 1 REP 11 4 171 17 Not used 18 Not used 19 848E17830 Middle right side cover 20 019K133...

Page 1340: ...r Q11 187 Offset away sensor Q11 176 16 130K75470 Bin 1 upper level sensor receiver Q11 332 REP 11 76 171 17 130K75900 Bin 1 rear wall sensor Q11 196 18 127K56550 Motor encoder assembly 19 127K56580 Bin 1 offset motor MOT11 034 REP 11 9 171 20 130K75480 Bin 1 upper level sensor transmitter Q11 332 REP 11 76 171 21 032E35301 Rear tamper arm W O TAG V 006 Rear tamper arm reinforced P O PL 11 140 Ite...

Page 1341: ...OT11 083 REP 11 51 171 14 Pinion gear Not Spared 15 Pinion gear shaft Not Spared 16 130E12830 Paper pusher upper sensor Q11 171 Paper pusher lower sensor Q11 173 REP 11 54 171 17 Stapler gate safety switch S11 365 P O PL 11 145 Item 22 18 Sensor screw P O PL 11 145 Item 22 19 Sensor assembly bracket P O PL 11 145 Item 22 20 Lower exit guide Not Spared 21 Pusher dampers P O PL 11 145 Item 8 22 674K...

Page 1342: ...ed motor MOT11 080 REP 11 64 171 3 Solenoid bracket P O PL 11 150 Item 4 4 121K45290 BM diverter solenoid SOL11 074 ADJ 11 14 171 Exit diverter solenoid SOL11 002 Buffer clamp solenoid SOL11 082 5 Solenoid connector Not Spared 6 127K56610 Paddle module driving motor assembly REP 11 48 171 7 Entry feed motor 1 belt Not Spared 8 Bypass feed motor belt Not Spared 9 Buffer feed motor belt Not Spared 1...

Page 1343: ...BM diverter gate P O PL 31 14 Item 11 W TAG V 008 REP 11 39 171 10 059K59531 Buffer pocket jam clearance guide 11 059K59540 Inserter jam clearance guide assembly 8a 12 059K59521 Input jam clearance guide 5a 13 059K59510 Buffer guide assembly 5b 14 Nip split motor cover P O PL 11 153 Item 13 15 Nip split motor MOT11 081 P O PL 11 153 Item 13 16 121K45300 Magnet 17 130E12810 Paper edge sensor NOTE 1...

Page 1344: ... 3 Buffer lower roll REF PL 11 155 Item 1 REP 11 44 171 4 Inserter guide roll REF PL 11 155 Item 1 REP 11 41 171 5 Booklet entrance roll REF PL 11 155 Item 1 REP 11 43 171 6 Buffer pocket roll REF PL 11 155 Item 1 REP 11 42 171 7 019K13660 Buffer clamp 8 Input roll REF PL 11 155 Item 1 REP 11 40 171 9 Bearing Not Spared 10 006K32690 Stacker exit roll 11 Top exit roll Not Spared 12 Top exit feed ro...

Page 1345: ...sor Q11 310 Front tamper tray away sensor Q11 174 Nip split sensor Q11 170 Nip home sensor Q11 159 2 130E12810 Entry sensor Q11 100 2nd to top exit sensor Q11 140 Buffer position sensor Q11 157 Buffer path sensor Q11 164 Inserter sensor NOTE 3 130E12840 Top exit sensor Q11 130 Booklet exit sensor Q11 158 NOTE There is no component code number for the Inserter sensor ...

Page 1346: ...nd Control Item Part Description 1 105K30211 HVF power supply unit REP 11 55 171 2 960K41772 HVF control PWB REP 11 57 171 3 960K41780 Pause to unload PWB REP 11 97 171 4 105K36840 Power cord 5 Inline fuse 10A slo blow Not Spared 6 Harness Not Spared 7 952K00410 Power communications cable ...

Page 1347: ...May 2013 5 105 Xerox WorkCentre 5790 Family PL 11 160 Parts Lists PL 11 160 HVF BM Module Complete Item Part Description 1 801K27251 BM Module REP 11 61 171 2 010K04360 Slide assembly REP 11 62 171 ...

Page 1348: ...REP 11 60 171 12 130K74072 Flapper home sensor Q11 391 P O PL 11 161 Item 30 REP 11 16 171 13 Bearing Not Spared 14 020E39990 BM Entry roll pulley REP 11 22 171 15 006K28660 BM Entry roll REP 11 22 171 16 130K74110 BM Entry sensor Q11 160 REP 11 23 171 17 125E00430 Static eliminator 18 Rear latch Not Spared 19 Shaft Not Spared 20 809E46411 Latch spring 21 Front latch Not Spared 22 Entrance baffle ...

Page 1349: ...10 REP 11 30 171 7 BM Rear tamper rack P O PL 11 162 Item 9 REP 11 30 171 8 BM Front tamper rack P O PL 11 162 Item 10 REP 11 30 171 9 007K13190 BM Rear tamper assembly REP 11 30 171 10 007K13180 BM Front tamper assembly REP 11 30 171 11 807E15450 BM Tamper gear REP 11 30 171 12 BM Tamper bracket Not Spared REP 11 30 171 13 BM Tamper rack guide Not Spared REP 11 30 171 14 802E59410 BM Connector co...

Page 1350: ...300 BM back stop drive belt REP 11 20 171 8 809E78370 BM back stop tensioner spring REP 11 20 171 9 Allen key 3mm Not Spared 10 802E59180 Sensor cover 11 BM back stop bearing Not Spared REP 11 26 171 12 BM back stop idler bracket Not Spared REP 11 26 171 13 BM back stop idler shaft Not Spared 14 BM back stop tensioner link Not Spared 15 809E25100 BM back stop link spring REP 11 26 171 16 012E20870...

Page 1351: ... 17 6 Flanged hex nut P O PL 11 164 Item 17 7 Back stop adjust spring P O PL 11 164 Item 17 8 809E71970 Anti play spring 9 Solenoid spring P O PL 11 164 Item 17 10 Shaft support Not Spared 11 Belt clamp P O PL 11 164 Item 17 12 BM back stop solenoid nut P O PL 11 164 Item 17 13 Pivoting clamp P O PL 11 164 Item 17 14 006K30790 BM back stop drive shaft REP 11 26 171 15 023E23140 BM back stop belt R...

Page 1352: ... BM Crease blade motor assembly MOT11 061 REP 11 18 171 4 014E47460 Motor encoder REP 11 18 171 5 Drive shaft Not Spared 6 007E69830 Drive gear 7 413W30654 Bearing REP 11 18 171 8 008E08220 Crank REP 11 18 171 9 012E20860 Connecting rod REP 11 36 171 10 Bearing Not Spared 11 802E59171 Motor cover 12 809E42861 Crease nip spring REP 11 58 171 13 815K11660 Crease blade assembly REP 11 36 171 14 032E1...

Page 1353: ...l gate motor MOT11 401 REP 11 24 171 9 107E22600 BM Crease roll gate home sensor Q11 415 BM Crease roll motor encoder sensor Q11 419 10 960K42390 BM PWB REP 11 17 171 11 Motor bracket P O PL 11 166 Item 12 12 127K54680 BM crease roll motor assembly MOT11 062 REP 11 19 171 13 014E47460 BM Crease roll motor encoder 14 Support bracket Not Spared 15 023E25430 Belt 16 127K55520 BM Compiler motor assemb...

Page 1354: ...1 8 007E69081 Crease roll gate rack gear REP 11 59 171 9 Not used 10 Not used 11 Not used 12 Bearing Not Spared 13 007E69070 Crease roll gate rack drive gear REP 11 59 171 14 007E68951 Crease roll gate rack REP 11 59 171 15 020E38701 Crease roll gate front guide REP 11 59 171 16 020E38081 Crease roll gate rear guide REP 11 59 171 17 Crease roll drive shaft Not Spared 18 Crease roll gate shaft Not ...

Page 1355: ...ridge 9 Staple bracket handle Not Spared REP 11 28 171 10 Stapler bracket assembly Not Spared REP 11 28 171 11 809E48830 Torsion spring REP 11 28 171 12 Bearing Not Spared REP 11 28 171 13 Spring Not Spared REP 11 28 171 14 802E42770 Staple head cover 15 BM Right hand cover Not Spared REP 11 56 171 16 125K03831 Static eliminator 17 130E11640 BM exit sensor Q11 409 REP 11 50 171 18 107E22600 BM Sta...

Page 1356: ... 2 extension 3 HVF BM Bin 2 upper cover P O PL 11 169 Item 8 4 127K53630 BM Conveyor belt drive motor MOT11 402 5 019E61171 HVF BM Bin 2 90 full sensor Q11 389 6 HVF BM Bin 2 lower cover P O PL 11 169 Item 8 7 Thumbscrew Not Spared 8 HVF BM Bin 2 assembly Not Spared 9 HVF BM Bin 2 connector Not Spared 10 809E47341 HVF Bin 2 actuator spring 11 007E69000 Gear 50T pulley 24T ...

Page 1357: ...nsor Q11 153 Not Spared REP 11 90 171 12 Sheet size detector 1 Q11 150 Sheet size detector 2 Q11 151 P O PL 11 175 Item 20 REP 11 89 171 13 Inserter paper width sensor 1 Q11 152 P O PL 11 175 Item 19 REP 11 90 171 Inserter paper width sensor 2 P O PL 11 175 Item 19 NOTE REP 11 90 171 14 Bottom tray bracket P O PL 11 175 Item 19 15 Bottom tray rack P O PL 11 175 Item 19 16 Bottom plate sensor Q11 1...

Page 1358: ...r pin Not Spared 3 Gear Not Spared 4 Pulley Not Spared 5 Belt Not Spared 6 Bracket Not Spared 7 Jam drive belt Not Spared 8 Top cover interlock switch S11 306 Not Spared REP 11 87 171 9 Loading lever Not Spared 10 Loading gear Not Spared 11 Bearing Not Spared 12 Torsion spring Not Spared 13 Loading shaft Not Spared 14 Front loading bracket Not Spared ...

Page 1359: ... REP 11 91 171 11 TE sensor Q11 155 REP 11 93 171 LE sensor Q11 154 REP 11 93 171 P O PL 11 179 Item 19 12 Idle roller assembly P O PL 11 179 Item 19 REP 11 98 171 13 Idler roller bracket Not Spared 14 Idler roller spring P O PL 11 179 Item 19 15 Top inside cover Not Spared 16 Idler roller cover P O PL 11 179 Item 19 17 Top cover door P O PL 11 179 Item 20 REP 11 91 171 18 050K68090 Reverse feed r...

Page 1360: ...127K61990 Inserter motor MOT11 078 REP 11 84 171 2 Idler Not Spared 3 Driver gear Not Spared 4 Idler Not Spared 5 Tray down gear Not Spared 6 Gear cover bracket Not Spared 7 Idler Not Spared 8 Bottom shaft drive Not Spared 9 Feed roller drive gear Not Spared 10 Tray down clutch Not Spared 11 Tray down clutch assembly Not Spared ...

Page 1361: ...PL 11 195 Item 10 REP 11 73 171 5 Top cover door assembly spring P O PL 11 190 Item 8 6 802E93931 Top cover REP 11 67 171 7 848E17430 Right hand side cover REP 11 67 171 8 Tri Folder complete Not Spared 9 Top cover door assembly shaft P O PL 11 190 Item 8 10 107E26490 Top cover interlock sensor Q11 394 REP 11 77 171 11 Top cover locking stud Not Spared 12 802E99581 Front cover 13 017K04190 Castor ...

Page 1362: ...belt 12 007K14460 Drive assembly 13 005K12690 Drive coupling assembly REP 11 69 171 14 675K53640 Tri Folder install kit REP 11 68 171 15 Thumb screw P O PL 11 193 Item 14 16 960K24000 Tri folder control PWB REP 11 80 171 17 Drive coupler P O PL 11 193 Item 12 18 Align gauge coupler P O PL 11 193 Item 12 19 962K49592 Bin 2 tray harness REP 11 81 171 20 962K49571 Tri folder harness REP 11 81 171 21 ...

Page 1363: ...r assembly spring Not Spared 3 Top cover door assembly shaft Not Spared 4 Latch hook P O PL 11 195 Item 10 5 Top door cover assembly base P O PL 11 195 Item 10 6 Latch handle P O PL 11 195 Item 10 7 Latch spring P O PL 11 195 Item 10 8 059K58690 Idler assembly REP 11 73 171 9 Idler spring P O PL 11 195 Item 10 10 848K11680 Top cover door assembly REP 11 73 171 11 Idler assembly Not Spared ...

Page 1364: ... stacking assembly Not Spared 6 130E11861 Assist gate sensor Q11 184 REP 11 78 171 7 020E38480 Crease roll pulley REP 11 74 171 8 121K44660 Assist gate solenoid SOL11 086 REP 11 71 171 9 011E13832 Centerfold entry gate lever REP 11 74 171 10 809E44040 Crease roll spring REP 11 72 171 11 130K74920 Entry sensor Q11 183 REP 11 78 171 12 130K74051 Exit sensor Q11 086 REP 11 79 171 13 Not used 14 Feed ...

Page 1365: ...re 5790 Family PL 12 10 Parts Lists PL 12 10 OCT Item Part Description 1 604K41660 OCT complete 2 Tray P O PL 12 10 Item 1 3 675K26824 OCT finger kit REP 12 1 4 Thumbscrew P O PL 12 10 Item 1 5 130E81311 OCT 90 full sensor Q12 300 ...

Page 1366: ...6 6 Spacer Not Spared REP 14 1 7 Grommet Not Spared 8 848E57531 Base cover REP 14 1 9 Single board controller PWB module UI harness PJ103 PJ104 PJ130 PJ133 PJ80 10 016E18310 Top cover plug 11 Spacer Not Spared 12 032E20580 Rubber stop 13 032K04061 CVT Ramp assembly REP 14 6 14 Document glass securing bracket P O PL 14 10 Item 1 15 Transit screw hole plug P O PL 14 10 Item 3 16 Scanner frame securi...

Page 1367: ...hter PWB scanner PWB video PWB harness PJ922 14 Scanner motor drive belt P O PL 31 12 Item 15 REP 14 16 15 CCD PWB Scanner PWB ribbon cable 1 PJ931 P O PL 14 10 Item 1 16 130K75130 Scan carriage home sensor Q14 100 REP 14 7 Input module angle sensor Q14 310 REP 14 8 Q14 310 17 020K12510 Scan idler pulley REP 14 10 18 030K79640 Scan motor bracket REP 14 15 19 CCD PWB 20 Actuator spring Not Spared 2...

Page 1368: ...NOTE REP 14 6 090E02590 CVT glass 31mm wide NOTE REP 14 6 5 090K02451 Document glass NOTE REP 14 6 6 Spacer Not Spared 014E61280 REP 14 1 7 Grommet Not Spared 8 802E93182 Base cover REP 14 1 9 Single board controller PWB module UI harness PJ130 PJ133 PJ104 Not Spared 10 016E18310 Top cover plug 11 Base cover plug Not Spared 12 032E20580 Rubber stop 13 032K04061 CVT Ramp assembly REP 14 6 NOTE Refe...

Page 1369: ...on harness 11 960K34340 Fuse USSG REP 14 2 12 960K34320 Exposure lamp inverter PWB REP 14 2 13 152S06184 Single board controller module scanner driver PWB CCD PWB PJ455 PJ450 PJ135 harness 14 023E25140 Scanner drive belt P O PL 14 20 Item 1 REP 14 13 15 Sensor bracket Not Spared 16 130K75130 Scan carriage home sensor Q14 100 REP 14 7 Input module angle sensor Q14 310 REP 14 8 17 020K12510 Scan idl...

Page 1370: ...ox secure access power supply 3 146E02180 Xerox secure access card reader HID 4 Xerox secure access card reader MAGSTRIPE Not Spared 5 146E02190 Xerox secure access card reader MIFARE 6 146E02200 Xerox secure access card reader LEGIC 7 Xerox secure access power cord NA Not Spared 8 Xerox secure access power cord EU Not Spared 9 Xerox secure access power cord UK Not Spared ...

Page 1371: ... Line W O TAG X 001 REP 3 2 960K52330 R9 1 Line W O TAG X 001 REP 3 2 R8 1 Line South Africa only W O TAG X 001 REP 3 2 960K58801 Embedded fax PWB 1 Line W TAG X 001 5 802E65251 Lower cover 6 Single board controller PWB module REF PL 3 24 Item 1 7 Grounding strip P O PL 20 10 Item 4 8 Telephone cable not shown on illustration see below for variants P O PL 20 10 Item 9 PL 20 10 Item 10 United Kingd...

Page 1372: ...er kit REF PL 31 11 Item 2 NOTE 2 Power cord P O PL 25 10 Item 1 3 PSU P O PL 25 10 Item 1 4 Staple cartridge 1 cartridge 5000 staples Staple cartridge refill 3 cartridges 3 x 5000 staples 5 Convenience stapler P O PL 25 10 Item 1 XE Convenience stapler USSG XCL P O PL 25 10 Item 1 NOTE The convenience stapler has no serviceable parts ...

Page 1373: ...ection Qty 100 WARNING 11 108R00493 Staple cartridge 3 x 5000 2K LCSS 12 Serial cable Not Spared 13 035E56460 Wiper 14 082E02000 Test pattern A3 11x17 15 082E02010 Test pattern A4 16 082E02020 Test pattern 8 5x11 17 082E08230 Test pattern solid area density scale 18 082P00448 Test pattern visual scale 19 008R90273 Antistatic fluid Not Spared 20 070P00043 Molub grease 777 21 146E02700 USB Reader HI...

Page 1374: ...artridge 5000 staples 2 006R01146 Black toner Includes waste toner bottle REF PL 9 15 Item 4 65 90 ppm Pack of 2 3 006R01046 Toner cartridge 2 pack REF PL 9 17 Item 4 35 55 ppm 4 008R12941 Convenience stapler cartridge refill staples only 3 x 5000 staples 5 Handset tool Not Spared 6 600T02329 PFP stack height sensor retard shield setting tool 7 600T02331 LVPS test tool ...

Page 1375: ... REF PL 7 26 W TAG 151 3 Main covers REF PL 8 10 4 2K LCSS covers REF PL 11 2 5 Not used 6 Not used 7 Scanner covers W TAG 150 REF PL 14 10 8 1K LCSS covers REF PL 11 100 9 Stand covers REF PL 7 40 10 Scanner covers W O TAG 150 REF PL 14 20 11 HVF covers REF PL 11 130 12 Not used 13 Tray 5 covers REF PL 7 60 14 Inserter covers REF PL 11 175 15 Tri folder covers REF PL 11 190 ...

Page 1376: ...punch kit LCSS USSG XCL XCL 498K10310 4 hole punch kit Sweden LCSS XE XE 498K10280 4 hole punch kit LCSS XE XE 498K11411 3 hole punch kit HVF XE 498K17900 4 hole punch kit HVF XE 498K17940 4 hole punch kit HVF Sweden 498K11400 2 hole punch kit HVF XE 6 604K67700 Seal replacement kit 7 Finishing devices see below for variants 1K LCSS no hole punch P O PL 11 100 32 45 ppm 2K LCSS no hole punch REF P...

Page 1377: ...10 Paper tray security kit 11 049K00280 Tray 6 install kit 12 604K41020 Ros spares kit 35 ppm REF PL 6 10 Item 4 604K34980 ROS spares kit REF PL 6 10 Item 4 40 55 ppm 604K34950 ROS spares kit REF PL 6 10 Item 4 65 90 ppm 13 Image module spares kit Not Spared 14 604K73160 Inverter spares kit 32 55 ppm Inverter spares kit 604K73150 65 87 ppm 15 604K73230 HVF ejector assembly safety cover kit 16 604K...

Page 1378: ...64 Item 17 13 604K67240 Registration clutch kit REF PL 8 15 Item 7 PL 8 17 Item 7 14 604K42120 Crease roll repair kit REF PL 11 167 Item 25 15 604K73470 CCDS replacement drive belt kit REF PL 14 15 Item 14 16 604K83680 Tray 3 transport shaft kit 17 604K42680 DADH feed bearing kit REF PL 5 15 Item 26 18 604K35340 Developer charge kit REF PL 9 17 Item 25 19 604K83690 Exit shaft kit 20 604K83711 Feed...

Page 1379: ...eveloper Drives interface kit REF PL 9 15 Item 23 13 801K20310 Separation strip kit REF PL 7 15 Item 19 14 604K83641 Feed Nudger Retard roll spares kit W TAG 151 15 604K53950 Tray 3 and 4 paper feed assembly kit REF PL 8 30 Item 1 PL 8 31 Item 1 16 1K LCSS mounting bracket repair kit REF PL 11 100 Item 5 17 848E17510 Cover infill kit REF PL 7 25 Item 10 PL 7 40 Item 11 18 604K54760 Envelope tray f...

Page 1380: ...29 W TAG D 003 7 LCSS Hole Punch Repair Kit REF PL 11 6 Item 9 8 604K55570 Drive roll repair kit Pre reg PL 8 15 Item 26 PL 8 17 Item 27 Duplex PL 8 20 Item 17 PL 8 22 Item 16 Inverter PL 10 14 Item 11 SPP PL 10 25 Item 11 W TAG 051 9 604K60701 DADH mylar guide kit REF PL 5 10 Item 17 10 498K17546 CAC enablement kit USSG XCL 11 604K73370 BM Diverter kit XE 12 146E02210 Magstripe USB reader 13 20A ...

Page 1381: ...Kingdom Spain Greece Ireland Portugal 497K06340 Austria Germany Switzerland Italy 497K06350 Netherlands Belgium France 497K06360 Sweden Norway Finland Denmark South Africa Not Spared 497K05671 USSG XCL 497K05661 XE 497K11270 Brazil USSG XCL NOTE 497 8K part numbers should not be ordered by the CSE 497 8K part numbers are customer install kits and are for reference only ...

Page 1382: ...K06370 United Kingdom Spain Greece Ireland Portugal 497K06380 Austria Germany Switzerland Italy 497K06390 Netherlands Belgium France 497K06400 Sweden Norway Finland Denmark 497K07280 South Africa 497K05691 USSG XCL 497K05681 XE NOTE 497 8K part numbers should not be ordered by the CSE 497 8K part numbers are customer install kits and are for reference only ...

Page 1383: ...rew M4x10 Self Tapping AT Screw M4x10 Self Tapping AU Screw M3x5 Machine AV E Clip M3 5 AW Screw M3x5 5 Taptite AX Screw M3x14 Machine AY Screw M3x18 Self Tapping AZ Washer M4 BA Screw M4x16 Machine BB Screw M4x5 Machine BC Screw M3x10 Machine BD Screw M3x6 Machine BE Screw M4x7 5 Machine BF Screw M3x5 5 Machine BG Washer M3 BH Spring Washer M3 BI Screw M3x6 Machine BJ Screw M3x22 Self Tapping BK ...

Page 1384: ... Screw M4x7 Self Tapping DL Screw M4x6 Taptite DM M3 Star Washer DN Screw M4x6 Machine DO Screw M3x6 Self Tapping DP M3 Nut Washer Head DQ Screw M4x11 Machine DR Washer M8 Nylatron DS Screw M3 x 8 DT Screw M3x17 Taptite DU Screw M2 5x8 Taptite DV Screw M3 5x10 Torx DW Screw M3 5x10 Taptite EA Screw M4x6 Machine EB Screw M4x10 Machine EC Screw M4x8 Machine EF Screw M5x6 machine EH Pivot pin M4X10 H...

Page 1385: ...n of Hazardous Substances RoHS 6 57 GP 27 Fuser Xerographic Module End of Life Extension 6 57 GP 28 USB Connection Mode 6 58 GP 29 Embedded Customer Documentation 6 58 GP 30 to GP 36 GP 30 Copier Only Machine Identification 6 59 GP 31 How to Set the Date and Time 6 59 GP 32 How to Enable HTTP 6 60 GP 33 How to Configure the PWS to Ping a Device 6 60 GP 34 How to Set the IP Address of the PWS 6 61 ...

Page 1386: ...May 2013 6 2 Xerox WorkCentre 5790 Family General Procedures Information ...

Page 1387: ...rk dC312 Echo Test dC314 Network Connectivity Tests Other routines dC001 Reset Auditron Master Pin dC104 Modal Usage Counters dC111 Tag Matrix dC606 Internal Print Test Patterns Fax routines dC109 Protocol Report dC131 NVM Read Write dC132 NVM Initialization dC330 Component Control How to Exit From Diagnostics 1 Touch the Exit button to exit from the dC procedures 2 Touch the Call Closeout button ...

Page 1388: ...S 15 IPS1 16 Network Controller 17 Disk Operation 18 Connectivity 19 Video Image Manipulation 20 Fax 21 RDT 22 Main Controller Module Diagnostic Routines Copier Routines dC131 NVM Read Write 01 Standby Power 02 Mode Selection UI 03 Machine Run Control NOTE Refer to GP 4 Machine Software 05 Document Transport 06 ROS 07 Paper Supply 08 Paper Feed Trans 09 Xerographics 10 Copy Trans Fusing 12 Finishe...

Page 1389: ...ork All Network NVM Variable NVM Configuration NVM dC312 Echo Test TCP IP Internal Tests internal IP stack and hosts file Network Tests the Network to find other IP hosts Novell Internal Tests the internal Novell stack and driver Network Tests the Network to find the other IPX devices NetBIOS NetBEUI Network Tests the Network to find the other NetBIOS devices AppleTalk Network Tests the Network to...

Page 1390: ...per supply Table 1 345 Because this starts with 3 it is a Controls code Table 2 The 4 and the 5 are sequence numbers and have no other significance NOTE Where possible the component related fault codes are the same as the component control codes Table 1 Function and fault code prefixes Chain Code Function 01 Standby power 02 User interface mode selection 03 Machine run control 04 Start print power...

Page 1391: ...tails will be shown for the selected chain A Rate button is displayed Touch the Rate button to show the jam rate per million sheets fed fault counter x 1 000 000 divided by sheets fed GP 3 Service Information Purpose To provide machine hardware and software information Service Information From The Diagnostic Screen Enter Diagnostics GP 1 select the Service Information tab This gives the following ...

Page 1392: ...git Product Code Primary Build Machines Primary build machines are supplied as WorkCentres Configuration changes to faster speeds and output modules are carried out as secondary build upgrades Malaysia built machines XEE 35 ppm DADH Stand Mono Scanner 60Hz XEF 35 ppm DADH HCF Color Scanner 60Hz XEG 35 ppm DADH HCF Mono Scanner 60Hz XEH 55 ppm DADH HCF Color Scanner 60Hz XEK 55 ppm DADH HCF Mono Sc...

Page 1393: ...r later software version When an upgrade has been initiated the machine will reboot with all modules in upgrade mode Progress and errors are displayed on the UI touch screen When the upgrade is complete the machine will reboot When a machine is switched on the single board controller PWB module compares its SCD with the software in the hardware modules If necessary a software upgrade or downgrade ...

Page 1394: ...net mask of the machine NOTE A default gateway setting is not required h Click on OK to close the properties dialog box i Click on Close to close the Local Area Connection Properties dialog box j If any settings have been changed reboot the PWS 3 Switch on the machine GP 14 4 Disconnect the ethernet cable from the machine 5 Connect the ethernet crossover cable PL 26 10 Item 6 between the machine a...

Page 1395: ...he machine may also display the upgrade progress screen Figure 10 If the power on failure screen is dis played switch off then switch on the machine GP 14 11 After the software has upgraded a software upgrade report will be printed Software Loading Progress During the software loading procedure a progress screen is displayed on the UI Figure 1 The display has the following features A progress bar ...

Page 1396: ...ars switch off then switch on the machine GP 14 12 Check that the software set has been installed Refer to the printed software upgrade report or by pressing the machine status button 13 Perform a NVM restore refer to GP 5 14 Switch off then switch on the machine GP 14 PWS Altboot Procedure Hardware requirements Serial cable PL 26 10 Item 12 9 way gender changer PL 26 10 Item 1 Ethernet crossover ...

Page 1397: ...indow Figure 3 Figure 3 Settings menu NOTE Check that the Received packet line is displayed and that the IP address is set one digit away from the packet was received from address Press y at the prompt and continue If the valid netmask is not set press n and change it to the value shown in Figure 3 13 From the next menu Figure 4 select action 5 Install ESS software Figure 4 Action menu 14 At the p...

Page 1398: ...d complete after approximately 5 minutes and the AltBoot com plete screen will open Figure 11 Ignore the instruction to remove the USB flash drive only press 0 to continue 21 If the AltBoot process fails the AltBoot failed screen will open Figure 12 Follow the on screen instructions Restart the procedure and refer to Troubleshooting as necessary 22 The UI displays the Data Encryption Decryption in...

Page 1399: ...set has been installed Refer to the printed software upgrade report or by pressing the machine status button 28 If the NVM was saved at the beginning of this procedure perform a NVM restore refer to GP 5 Figure 9 Software upgrade Figure 10 Start of upgrade Figure 11 Altboot complete Figure 12 Upgrade failed ...

Page 1400: ...s Net work Scanning E Mail Internet Fax Network Accounting Server Fax Hard Disk Overwrite Xerox Standard Accounting XSA Check with the customer that they have the necessary codes to enable their Optional Services and they can restore any configuration information for the installed options NOTE To restore the XSA data use the customers XSA data backup clone file on the cus tomers PC Refer to the Cu...

Page 1401: ...settings record the original IP address and Subnet mask The original settings are reset at the end of this procedure f Set the IP address of the PWS to 192 168 0 2 g Set the Subnet mask of the PWS to 255 255 255 0 NOTE A default gateway setting is not required h Click on OK to close the properties dialog box i Click on Close to close the Local Area Connection Properties dialog box j If any setting...

Page 1402: ...ed from address Press y at the prompt and continue If the valid netmask is not set press n and change it to the value shown in Figure 15 13 From the next menu Figure 16 select action 11 Forced Install ESS software Figure 16 Action menu 14 At the proceed prompt Figure 17 select Y Figure 17 Install confirmation window 15 At the second proceed prompt Figure 18 select Y Figure 18 Release image install...

Page 1403: ...o continue 21 If the Forced AltBoot process fails the AltBoot failed screen will open Figure 24 Follow the on screen instructions Restart the procedure and refer to Troubleshooting as neces sary 22 The UI displays the Data Encryption Decryption in progress screen Figure 25 NOTE Do not switch off the machine until directed to on the UI During the reboot the hard disk drive is encrypted Switching of...

Page 1404: ...May 2013 6 20 Xerox WorkCentre 5790 Family GP 4 General Procedures Information Figure 21 Software upgrade Figure 22 Start of upgrade Figure 23 Altboot complete Figure 24 Upgrade failed ...

Page 1405: ... Configuration is used to manage network systems This tool displays the state of the network settings Network Controller Logging Network Controller Logging is used to enable or disable network controller logging and also retrieve log files for off line viewing The following logging files are stored on the network con troller and can be accessed and with one exception displayed on the PWS Network c...

Page 1406: ... instructions If the PWS suffers a power failure or crash during the procedure the machine should recover If the machine has not recovered after 5 minutes perform the following 1 Switch on the PWS Open the NVM Save and Restore application on the PWS 2 Select the Exit button in the NVM Save and Restore window 3 Restart the NVM Save and Restore procedure 4 Set the USB connection mode to Walk Up USB ...

Page 1407: ...s of the machine Procedure 1 Assess the fault Is the part broken too loose too tight Check if it needs cleaning or lubri cating 2 Check the following items as appropriate Actuators Free movement Damage Contamination Bearings Wear Damage Contamination Drive Belts Wear Damaged teeth Correct tension Contamination of tension rollers and support shafts Gears Contamination Chips or cracks Wear Misalignm...

Page 1408: ...Background USB cable PL 26 10 Item 5 PWS portable work station to single board controller PWB Xerox approved USB pen drive GP 9 Secure Diagnostic Purpose The purpose is to provide increased security to Diagnostics pathways Use this procedure when the diagnostics entry code 1934 has been compromised or added security has been requested by the customer How to Enable Secure Diagnostics 1 Enter diagno...

Page 1409: ...tor is entered Check the wiring and the connectors for the motor circuit References 01G 24V Distribution RAP 01B 0V Distribution RAP REP 1 2 Wiring Harness Repairs Four Wire Stepper Motor NOTE A stepper motor with an internal open circuit may appear to be fully functional under dC330 component control However under normal operation it will run with intermittent failure Use the standard digital met...

Page 1410: ...May 2013 6 26 Xerox WorkCentre 5790 Family GP 10 General Procedures Information Figure 1 Circuit diagram ...

Page 1411: ...cts check that the surface is clean Also make sure that there is not an obstruction between the sensor and the surface 6 If the sensor actuates by an encoder disc ensure the holes or gaps in the disc are aligned correctly with the sensor Sensor Action In the upper sensor in Figure 1 when light from the LED is allowed to fall on the photo sensi tive transistor the sensing line PJA pin2 is low When ...

Page 1412: ...in numbers and PWB names shown are an example only Go to the circuit diagram in the RAP for the correct information NOTE When a solenoid is energized in diagnostics armature movement is seen When a clutch is energized in diagnostics the sound of the clutch action is heard If possible energize the motor connected to the clutch to confirm when the clutch is energized Go to Flag 1 Check that the sign...

Page 1413: ... device The on off switch is not a disconnect device Disconnect the power cord from the supply to isolate the equipment Refer to Switch Off Procedure Switch Off Failure Procedure Quick Restart Switch On Procedure Power Saver Mode Switch Off Procedure CAUTION Do not disconnect the power lead or interrupt the electricity supply before the power down is complete unless advised The data and software c...

Page 1414: ...n the Quick Restart Confirmation window is displayed touch the Confirm button 4 The Quick Restart window is displayed with the following message Quick Restart is underway and will take approximately 1 minute Switch On Procedure 1 After a machine has been switched off wait a minimum of two minutes before the machine is switched on 2 After a service call ensure that all service tools are removed fro...

Page 1415: ...Lift or Move Heavy Modules Purpose Use this procedure when lifting or moving heavy modules Procedure When removing heavy modules from the machine the following instructions must be observed 1 Ensure that a suitable stable surface to support the module after removal is located in close proximity to the machine NOTE Other parts of the machine are not a suitable stable surface 2 Ensure that the heigh...

Page 1416: ...the Undo button This stops the process and the old value is retained A threshold value of zero indicates that there is no threshold value assigned to the item and the status will be Off not tracked The maximum life setting and the threshold settings are independent of each other The threshold value can exceed the maximum life value To reset the HFSI item Actual count value to zero perform the foll...

Page 1417: ...al IP address and Subnet mask The original settings are reset at the end of this procedure d Refer to the configuration report for IP address of the machine Set the IP address of the PWS one number higher than that of the machine For example if the IP address of the machine is 192 168 196 112 set the IP address of the PWS to 192 168 196 113 e Refer to the configuration report for Subnet mask of th...

Page 1418: ...ter the machine IP address in the web browser address field Then press the Enter key The machine web page will open NOTE Refer to the configuration report for the machine IP address 2 Select Index 3 Select Cloning 4 At install clone file scroll down and select the Browse and select the floppy drive 5 Select the clone file open the file and press install NOTE There is no indication or message to sa...

Page 1419: ... con straints for the output Performance will not be guaranteed for media not listed in the table Media that is smaller than 139 mm 5 5 inches in either the process or cross pro cess direction cannot be duplexed Table 10 Input document material definitions Table 11 Input document quality definitions Envelope Specifications Table 1 Performance indication Code Description 3 Excellent performance 2 G...

Page 1420: ...or fusing on 35 65 ppm machines All All LEF SEF Envelopes see NOTE 1 2 X 2 X X Wrinkle All 100 LEF SEF Conqueror finely ridged laid 2 2 2 2 2 Poor fusing on 35 65 ppm machines All 80 LEF SEF Recycled 1 1 1 1 1 Excessive curl Any Any LEF SEF Jobs with covers 1 X 1 1 X Rear cover of stapled sets of more than 35 sheets plus 2 cov ers may be mis registered in the 1K LCSS and 2K LCSS All 200 LEF SEF Co...

Page 1421: ... 20 32 SEF Plain paper X X 3 3 X Not tested 8 5 x 5 5 34 53 LEF Plain paper 2 X 2 2 X Not tested 8 5 x 5 5 34 53 SEF Plain paper X X 2 1 X Not tested 5 5 x 4 25 16 LEF Plain paper X X X X X Out of specification 5 5 x 4 25 16 SEF Plain paper X X 2 X X Out of specification 5 5 x 4 25 20 32 LEF Plain paper X X X X X Out of specification 5 5 x 4 25 20 32 SEF Plain paper X X 3 X X Out of specification ...

Page 1422: ...2 183 100 123 150 166 271 Table 4 U S paper weight conversion US post card thickness mm see NOTE US bond weight lb US text book weight lb US cover weight lb US Bristol weight lb US index weight lb US tag weight lb Metric weight gsm Table 5 Input output Paper sizes Paper size Orientation Paper tray size sensing DADH size sensing Document glass size sensing Output device Notes Common Name Inch W x L...

Page 1423: ...uroletter 8 5 x 13 216 x 330 SEF Y Y N N Y Y Y U Y Y Y ISO A4 or 8 5 x 13 depends on NVM 1 setting JIS B5 7 17 x 10 12 182 x 257 SEF U Y N N Y Y Y Y Y Y Y JIS B5 7 17 x 10 12 182 x 257 LEF U Y N N Y Y Y Y Y Y Y JIS B4 10 12 x 14 33 257 x 364 SEF U Y N N U U U Y Y Y Y Detected as ISO B4 JIS B6 5 08 x 7 17 128 x 182 SEF N Y N N N N N Y Y Y Y JIS B6 5 08 x 7 17 128 x 182 LEF N N N N U U U U U U Y Det...

Page 1424: ...5 x 10 5 184 x 267 LEF U U N N U U U U U U Y Detected as 8 5 x 11 16K Taiwan 7 64 x 10 51 194 x 267 SEF U U N N U U U U U U Y Detected as 8 5 x 11 16K Taiwan 7 64 x 10 51 194 x 267 LEF U U N N U U U U U U Y Detected as 8 5 x 11 Quarto 8 x 10 203 x 254 SEF U U N N U U U U U U Y Detected as 8 5 x 11 Quarto 8 x 10 203 x 254 LEF U U N N U U U U U U Y Detected as 8 5 x 11 8 x 10 5 203 x 267 SEF U U N N...

Page 1425: ...9 252 x 258 SEF U U N N U U U U U U Y Detected as ISO B4 SB4 9 92 x 14 09 252 x 258 LEF U U N N U U U U U U Y Detected as ISO B4 Accounting 10 x 14 254 x 356 SEF U U N N U U U U U U Y Detected as ISO B4 10 x 15 254 x 381 SEF U U N N U U U U U U Y Detected as ISO B4 8K Taiwan 10 51 x 15 28 267 x 388 SEF U U N N U U U U U U Y Detected as ISO B4 Table 5 Input output Paper sizes Paper size Orientation...

Page 1426: ...LEF Y Y Y Postcard Lakes 4 5 x 6 114 x 152 SEF N N Y Postcard Lakes 4 5 x 6 114 x 152 LEF N N N Postcard 5 x 7 127 x 178 SEF N N Y Postcard 5 x 7 127 x 178 LEF N N N Oufuku Hagaki Postcard 5 83 x 7 87 148 x 200 SEF Y Y Y Oufuku Hagaki Postcard 5 83 x 7 87 148 x 200 LEF Y Y Y 6 x 9 inch 6 x 9 152 x 229 SEF Y Y Y 6 x 9 inch 6 x 9 152 x 229 LEF Y Y Y Royal Octavo 6 x 9 5 152 x 241 SEF Y Y Y Royal Oct...

Page 1427: ...5 254 x 381 SEF Y Y Y 8K Taiwan 10 51 x 15 28 267 x 388 SEF Y Y Y Table 6 1K LCSS output paper sizes Paper Size Orientation Output Staple position Output Common Name Inch W x L mm W x L LEF SEF Stack Corner Top Tray Table 7 2K LCSS output paper sizes Paper Size Orientation Output Staple position Option Output Common Name Inch W x L mm W x L LEF SEF Stack Front Rear Dual Hole punch all types Top Tr...

Page 1428: ... Lakes 4 5 x 6 114 x 152 LEF N N N N N N Postcard 5 x 7 127 x 178 SEF N N N N N Y Postcard 5 x 7 127 x 178 LEF N N N N N N Oufuku Hagaki Postcard 5 83 x 7 87 148 x 200 SEF Y Y N N N Y Oufuku Hagaki Postcard 5 83 x 7 87 148 x 200 LEF Y Y Y N N Y 6 x 9 inch 6 x 9 152 x 229 SEF Y Y N N N Y 6 x 9 inch 6 x 9 152 x 229 LEF Y Y N N N Y Royal Octavo 6 x 9 5 152 x 241 SEF Y Y N N N Y Royal Octavo 6 x 9 5 1...

Page 1429: ... N N N Y 8K Taiwan 10 51 x 15 28 267 x 388 SEF Y Y N N N Y Table 7 2K LCSS output paper sizes Paper Size Orientation Output Staple position Option Output Common Name Inch W x L mm W x L LEF SEF Stack Front Rear Dual Hole punch all types Top Tray Table 8 HVF output paper sizes Paper Size Orientation Output Staple position Option Output Common Name Inch W x L mm W x L LEF SEF Stack Front Rear Dual M...

Page 1430: ...F Y N N N N N Y N Postcard Lakes 4 5 x 6 114 x 152 LEF N N N N N N N N Postcard 5 x 7 127 x 178 SEF Y N N N N N Y N Postcard 5 x 7 127 x 178 LEF N N N N N N N N Oufuku Hagaki Postcard 5 83 x 7 87 148 x 200 SEF Y N N N N N Y N Oufuku Hagaki Postcard 5 83 x 7 87 148 x 200 LEF Y Y Y Y Y N Y N 6 x 9 inch 6 x 9 152 x 229 SEF Y N N N N N Y N 6 x 9 inch 6 x 9 152 x 229 LEF Y Y Y Y Y N Y N Royal Octavo 6 ...

Page 1431: ...0 x 14 254 x 356 SEF Y Y Y Y Y N Y N 10 x 15 254 x 381 SEF Y Y Y Y Y N Y N 8K Taiwan 10 51 x 15 28 267 x 388 SEF Y Y Y Y Y N Y N Custom size cross process direction minimum 4 13 105 N N N N N N Y N Custom size process direction minimum 5 5 138 N N N N N N Y N Custom size cross process direction maximum 11 69 297 N N N N N N Y N Custom size process direction maximum 17 01 432 N N N N N N Y N Table ...

Page 1432: ... 2 ID 10 envelopes can be fed from tray 2 if the optional envelope kit is installed 3 LCSS Top tray only Carbonless paper N N N N N N N N N N N N Table 9 Output stock performance Stock Type Trays 1 and 2 Bypass Trays 3 and 4 Tray 5 Duple x Offset Stack Staple Hole punch Booklet Maker Tri folder Inserter Notes Table 10 Input document material definitions Category Material Image Type Group I Common ...

Page 1433: ...ulting in dog ears Staples not removed Edge defects None Any cut or tear near a corner less than 3mm 0 125 inch in length Any cut or tear not at a corner or greater than 3 mm 0 125 inch in length Folds in the feed direction Two letter folds less than 1 5 mm 0 062 inch high Two letter folds less than 3mm 0 125 inch high Any fold greater than 3mm 0 125 inch high Folds must be flattened to within 6mm...

Page 1434: ...h Feed orientation DL 110 x 220mm 4 33 x 8 66 inch 25mm 1 0 inch 55mm 2 1 inch LEF open trailing flap C5 162 x 229mm 6 38 x 9 02 inch 55mm 2 1 inch LEF open non leading flap Table 13 American envelope sizes ID Size Flap minimum length Flap maximum length Feed orientation 7 3 4 Monarch 98 x 190mm 3 87 x 7 5 inch 36mm 1 4 inch 55mm 2 1 inch LEF open trailing flap 10 105 x 241mm 4 12 x 9 5 inch 29mm ...

Page 1435: ...e weight does not include the weight of the finisher or tray 5 Optional Tray Tray 5 30 kg 66lbs Finishers OCT 2 kg 4 5lbs 1K LCSS 25 kg 55lbs 2K LCSS 30 kg 66 5lbs HVF 72 8 kg 160lbs HVF BM 100 3 kg 220 6lbs HVF BM with PPI 107 5 kg 236 5lbs HVF BM with PPI and Tri folder 127 8 kg 281 1lbs Machine Dimensions and Installation Space Requirements Table 1 shows the dimensions of the WC5790F machines a...

Page 1436: ...725 28 5 2556 100 6 3556 140 1725 68 2725 107 3 100 4 1000 39 4 WC5765 WC5790 with 1K LCSS and tray 5 1603 63 725 28 5 2603 102 5 3603 140 1725 68 2725 107 3 100 4 1000 39 4 WC5765 WC5790 with 2K LCSS and media shelf 1556 61 3 725 28 5 2556 100 6 3556 140 1725 68 2725 107 3 100 4 1000 39 4 WC5765 WC5790 with 2K LCSS and tray 5 1603 63 725 28 5 2603 102 5 3603 140 1725 68 2725 107 3 100 4 1000 39 4...

Page 1437: ...age Average current Comments 35 55 ppm 65 90 ppm 110VAC 60Hz Plus 6 minus 10 Less than or equal to 13 2A RMS Less than or equal to 17 6A RMS Specific XLA markets only 127VAC 60Hz Plus 6 minus 10 Less than or equal to 13 2A RMS Less than or equal to 17 6A RMS Mandatory for Saudi Arabia only 127VAC 60Hz Plus 6 minus 10 Less than or equal to 13 2A RMS Less than or equal to 17 6A RMS To operate at 127...

Page 1438: ... N A Additional power for HVF 55 ppm 160 30 0 0 0 N A Additional power for HVF 65 90 ppm 190 30 0 0 0 N A Additional power for HVF BM 55 ppm 160 30 0 0 0 N A Additional power for HVF BM 65 90 ppm 190 30 0 0 0 N A Table 3 Power consumption in all modes Configuration Run mode Watt Standby Watt Low power Watt Sleep Watt Plug in off mode Watt EPA Typical Energy Consumption Value Kwh week ...

Page 1439: ...Reset Auditron Master PIN to reset the password to default Inform the cus tomer that the password has been changed 5 Select Tools Pathway NOTE After entering customer administration tools all existing copy jobs are cancelled The network controller will stop accepting jobs and a Offline screen message is displayed When exiting Customer Administration Tools an Online screen message is displayed The ...

Page 1440: ...ime to ready to copy Less than or equal to 28 sec onds Less than or equal to 28 sec onds Less than or equal to 28 sec onds Less than or equal to 28 sec onds Less than or equal to 28 sec onds Less than or equal to 28 sec onds Less than or equal to 28 sec onds Ready to copy is indicated by the message Ready to Scan being displayed on the user interface Power on time to ready to print Less than or eq...

Page 1441: ...milar machines even if the parts look identical All WC5790F machines are RoHS com pliant at time of manufacture and must be maintained as RoHS compliant GP 27 Fuser Xerographic Module End of Life Extension Purpose To allow the customer a further 5000 prints while a new module is ordered and delivered NOTE Ensure that the customer has ordered a replacement module This is a one time only procedure a...

Page 1442: ...nter Customer Administration Tools GP 24 2 Press the Machine Status button 3 Select Tools 4 Select Network Settings 5 Select USB Printer Port 6 Select Xerox Copier Assistant PWS Service Tool 7 Select Save 8 Exit Customer Administration Tools GP 24 GP 29 Embedded Customer Documentation Purpose To explain how to print the embedded customer documentation Procedure Perform the following 1 Press the Ma...

Page 1443: ...and activation code label there are no other methods for identifying a copier only machine Copier only machines Will display the network controller booting up message when the machine is switched on Will display a status message if a network controller fault is detected Have some network controller maintenance features still present for example on demand image overwrite Can not have software upgra...

Page 1444: ...vice Purpose To configure the PWS to ping a device on a network Procedure Perform the following 1 Set the IP address of the PWS one digit higher or lower than the device to be pinged For example if the IP address of the device is 192 168 10 15 set the PWS to 192 168 10 14 or 192 168 10 16 To set the IP address of the PWS refer to GP 34 2 Set the subnet mask of the PWS the same as the devise to be ...

Page 1445: ... to the Windows XP operating system Perform the following 1 On the PWS right click on the My Network Places desktop icon or select Start then My Network Places Select Properties from the menu The Network and Dial up Connections window will open 2 Right click on Local Area Connection icon then select Properties The Local Area Con nection Properties window will open 3 Highlight Internet Protocol TCP...

Page 1446: ...col TCP IP Properties window 6 Select OK to close the Local Area Connection Properties window GP 35 How to Change Ethernet Speed Purpose To change the machines ethernet speed Procedure Perform the following 1 Enter Customer Administration Tools GP 24 2 Press the Machine Status button 3 Select the Tools tab 4 Select Network Settings 5 Select Ethernet Physical Media 6 Select the speed then Save 7 Lo...

Page 1447: ...w will open 2 Check if the firewall is enabled or disabled If the Local Area Connection icon has a pad lock symbol the firewall is enabled Figure 1 If the firewall is enabled continue with this procedure Figure 1 Padlock symbol 3 Right click on Local Area Connection icon then select Properties The Local Area Con nection Properties window will open Figure 2 Figure 2 Properties window 4 Select the A...

Page 1448: ...GP 36 General Procedures Information 5 Select the Off not recommended radio button to disable the windows firewall Figure 4 Figure 4 Settings button 6 Close all open windows 7 Disable any other Firewall software or utilities that may be running ...

Page 1449: ...er Interface Bluetooth Wireless local area network BM Booklet Maker BMF Basic Multi Function device BootP Boot Protocol AN IP protocol for automatically assigning IP addresses BPS Bits Per Second BS Behavior Specification BT Busy Tone C Celsius CAT Customer Admin Tool CB Certification Bodies CC Copy Centre CCA Cenelec Certification Agreement CCA Customer Call Assistance CCD Charged Coupled Device ...

Page 1450: ...odule DMO E Developing Markets Operations East was part of RX DMO W Developing Markets Operations West was part of ACO DOS Disk Operating Systems DPHM Defects Per Hundred Machines DIS Digital Identification Signal DMA Direct Memory Access DMO Developing Markets Operations Table 1 Abbreviations Term Description DOF Direction Of Feed paper width sensors DPI Dots per inch DRAM Dynamic Random Access M...

Page 1451: ...98 a similar but less powerful unidriver format was used GS German safety GSM Grams per square metre Table 1 Abbreviations Term Description GUI Graphics User Interface GWA Green World Alliance HC High Capacity HCF High Capacity Feeder HDD Hard Disk Drive HDLC High Level Data Link Control HFLEN High Frequency random Line Edge Noise image quality metric HFSI High Frequency Service Intervals HLD High...

Page 1452: ...user Interface m metre MAC Address Media Access Code This is the basic unique identifier of a networked device An incoming message is analysed and an address in another form such as an IP address is resolved by a lookup table to a MAC address The message is then directed to and accepted by the equip ment thus identified It is the burnt in hardware address of a NIC MB Megabyte one MB 1 048 576 byte...

Page 1453: ...sociation PD Process Direction PDF Adobe Acrobat Portable Document Format PDL Page Description Language PDT Product Delivery Team Pels Picture Data Pixel PFM Paper Feed Module PFP Paper Feed Platform PHI per Hundred Installs PIN Procedural Interrupt Negative PIN Personal Identification Number ping Packet InterNet Groper Tool to test connections between nodes by send ing and returning test data PIP...

Page 1454: ...ew Board Table 1 Abbreviations Term Description RS 232 RS 423 RS 422 RS 485 Series of standards for serial communication of data by wire RS 232 operates at 20kbits s RS 423 operates at 100kbits s RS 422 and RS 485 operate at 10Mbits s See FireWire and USB RTN Retrain Negative RTP Retrain Positive RTS Request To Send Rx Receive S2E Scan to E mail S2F Scan to File S2X Scan to Export SA Systems Admin...

Page 1455: ...fier TIFF Tagged Image File Format TIFF FX TIFF Fax eXtended TIFFX Tagged Image File Format for internet FAX Table 1 Abbreviations Term Description TP Test Point TOS Teflon over Silicon TPM Technical Programme Manager Transmissive LCD Liquid Crystal Display lit from the back TRC Toner Reproduction Curve Tri Folder Output device that creates C and Z folds TRN Train TSH Technical Service Hours TSI T...

Page 1456: ...es Information XI Xerox Initiated XL Xerox Limited XLA Xerox Latin America XOG Xerox Office Group XRU Xerographic Replacement Unit XSA Xerox Standard Accounting XUL Xerox Unique Login enables use of the xerox corporate directory Table 1 Abbreviations Term Description ...

Page 1457: ...ther Routines select 001 Reset Auditron Master PIN 3 Select Reset Auditron Master PIN 4 Select confirm or cancel dC104 Modal Usage Counters Purpose To list counters that provide information about features of the machine that have been used by the customer Procedure 1 Enter diagnostics GP 1 2 Select Diagnostic Routines select Other Routines select 104 Modal Usage Counters The modal usage counters s...

Page 1458: ... the Fax NVM This is the equivalent of an active Fax job in the Fax card queue The job does not print it remains in the queue until the Fax card exits diagnostics 6 Exit Diagnostics GP 1 7 The protocol report prints out Analyse the Protocol Report For an example of a send and a receive Fax protocol report refer to Figure 1 or Figure 2 In Job Details The results column also shows the line speed i e...

Page 1459: ...the quality of the line ERR Response for end of transmission FCD Facsimile coded data FCF Fax Code Field FIF Fax Information Field FTT Failure to train JM Joint menu MCF Message confirmation MPS Multi page signal NSC Non to standard facilities command NSF Non to standard facilities NSS Non to standard setup PID Procedure interrupt PIN Procedure interrupt negative PIP Procedure interrupt positive P...

Page 1460: ...es Procedure 1 Save the NVM GP 5 2 Enter diagnostics GP 1 3 Select Diagnostic Routines 4 Select required dC routine category Copier Routines Fax Routines 5 For copier routines select the appropriate button for the NVM chain to be viewed 6 Use the scroll buttons to view the other NVM locations of the chain Use the keyboard to type the three digit identifier code into the Find field and then touch t...

Page 1461: ...led 1 03 007 Value Added Reseller Defines installation s value added reseller Password protected 0 to 255 255 03 008 Product Identifier Sets the product identifier This is used to identify the printer type over the net work through the sysOb jectID Object Password protected NOTE For machine identi fication refer to SCP 7 Machine Features 151 35 ppm 152 40 ppm 153 45 ppm 154 55 ppm 155 65 ppm 156 7...

Page 1462: ... 03 404 IQA K3 Constant Image quality adjustment K3 constant Range 0 to 200 0 Table 3 NVM chain 3 Location NVM Name NVM Description Value Default 03 405 IQA K4 Constant Image quality adjustment K4 constant Range 0 to 5000 35 55 ppm 0 65 90 ppm 3000 03 406 IQA K5 Constant Image quality adjustment K5 constant Range 0 to 500000 35 55 ppm 135000 65 90 ppm 91000 03 407 IQA K6 Constant Image quality adj...

Page 1463: ... to 20000ms 5000 Table 3 NVM chain 3 Location NVM Name NVM Description Value Default 06 005 Extended Rng Ros Enable Indicates which type of ROS is fitted 35 ppm only 0 3 to 6 Erg cm2 range ROS 1 1 5 to 6 Erg cm2 Extended range ROS 1 Table 6 NVM chain 7 Location NVM Name NVM Description Value Default 07 001 Feeder Module Type Defines feeder module type 67 2 internal trays bypass 68 2 internal trays...

Page 1464: ...mber of steps from tray 4 feed motor to LE at tray 4 feed sensor 0 to 800 400 07 023 T3 Buckle Size Size of de skew buckle 0 to 15 3 07 024 T4 Buckle Size Size of de skew buckle 0 to 15 10 Table 6 NVM chain 7 Location NVM Name NVM Description Value Default 07 025 Release Steps T3 T4 Number of steps the HCF transport motor should run after the release sheet com mand 0 to 15 5 07 026 LE Late T4 From...

Page 1465: ...rved for future use 07 057 FeedMotorVelocity HCF W TAG 151 Nominal feed motor velocity 200 to 1000mm s 525 Table 6 NVM chain 7 Location NVM Name NVM Description Value Default 07 058 HCFMotorNom Speed HCF W TAG 151 Nominal HCF transport motor velocity 100 to 1000mm s 525 07 059 HCFMatchPFM Speed HCF W TAG 151 Speed that HCF transport motor will use to match the required PFM process speed 100 to 100...

Page 1466: ...CFNVM58 Reserved for future use 07 090 HCFNVM59 Reserved for future use 07 091 HCFNVM60 Reserved for future use Table 6 NVM chain 7 Location NVM Name NVM Description Value Default Table 7 NVM chain 8 Location NVM Name NVM Description Value Default 08 001 Print Rate Number of prints per minute Controls the IOT print rate 03 012 must be set to the same speed 0 35 ppm 9 40 ppm 1 45 ppm 2 55 ppm 3 65 ...

Page 1467: ...ex registration mode 1 100 to 380 35 ppm 314 40 55 ppm 219 65 90 ppm 154 Table 7 NVM chain 8 Location NVM Name NVM Description Value Default 08 152 Le Reg Snr To Clutch On Simplex buckle 100 to 900 35 ppm 630 40 55 ppm 440 65 90 ppm 290 08 153 Sync To Reg Clut On Simp Simplex registration 100 to 360 35 ppm 314 40 55 ppm 219 65 90 ppm 154 08 154 Te Reg Snr To Clutch Off Ensures sheet clear of reg n...

Page 1468: ...m 290 Table 7 NVM chain 8 Location NVM Name NVM Description Value Default 08 200 Pitch Tick Simp Mode 1 IOT paper path timing pitch tick setting Simplex mode 1 400 to 3500 35 ppm 1460 40 ppm 1330 45 ppm 1220 55 ppm 1090 65 ppm 920 75 ppm 800 90 ppm 690 08 201 Pitch Tick Simp Mode 2 IOT paper path timing pitch tick setting Simplex mode 2 1000 to 3500 35 ppm 2390 40 55 ppm 1670 65 75 ppm 1220 90 ppm...

Page 1469: ... starts to reverse duplex for mode 2 10 to 1600ms 35 ppm 1300 40 55 ppm 900 65 90 ppm 240 08 216 Nip Open Inv Mot Rev M3 Time for nip to open after inverter motor starts to reverse duplex for mode 3 10 to 2000ms 35 ppm 1300 40 55 ppm 900 65 90 ppm 640 08 217 Nip Open Inv Mot Rev M4 Time for nip to open after inverter motor starts to reverse duplex for mode 4 SEF Heavyweight invert only pitch 10 to...

Page 1470: ...direction 0 to 1000ms 35 ppm 100 40 55 ppm 100 65 90 ppm 100 08 233 Inv Mot Slow Down M4 Inverter motor slow down for mode 4 SEF heavy weight invert only pitch mode 2 0 to 1000ms 35 ppm 100 40 55 ppm 100 65 90 ppm 100 Table 7 NVM chain 8 Location NVM Name NVM Description Value Default 08 234 Inv Mot Slow Down M5 Inverter motor slow down for mode 5 Transparencies pitch mode 1 simplex 0 to 1000ms 35...

Page 1471: ...m window to indicate lead trail late 90 to 350ms 35 ppm 220 40 55 ppm 170 65 90 ppm 130 Table 7 NVM chain 8 Location NVM Name NVM Description Value Default 08 254 Le Top Exit TE Top Exit Win Lead edge top exit to trail edge top exit jam window to indicate lead edge trail edge late 90 to 350ms 35 ppm 220 40 55 ppm 170 65 90 ppm 130 08 255 LE late To Reg Cltch On Lead edge late to registra tion afte...

Page 1472: ...VM chain 8 Location NVM Name NVM Description Value Default 08 275 Inv Mot Rev To Stop Dup 5 Inverter motor reverse to inverter motor stop duplex 5 transparencies 0 to 1000ms 35 ppm 628 40 55 ppm 343 65 90 ppm 500 08 276 Inv Mot Rev To Stop Dup 6 Inverter motor reverse to inverter motor stop duplex 6 envelopes 0 to 1000ms 35 ppm 628 40 55 ppm 343 65 90 ppm 500 08 277 Add To MSUI Pitch Period Additi...

Page 1473: ...Sol On Exit Actuates inverter path sole noid to divert duplex sheet to output from TE of previ ous sheet when registration clutch turns on 500 to 800 steps 35 55 ppm 628 65 90 ppm 620 08 302 TE Inv Snr To Inv Sol Off Disables inverter path sole noid to divert sheet into invert path after TE at inverter sensor 0 to 100 steps 35 45 ppm 0 55 90 ppm 40 08 303 TE Inv Snr To Mot Of Smp S2 Inverter motor...

Page 1474: ...ption Value Default 08 326 Pitch Simp Mode 5 Alt IOT paper path timing pitch tick setting simplex mode 5 transparency pitch mode 1 simplex 600 to 3500ms 35 ppm 2600 40 55 ppm 1800 65 75 ppm 1040 90 ppm 1280 08 327 Pitch Simp Mode 6 Alt IOT paper path timing pitch tick setting simplex mode 6 transparency pitch mode 1 simplex 1000 to 3500ms 35 ppm 2760 40 55 ppm 1700 65 90 ppm 1210 08 328 Pitch Simp...

Page 1475: ...uplex buckle timer mode 1 0 to 700ms 35 ppm 496 40 55 ppm 343 65 75 ppm 425 90 ppm 431 08 605 LE Dup Snr To Clutch On M4 Duplex buckle timer mode 1 0 to 700ms 35 ppm 496 40 55 ppm 343 65 75 ppm 425 90 ppm 431 Table 7 NVM chain 8 Location NVM Name NVM Description Value Default 08 606 LE Dup Snr To Clutch On M5 Duplex buckle timer mode 1 0 to 700ms 35 ppm 496 40 55 ppm 343 65 75 ppm 244 90 ppm 256 0...

Page 1476: ...0 ppm 2050 09 003 Charge Grid Charge scorotron grid Absolute value in NVM real value is negative 150 to 700 V 35 ppm 420 40 55 ppm 430 65 90 ppm 420 Table 7 NVM chain 8 Location NVM Name NVM Description Value Default 09 004 Chute Bias LE Chute bias print level Unsigned no in NVM table displayed on GUI to be converted to signed no over range of 500 to 900 Volts by subtraction of 500 from table valu...

Page 1477: ...ide 2 detack corotron intradocument Unsigned no in NVM table and dis played on GUI to be con verted to signed no over range of 20 to 200 micro ampere by subtraction of 200 from value in table 0 to 220 micro ampere 35 ppm 165 40 90 ppm 160 Table 8 NVM chain 9 Location NVM Name NVM Description Value Default 09 020 Detack TE Side 2 Side 2 detack corotron TE Unsigned no in NVM table and displayed on G...

Page 1478: ...VM Description Value Default 09 049 T MMOFCO Main motor off cycle out 0 to 500 ms 35 ppm 390 40 55 ppm 270 65 90 ppm 190 09 050 T PCELOFCO PR erase lamp off cycle out 0 to 1500 ms 35 ppm 1100 40 55 ppm 770 65 90 ppm 550 09 051 T PRMOFCO Photoreceptor motor off cycle out 0 to 1500 ms 35 ppm 1130 40 55 ppm 790 65 90 ppm 560 09 052 T MMOFCO alt Main motor off cycle out alternative 0 to 1500 ms 35 ppm...

Page 1479: ...ding 1150 to both of the read NVM val ues for IOT NVM 0 disabled 1 enabled 0 Table 8 NVM chain 9 Location NVM Name NVM Description Value Default 09 101 Ambient Temp Actual ambient temp as measured by sensor Degrees C 0 09 110 Replenisher capacity Replenisher capacity 1050 to 1787 grams 35 55 ppm 1353 65 90 ppm 1750 09 111 Repl Delivery Rate Replenisher delivery rate 15 to 60 decigrams min 35 55 pp...

Page 1480: ...to 900 Volts by subtraction of 500 from table value 0 to 1400V 0 Table 8 NVM chain 9 Location NVM Name NVM Description Value Default 09 275 TC Setup Target Voltage Toner concentration setup target voltage 0 to 500 mVx10 35 45 ppm 0 55 90 ppm 185 09 276 TC lockout high CSF NVM lockout for TC process control Failure high 0 0 09 277 Int Man Clean Enable Interim manual charge scorotron cleaning ennobl...

Page 1481: ...ycle out bands 0 to 100mg 35 ppm 8 40 55 ppm 9 65 90 ppm 11 09 404 XRU Blade Level 1 XRU Blade maintenance threshold level 1 2 to 3000mg 10 09 405 XRU Blade Level 2 XRU Blade maintenance threshold level 2 1 to 3000mg 30 Table 8 NVM chain 9 Location NVM Name NVM Description Value Default 09 406 XRU Blade Count 1 XRU Blade maintenance event type 1 counter 0 to 3000 0 09 407 XRU Blade Count 2 XRU Bla...

Page 1482: ...ue i e 8 displayed in NVM is equivalent to 2 degrees Cel sius 0 to 20 10 Table 9 NVM chain 10 Location NVM Name NVM Description Value Default 10 047 201 220 mm offset Offset temperature required on thermistor B for paper width Unsigned number in NVM table displayed on GUI to be converted to signed number by subtrac tion of 10 from table value i e 8 displayed in NVM is equivalent to 2 degrees Cel s...

Page 1483: ... NVM Description Value Default 10 061 Labels Offset Media type offset for fuser roll temperature Unsigned num ber in NVM table displayed on GUI to be converted to signed number by subtrac tion of 10 from table value i e 8 displayed in NVM is equivalent to 2 degrees Cel sius 0 to 30 15 10 063 Total Fsr Web Count Total fuser web count Cycles 0 10 064 Transparency delay Media type time delay for fuse...

Page 1484: ...stor B for paper width Unsigned number in NVM table displayed on GUI to be converted to signed number by subtrac tion of 10 from table value i e 8 displayed in NVM is equivalent to 2 degrees Cel sius 0 to 20 10 Table 9 NVM chain 10 Location NVM Name NVM Description Value Default 10 343 121 140mm Offset 2 Offset temperature required on thermistor B for paper width Unsigned number in NVM table displ...

Page 1485: ...ription Value Default 10 351 281 300mm Offset 2 Offset temperature required on thermistor B for paper width Unsigned number in NVM table displayed on GUI to be converted to signed number by subtrac tion of 10 from table value i e 8 displayed in NVM is equivalent to 2 degrees Cel sius 0 to 20 10 10 353 80gms Offset 2 Media type offset for fuser roll temperature Unsigned num ber in NVM table display...

Page 1486: ...s Cel sius 0 to 30 15 10 372 Rough Stock Delay 2 Media type time delay for fuser roll temperature 0 to 8 seconds 4 10 423 Fsr Range 2 Temperature range below standby in which start print can begin 10 to 30 deg C 35 ppm 30 40 55 ppm 10 65 90 ppm 28 10 426 Web Advance Group 2 Web advance group banding select 1 group 1 2 group 2 3 group 3 2 Table 9 NVM chain 10 Location NVM Name NVM Description Value...

Page 1487: ...ements of 1 bit 35 55 ppm 212 65 90 ppm 214 14 026 Scan CCD Offset Pnt To adjust offset point during scanner CCD calibration 0 to 20 Incre ments of 1 bit 0 Table 1 NVM chain 12 Location NVM Name NVM Description Value Default 14 027 Scanner Mag Adj Adjust platen scan speed in slow scan direction to com pensate for magnification errors 50 to 150 100 14 028 Green Gain Set point Nvm Green scan calibra...

Page 1488: ...imit Maximum number of network controller images that can be in EPC at any given time 35 to 5000 3501 19 008 EPC Setting Governs the setting of the EPC low and intermediate thresh olds 1 Optimized for smaller sheets A4 8 5x11inch EPC less than 256Mb 2 Intermediate setting optimized for medium size sheet 3 Optimized for large sheet A3 11x17 inch EPC greater than 256Mb 1 19 009 Ncomp EPC Simp Img No...

Page 1489: ... are reset to default All Copier NVM Machine Variable NVM i e paper path platen and DADH registration SA KO Dust Off System Counters Dust Off NOTE The NVM window will gray out while the initialization is in progress 6 Switch off the machine then switch on the machine GP 14 7 Enter dC131 location 09 069 TCSensorCtrlVoltage Set the value to the value recorded on the NVM sheet stored in the wallet on...

Page 1490: ... Dust Off NVM ALL IOT with Flag type Reset All Billing Counter N System Usage Counter Y Y Fault Counter Y Y Diagnostic Counter Y Y SA KO Setting Y Y Fault Log Y Configuration Y Diagnostic Y Debug Y NVM Machine Variable IOT with Flag type Reset Nominal Y Y Machine Variable Zero Y Y Machine Variable Registration Y Y Machine Variable Paper Path Y Y Machine Variable DADH Y Y Machine Variable Platen Y ...

Page 1491: ... Communications Self Test tests communications with the single board controller PWB 8 Reset User Interface used to restart reboot the UI will cause the POST to start 9 Application Checksum Verification permits access to a procedure that displays and veri fies the checksum and can display any errors found 10 Calibration Mode enables the user to calibrate the user interface touch screen Procedure 1 ...

Page 1492: ...o assist the SA and CSE to isolate the cause of printing feature network scanning or network fax problems The test will interrogate each device on the network so that they respond with their identity and other information The data files will be stored on the machine files deleted at next boot and can be retrieved Refer to GP 5 Portable Workstation and Tools Description The network interface tests ...

Page 1493: ...ce meter This will not necessarily be the same as the logic state shown on the UI especially where the output is inverted When testing components using these control codes look for a change in state not for a high or low The displayed status of the input component can be changed by causing the component status to change e g operating a sensor with a sheet of paper When a sensor is operated a beep ...

Page 1494: ...This will add the component to the top of the Component Name table list and when the list is full the addition of more components will cause com ponents to be deleted from the bottom of the list NOTE Fax component control codes can only be energized one at a time b If a control code is not known it can be selected from the list displayed when the Find Component button is touched as follows NOTE Th...

Page 1495: ...only be set once the ROS motor has reached the required speed Table 4 Input codes 07 Code Displayed Name Description General 07 301 T1 Home Switch Tray 1 home switch S07 301 High tray home low tray not home 07 302 T2 Home Switch Tray 2 home switch S07 302 High tray home low tray not home 07 303 T3 Home Switch Tray 3 home switch S07 303 W O TAG 151 High tray home low tray not home 07 303 T3 Home Se...

Page 1496: ...ayed Name Description General 08 100 Wait Sensor Wait sensor Q08 100 detects when lead edge of paper at wait point High paper present low no paper Table 4 Input codes 07 Code Displayed Name Description General 08 101 T1 Feed Sensor Detects when lead edge of paper is at tray 1 feed sensor Q08 101 High paper present low no paper 08 102 T2 Feed Sensor Detects when lead edge of paper is at tray 2 feed...

Page 1497: ... unit home sensor Q11 044 High home low unit not home Table 6 Input codes 09 Code Displayed Name Description General 11 100 Entry Sensor LCSS and HVF entry sensor Q11 100 High paper present low no paper 11 110 Punch Sensor LCSS and HVF punch position sen sor Q11 110 High paper present low no paper 11 112 Chad Bin Set Sensor HVF chad bin set sensor Q11 112 detects when the chad bin installed High c...

Page 1498: ...oint for CL80 High made low not detected 11 184 Tri Folder Assist Sen sor HVF tri folder assist sensor Q11 184 detects trigger point for L81 High made low not detected Table 8 Input codes 11 Code Displayed Name Description General 11 185 Tri Folder Exit Sensor HVF tri folder exit sensor Q11 185 detects booklet and tri folder exit to tray High made low not detected 11 187 Offset Unit Index Sen sor ...

Page 1499: ...detects the home position of the punch head High punch home low punch not home Table 8 Input codes 11 Code Displayed Name Description General 11 351 Punch Hd Present Snr LCSS punch head present sensor Q11 351 detects if a hole punch is installed High punch installed low punch not installed 11 360 SH 1 Home Sensor LCSS and HVF staple head 1 home sensor Q11 360 detects when the staple head is fully ...

Page 1500: ... BM crease blade motor encoder sensor Q11 418 gener ates motor speed pulses High bar in encoder wheel low gap in encoder wheel 11 419 BM Crease Mot Encode HVF BM crease roll motor encoder sensor Q11 419 generates motor speed pulses High bar in encoder wheel low gap in encoder wheel 11 421 BM SH Carrier Closed HVF BM staple head carrier closed sensor Q11 421 detects when the carrier is in the close...

Page 1501: ...ut Table 12 Output codes 05 Code Displayed Name Description General Table 15 Output codes 08 Code Displayed Name Description General 08 010 T1 Feed Motor Energizes the tray 1 feed motor MOT 08 010 On off Linked to tray 1 home sensor Paper tray must be open when motor energized 90 seconds time out 08 020 T2 Feed Motor Energizes the tray 2 feed motor MOT08 020 On off Linked to tray 2 home sensor Pap...

Page 1502: ...70 in the forward direction On Off 13 seconds timeout Stack with scorotron cleaner home sensor Table 15 Output codes 08 Code Displayed Name Description General 09 072 Scorotron Cleaner Motor Reverse Energizes the scorotron cleaning motor MOT09 070 in the reverse direction On off 13 seconds timeout Stack with scorotron cleaner home sensor 09 075 Transfer Detack Motor Forward When set to ON the tran...

Page 1503: ...ot Up Energizes the LCSS and HVF bin 1 ele vate motor MOT11 030 by increments up On off 15 seconds timeout Table 18 Output codes 11 Code Displayed Name Description General 11 032 Bin 1 Elev Mot Down Energizes the LCSS and HVF bin 1 ele vate motor MOT11 030 by increments down On off 15 seconds timeout 11 033 Bin1 Elev Mot Cycle Energizes the LCSS and HVF bin 1 ele vate motor MOT11 033 to cycle bins...

Page 1504: ...11 400 On off 5 seconds timeout 11 401 BM Crease Roll Motor Energizes the HVF crease roll gate motor MOT11 401 cycle routine On off 15 seconds timeout 11 402 BM Mt Conveyor Drive Energizes the HVF BM conveyor belt drive motor On off 90 seconds timeout 11 403 BM Staple Hd 2 Motor Energizes the HVF staple head 2 motor MOT11 403 On off 5 seconds timeout Table 18 Output codes 11 Code Displayed Name De...

Page 1505: ...Tone 1300Hz Ln2 Emits single tone 1300Hz on line 2 On off 20 084 Sngl Tone 1650Hz Ln2 Emits single tone 1650Hz on line 2 On off 20 085 Sngl Tone 1850Hz Ln2 Emits single tone 1850Hz on line 2 On off Table 21 Output codes 20 Code Displayed Name Description General 20 086 Sngl Tone 2100Hz Ln2 Emits single tone 2100Hz on line 2 On off 20 087 ANSAM Ln2 On off 20 088 CI Ln2 On off 20 090 DTMF Line2 Emit...

Page 1506: ...rail edge Zone B on Figure 1 will measure 16mm from the edge of the paper Initial Action Ensure that 8 5 x 11 or A4 LEF paper is loaded in tray 1 Ensure that the ROS is secured and positioned correctly Check that the ROS securing screw at the front of the machine is present and secure refer to REP 6 1 Procedure NOTE Always perform the IOT Registration Side 1 adjustments before performing any other...

Page 1507: ...er dC132 NVM Initialization select Machine Variable NVM and initialize This will reset all of the registration values to default return to step 3 complete all four routines 8 Take samples from each tray using the individual tray select button and check the lead edge and top edge registration is within specification Figure 2 If the top edge registration is not correct on individual trays then go to...

Page 1508: ...rmation Figure 2 IOT registration Figure 3 Scanner and DADH registration Top edge registration on the 20mm line Lead edge registration on the 20mm line Top edge registration on the 10mm line Lead edge registration on the 10mm line Top edge of the paper Lead edge of the paper ...

Page 1509: ...atterns 5 Select Image Quality Test Patterns 1 19 6 Select the Features 1 or 2 sided and paper size NOTE Two sided test patterns are always backed with test pattern 16 quadrille 7 Select the Format Label on or off and Border on or off 8 Select Saved 9 Touch the Start Test 10 Press Exit to return to the main diagnostic menu select another feature or exit diagnos tics NOTE The system administrator a...

Page 1510: ...l by varying the control voltage applied to the sensor The output of the sensor depends on the Magnetic properties of the developer material this is a fixed value Applied control voltage Developer temperature Humidity Procedure 1 Enter diagnostics GP 1 2 Select Diagnostics Routines Copier Routines dC905 TC Sensor Calibration 3 Touch the Start button to start the routine and follow the on screen in...

Page 1511: ...s a brief description of the modification Name gives the name of the part or modification Kit Number gives the part number of the kit or part required to install the modification Reference or Parts List On indicates the parts list where the kit or modification part can be found Mod Tag Plate Location The processor module Open the front door and the Mod Tag plate is located on the left side of the ...

Page 1512: ...to eliminate transparencies from sticking and causing jams on exit from the fuser Related faults codes are 10 121 and 10 107 KIT NUMBER PARTS LIST ON PL 10 12 Item 24 TAG 005 CLASS 3 NAME Rear gravity gate finger Kit PURPOSE This kit is to eliminate paper catching in the gap between the tri roll guide and the rear gravity gate finger KIT NUMBER PARTS LIST ON PL 10 12 Item 25 TAG 046 CLASS 4 NAME I...

Page 1513: ...CLASS 4 NAME Tray 3 and 4 multifeed roll fix kit rough tread rolls PURPOSE To improve paper feeding reliability KIT NUMBER PARTS LIST ON PL 8 30 PL 8 31 TAG 111 CLASS 4 NAME HCF Heater kit PURPOSE To prevent paper curl in trays 3 and 4 in high humidity environments KIT NUMBER Kit part number not available for this issue of the service manual PARTS LIST ON PL 31 14 TAG 114 CLASS 3 NAME De populated...

Page 1514: ...KIT NUMBER 604K83711 PARTS LIST ON PL 8 32 TAG 154 CLASS 4 NAME Introduction of a new tray 4 paper feed assembly PURPOSE Applicable to W TAG 151 machines only To prevent jams or skew caused by bowl curl KIT NUMBER 604K83711 PARTS LIST ON PL 8 33 TAG 155 CLASS 3 NAME Introduction of a new IOT PWB PURPOSE A new IOT PWB has been introduced to prevent a shortage of IOT PWBs A new version of software h...

Page 1515: ...D002 DADH only To improve actuation of the DADH feed gates KIT NUMBER PARTS LIST ON PL 5 17 Item 6 TAG D 002 CLASS 5 NAME Introduction of the Quiet 100 sheet DADH PURPOSE Features a motorised nudger in place of the feed solenoid to give a quieter working performance New DADH PWB introduced with driver circuitry to support the motorised nudger KIT NUMBER PARTS LIST ON PL 5 10 and PL 5 17 TAG D 003 ...

Page 1516: ...a clearance bulge in the motor cover and a cut away in the top cover KIT NUMBER PARTS LIST ON PL 31 11 Item 8 TAG D 007 CLASS 3 NAME DADH Length sensors 1 and 2 PURPOSE Less sensitive to overhead light sensors KIT NUMBER PARTS LIST ON PL 5 35 Item 8 2K LCSS Tags TAG F 001 CLASS 5 NAME New LCSS graphic labels PURPOSE New jam clearance instructions KIT NUMBER None PARTS LIST ON None TAG F 002 CLASS ...

Page 1517: ...o the cutout in the rear frame to accommodate all configurations of hole punches KIT NUMBER PARTS LIST ON TAG F 008 CLASS 4 NAME LCSS legal 2 hole enable kit PURPOSE For use on machines with TAG F007 installed TAG F008 moves the position of the punch sensor Q11 110 All types of hole punch 2 hole 3 hole 4 hole Swedish and Legal SEF are compatible with TAG F008 KIT NUMBER PARTS LIST ON PL 31 10 Item...

Page 1518: ...r kit PURPOSE To implement an adjustment for the LCSS hole punch in the outboard direction KIT NUMBER PARTS LIST ON PL 11 6 TAG F 015 CLASS 2 NAME 2K LCSS Control PWB kit PURPOSE To enable the erase part of the software load KIT NUMBER PARTS LIST ON PL 11 26 Item 1 TAG F 016 CLASS 3 NAME LCSS Paddle assembly PURPOSE New paddle wheel shaft assembly featuring increased grip paddles that are now a cl...

Page 1519: ...ment shaft diverter assembly with 3 KL clip fixings KIT NUMBER PARTS LIST ON PL 31 13 Item 6 TAG L 013 CLASS 4 NAME LCSS bin 1 kit PURPOSE Modified angle to the output tray to reduce problem with paper curl KIT NUMBER PARTS LIST ON PL 11 100 TAG L 016 CLASS 3 NAME LCSS Paddle assembly PURPOSE New paddle wheel shaft assembly featuring increased grip paddles that are now a clip in fitting KIT NUMBER...

Page 1520: ...3 CLASS 5 NAME Guide hinge pin PURPOSE Mod TAG003 may have been struck in manufacturing but is not a valid mod tag KIT NUMBER PARTS LIST ON TAG V 004 CLASS 5 NAME Paper base middle bearing PURPOSE Mod TAG 004 may have been struck in manufacturing but is not a valid mod tag KIT NUMBER PARTS LIST ON TAG V 005 CLASS 5 NAME Three blade lower paddle PURPOSE To improve the contact force on documents in ...

Page 1521: ...MBER PARTS LIST ON PL 11 153 Tray 6 Inserter Tags TAG I 001 CLASS 5 NAME Safety hazard with the inserter connector PURPOSE Pin 3 ground 24V and pin 4 24V on the bulk head connector on the HVF for the inserter unit are to close together and could be shorted On the HVF PWB PJ703 pins 2 and 3 are repositioned On the Inserter PWB PJ5 pins 2 and 3 are repositioned This changes the position of the groun...

Page 1522: ...e castor for uneven floors Supersedes TAG P 001 KIT NUMBER PARTS LIST ON TAG P 050 CLASS 3 NAME Stack height sensor adjustment PURPOSE Introduction of an adjustable stack height sensor and PFP setting tool in order to reduce misfeeds multifeeds and prolong the life of the feed nudger and retard rolls KIT NUMBER PARTS LIST ON PL 26 11 TAG P 051 CLASS 3 NAME Retard shield adjustment PURPOSE Introduc...

Page 1523: ...May 2013 6 139 Xerox WorkCentre 5790 Family Fax Tags General Procedures Information Fax Tags TAG X 001 CLASS 4 NAME L1 fax PURPOSE Introduces a new single line fax KIT NUMBER PARTS LIST ON PL 20 10 ...

Page 1524: ...May 2013 6 140 Xerox WorkCentre 5790 Family Fax Tags General Procedures Information ...

Page 1525: ...May 2013 7 1 Xerox WorkCentre 5790 Family Wiring Data 7 Wiring Data Plug Jack Locations PJ Locations 7 3 Wiring Diagrams Wiring Diagrams 7 31 ...

Page 1526: ...May 2013 7 2 Xerox WorkCentre 5790 Family Wiring Data ...

Page 1527: ...3 LVPS and Base Module Figure 6 24 Main Drive PWB Figure 4 25 In line connectors PJ36 and PJ636 Figure 34 26 In line connectors PJ82 and PJ299 Figure 35 27 In line connectors PJ279 and PJ280 Figure 33 28 In line connector PJ530 Figure 32 29 Power and control module Figure 5 30 Power distribution PWB Figure 9 31 Riser PWB Figure 10 32 ROS Figure 27 33 Scanner PWB Figure 11 34 Scanner daughter PWB W...

Page 1528: ...2 17 Figure 5 Figure 6 Power and control assembly LVPS WD 1 Table 1 PJ1 to PJ49 PJ number PJ location figure PJ location Wiring diagram 17 Figure 26 1K LCSS PWB WD 32 18 Figure 5 Figure 6 Power and control assembly LVPS WD 1 19 Figure 5 Figure 6 Power and control assembly LVPS WD 1 19 Figure 3 HCF control PWB W TAG 151 WD 46 21 Figure 5 Power and control assembly bulkhead WD 1 22 Figure 5 Power an...

Page 1529: ...d Controller PWB WD 12 102 Figure 31 HVF Control PWB WD 34 102 Figure 38 Single Board Controller PWB WD 12 103 Figure 31 HVF Control PWB WD 33 103 Figure 38 Single Board Controller PWB WD 12 104 Figure 31 HVF Control PWB WD 33 104 Figure 38 Single Board Controller PWB WD 12 105 Figure 38 Single Board Controller PWB WD 6 106 Figure 38 Single Board Controller PWB WD 3 107 Figure 38 Single Board Cont...

Page 1530: ...n Wiring diagram Table 5 PJ200 to JP249 PJ number PJ location figure PJ location Wiring diagram 200 DADH feed sensor WD 13 201 DADH Nudger motor WD 13 201 Figure 31 HVF Control PWB WD 35 201 Figure 38 Single Board Controller PWB WD 12 202 DADH feed clutch WD 13 202 Figure 31 HVF Control PWB WD 35 202 Figure 38 Single Board Controller PWB 203 DADH CVT motor WD 13 203 Figure 38 Single Board Controll...

Page 1531: ...e 3 HCF control PWB WD 22 Table 7 PJ300 to PJ349 PJ number PJ location figure PJ location Wiring diagram Table 9 PJ400 to PJ449 PJ number PJ location figure PJ location Wiring diagram 401 Figure 31 HVF Control PWB WD 36 402 Figure 31 HVF Control PWB WD 36 403 Figure 31 HVF Control PWB WD 36 Table 10 PJ450 to PJ499 PJ number PJ location figure PJ location Wiring diagram 451 Figure 25 CCD PWB WD 31 ...

Page 1532: ...lder control PWB WD 42 Table 11 PJ500 to PJ999 Connection PJ location figure PJ location Wiring diagram 601 Figure 31 HVF Control PWB WD 37 601 Figure 36 Tri Folder control PWB WD 42 602 Figure 36 Tri Folder control PWB WD 42 602 Figure 31 HVF Control PWB WD 37 603 Figure 36 Tri folder control PWB WD 42 604 Figure 35 Tri folder control PWB WD 42 605 Figure 36 Tri folder control PWB WD 42 636 Figur...

Page 1533: ...May 2013 7 9 Xerox WorkCentre 5790 Family PJ Locations Wiring Data IOT PWB Location PL 1 10 Item 2 Figure 1 IOT PWB Tray 1 and 2 Control PWB Location PL 7 10 Item 2 Figure 2 Tray 1 and 2 control PWB ...

Page 1534: ...Family PJ Locations Wiring Data HCF Control PWB Location W O TAG 151 PL 7 20 Item 2 W TAG 151 PL 7 21 Item 2 Figure 3 HCF control PWB Main Drive Module Location 35 55 ppm PL 4 15 Item 1 65 90 ppm PL 4 10 Item 1 Figure 4 Main drive module ...

Page 1535: ...Xerox WorkCentre 5790 Family PJ Locations Wiring Data Power and Control Assembly Location PL 1 10 Item 1 Figure 5 Power and control Assembly LVPS and Base Module Location PL 1 10 Item 3 Figure 6 LVPS and base module ...

Page 1536: ...May 2013 7 12 Xerox WorkCentre 5790 Family PJ Locations Wiring Data 2K LCSS PWB Location PL 11 26 Item 1 Figure 7 2K LCSS PWB DADH PWB Location PL 5 10 Item 5 Figure 8 DADH PWB ...

Page 1537: ...Family PJ Locations Wiring Data Power Distribution PWB Location PL 3 24 Item 5 Figure 9 Power distribution PWB Riser PWB Location PL 3 22 Item 3 NOTE Later riser PWBs do not have PJ156 Figure 10 Riser PWB PJ155 PJ101 PJ157 PJ156 see NOTE ...

Page 1538: ...y PJ Locations Wiring Data Scanner PWB Location W O TAG 150 PL 14 25 Item 4 W TAG 150 PL 3 22 Item 4 Figure 11 Scanner PWB Exposure Lamp Inverter Location W O TAG 150 PL 14 25 Item 12 W TAG 150 PL 14 15 Item 12 Figure 12 Exposure lamp inverter ...

Page 1539: ...ay 2013 7 15 Xerox WorkCentre 5790 Family PJ Locations Wiring Data BM PWB Location PL 11 166 Item 10 Figure 13 BM PWB In line Connector PJ63 Location PL 7 10 Figure 14 PJ63 PJ63 Tray 1 and 2 control PWB ...

Page 1540: ...ocations Wiring Data In line Connector PJ49 and PJ76 Location PL 10 11 Figure 15 PJ49 and PJ76 In line Connectors PJ40 and PJ44 Location PL 8 20 Figure 16 PJ40 and PJ44 PJ49 Inverter assembly PJ76 65 90ppm W O TAG 120 only PJ40 PJ44 Duplex transport ...

Page 1541: ...ocations Wiring Data In line Connector PJ93 Location PL 9 15 Figure 17 PJ93 In line Connectors PJ152 and PJ800 Location PL 3 24 Figure 18 PJ152 and PJ800 PJ93 Developer bias connection Developer module PJ152 Single board controller PWB module PJ800 ...

Page 1542: ...y 2013 7 18 Xerox WorkCentre 5790 Family PJ Locations Wiring Data In line Connector PJ75 Location PL 9 15 Figure 19 PJ75 UI Control PWB Location PL 2 10 Figure 20 UI control PWB PJ75 Toner dispense module ...

Page 1543: ... 7 19 Xerox WorkCentre 5790 Family PJ Locations Wiring Data Embedded Fax PWB Location PL 20 10 Item 4 Figure 21 Embedded Fax PWB Duplex Motor Driver PWB Location PL 8 20 Item 9 Figure 22 Duplex motor driver PWB ...

Page 1544: ...May 2013 7 20 Xerox WorkCentre 5790 Family PJ Locations Wiring Data Inverter Motor Driver PWB Location PL 10 11 Item 22 Figure 23 Inverter motor driver PWB HVPS Location PL 1 10 Item 5 Figure 24 HVPS ...

Page 1545: ...ay 2013 7 21 Xerox WorkCentre 5790 Family PJ Locations Wiring Data CCD PWB W O TAG 150 Location PL 14 25 Item 19 Figure 25 CCD PWB W O TAG 150 1K LCSS PWB Location PL 11 124 Item 1 Figure 26 1K LCSS PWB ...

Page 1546: ... Data ROS Location PL 6 10 Item 4 Figure 27 ROS Fuser Module Location 35 55 ppm PL 10 8 Item 1 65 90 ppm PL 10 10 Item 1 Figure 28 Fuser module PJ2 harness PJ121 PJ120 PJ122 PJ18 harness PJ109 35 55 ppm PJ228 65 90 ppm Fuser CRUM PJ141 Fuser drawer connector PJ100 ...

Page 1547: ...rox WorkCentre 5790 Family PJ Locations Wiring Data Xerographic Module Location PL 9 20 Item 2 Figure 29 Xerographic module Tray 5 Control PWB Location PL 7 68 Item 8 Figure 30 Tray 5 Control PWB Xerographic CRUM PJ144 ...

Page 1548: ...y 2013 7 24 Xerox WorkCentre 5790 Family PJ Locations Wiring Data HVF Control PWB Location PL 11 157 Item 2 Figure 31 HVF Control PWB In line connector PJ530 Location PL 7 68 Item 4 Figure 32 PJ530 PJ530 ...

Page 1549: ...entre 5790 Family PJ Locations Wiring Data In line connectors PJ279 and PJ280 Location PL 8 25 Item 9 Figure 33 PJ279 and PJ280 In line connectors PJ36 and PJ636 Location PL 7 30 Figure 34 PJ36 and PJ636 PJ279 PJ280 PJ36 PJ636 ...

Page 1550: ...e 5790 Family PJ Locations Wiring Data In line connectors PJ82 and PJ299 W O TAG 114 Location 45 90 ppm PL 9 20 Figure 35 PJ82 and PJ299 Tri Folder Control PWB Location PL 11 193 Item 16 Figure 36 Tri Folder Control PWB PJ82 PJ299 ...

Page 1551: ...7 27 Xerox WorkCentre 5790 Family PJ Locations Wiring Data Inserter PWB Location PL 11 179 Item 9 Figure 37 Inserter PWB Single Board Controller PWB Location PL 3 24 Item 3 Figure 38 Single Board Controller PWB ...

Page 1552: ...rox WorkCentre 5790 Family PJ Locations Wiring Data Foreign Interface PWB Location PL 3 22 Item 4 Figure 39 Foreign Interface PWB Scanner Daughter PWB W TAG 150 Location PL 3 24 Figure 40 Scanner Daughter PWB W TAG 150 ...

Page 1553: ...May 2013 7 29 Xerox WorkCentre 5790 Family PJ Locations Wiring Data UI LCD PWB Location PL 2 10 Figure 41 UI LCD PWB ...

Page 1554: ...May 2013 7 30 Xerox WorkCentre 5790 Family PJ Locations Wiring Data ...

Page 1555: ... distribution Wiring Diagram 2 OCT Wiring Diagram 29 Power distribution Wiring Diagram 3 Scanner PWB W O TAG 150 1 of 2 Wiring Diagram 14 Scanner PWB W O TAG 150 2 of 2 Wiring Diagram 15 Scanner PWB W TAG 150 1 of 3 Wiring Diagram 16 Scanner PWB W TAG 150 2 of 3 Wiring Diagram 17 Scanner PWB W TAG 150 3 of 3 Wiring Diagram 18 Scanner daughter PWB W TAG 150 Wiring Diagram 19 Single board controller...

Page 1556: ...May 2013 7 32 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 1 Figure 1 Wiring Diagram 1 ...

Page 1557: ...May 2013 7 33 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 2 Figure 2 Wiring Diagram 2 ...

Page 1558: ...May 2013 7 34 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 3 Figure 3 Wiring Diagram 3 ...

Page 1559: ...May 2013 7 35 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 4 Figure 4 Wiring Diagram 4 ...

Page 1560: ...May 2013 7 36 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 5 Figure 5 Wiring Diagram 5 ...

Page 1561: ...May 2013 7 37 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 6 Figure 6 Wiring Diagram 6 ...

Page 1562: ...May 2013 7 38 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 7 35 ppm Only Figure 7 Wiring Diagram 7 ...

Page 1563: ...May 2013 7 39 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 8 40 55 ppm Only Figure 8 Wiring Diagram 8 ...

Page 1564: ...May 2013 7 40 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 9 65 90 ppm Only Figure 9 Wiring Diagram 9 ...

Page 1565: ...May 2013 7 41 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 10 Figure 10 Wiring Diagram 10 ...

Page 1566: ...May 2013 7 42 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 11 Figure 11 Wiring Diagram 11 ...

Page 1567: ...May 2013 7 43 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 12 Figure 12 Wiring Diagram 12 ...

Page 1568: ...May 2013 7 44 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 13 Figure 13 Wiring Diagram 13 ...

Page 1569: ...May 2013 7 45 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 14 W O TAG 150 Figure 14 Wiring Diagram 14 ...

Page 1570: ...May 2013 7 46 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 15 W O TAG 150 Figure 15 Wiring Diagram 15 ...

Page 1571: ...May 2013 7 47 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 16 W TAG 150 Figure 16 Wiring Diagram 16 ...

Page 1572: ...May 2013 7 48 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 17 W TAG 150 Figure 17 Wiring Diagram 17 ...

Page 1573: ...May 2013 7 49 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 18 W TAG 150 Figure 18 Wiring Diagram 18 ...

Page 1574: ...May 2013 7 50 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 19 W TAG 150 Figure 19 Wiring Diagram 19 ...

Page 1575: ...May 2013 7 51 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 20 Figure 20 Wiring Diagram 20 ...

Page 1576: ...May 2013 7 52 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 21 Figure 21 Wiring Diagram 21 ...

Page 1577: ...May 2013 7 53 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 22 W O Tag 151 Figure 22 Wiring Diagram 22 W O Tag 151 ...

Page 1578: ...May 2013 7 54 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 23 Figure 23 Wiring Diagram 23 ...

Page 1579: ...May 2013 7 55 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 24 Figure 24 Wiring Diagram 24 ...

Page 1580: ...May 2013 7 56 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 25 Figure 25 Wiring Diagram 25 ...

Page 1581: ...May 2013 7 57 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 26 Figure 26 Wiring Diagram 26 ...

Page 1582: ...May 2013 7 58 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 27 Figure 27 Wiring Diagram 27 ...

Page 1583: ...May 2013 7 59 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 28 Figure 28 Wiring Diagram 28 ...

Page 1584: ...May 2013 7 60 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 29 Figure 29 Wiring diagram 29 ...

Page 1585: ...May 2013 7 61 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 30 Figure 30 Wiring Diagram 30 ...

Page 1586: ...May 2013 7 62 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 31 Figure 31 Wiring Diagram 31 ...

Page 1587: ...May 2013 7 63 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 32 Figure 32 Wiring Diagram 32 ...

Page 1588: ...May 2013 7 64 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 33 Figure 33 Wiring Diagram 33 ...

Page 1589: ...May 2013 7 65 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 34 Figure 34 Wiring Diagram 34 ...

Page 1590: ...May 2013 7 66 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 35 Figure 35 Wiring Diagram 35 ...

Page 1591: ...May 2013 7 67 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 36 Figure 36 Wiring Diagram 36 ...

Page 1592: ...May 2013 7 68 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 37 Figure 37 Wiring Diagram 37 ...

Page 1593: ...May 2013 7 69 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 38 Figure 38 Wiring Diagram 38 ...

Page 1594: ...May 2013 7 70 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 39 Figure 39 Wiring Diagram 39 ...

Page 1595: ...May 2013 7 71 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 40 Figure 40 Wiring Diagram 40 ...

Page 1596: ...May 2013 7 72 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 41 Figure 41 Wiring Diagram 41 ...

Page 1597: ...May 2013 7 73 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 42 Figure 42 Wiring Diagram 42 ...

Page 1598: ...May 2013 7 74 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 43 Figure 43 Wiring Diagram 43 ...

Page 1599: ...May 2013 7 75 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 44 Figure 44 Wiring Diagram 44 ...

Page 1600: ...May 2013 7 76 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 45 Figure 45 Wiring Diagram 45 ...

Page 1601: ...May 2013 7 77 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 46 W Tag 151 Figure 46 Wiring Diagram 46 W Tag 151 ...

Page 1602: ...May 2013 7 78 Xerox WorkCentre 5790 Family Wiring Diagrams Wiring Data Wiring Diagram 47 W Tag 151 Figure 47 Wiring Diagram 47 W Tag 151 ...

Page 1603: ...May 2013 8 1 Xerox WorkCentre 5790 Family Accessories 8 Accessories ACC 1 Foreign Device Checkout 8 3 ...

Page 1604: ...May 2013 8 2 Xerox WorkCentre 5790 Family Accessories ...

Page 1605: ...May 2013 8 3 Xerox WorkCentre 5790 Family ACC 1 Accessories ACC 1 Foreign Device Checkout Procedure Go to the 03 412 Foreign Device PWB Fault RAP ...

Page 1606: ...May 2013 8 4 Xerox WorkCentre 5790 Family ACC 1 Accessories ...

Page 1607: ...nd affected part s of the machine by description and part number Description Part Number Location of product and affected part s Customer Identification Customer Name Name of Customer Contact Person Telephone Address E mail Fax Customer Service Engineer Identification Name required for Xerox serviced equipment Employee E mail Location Phone required for Xerox serviced equipment Individual Providin...

Page 1608: ...S DATA INCLUDED OR ATTACHED Any damage to customer property No Yes Describe Did external emergency response provider s such as fire department ambulance etc respond No Yes Identify i e source names of individuals Apparent cause of incident identify part that is suspect to be responsible for the incident Preliminary actions taken to mitigate incident Instructions E mail or fax both pages of this co...

Page 1609: ...and CBU District location code are fully completed NAME JOB TITLE ENGINEER NUMBER CONTACT TELEPHONE NUMBER DATE OPERATING COMPANY CBU DISTRICT LOCATION CODE PRODUCT AND PUBLICATION TITLE PUBLICATION REVISION DATE SOFTWARE REVISION LEVEL PAGE NUMBER COMMENT Please submit a marked up photocopy of the relevant pages CUSTOMER SATISFACTION QUESTION SET QUESTION NOT APPLICABLE VERY SATISFIED SATISFIED N...

Page 1610: ...XEROX EUROPE ...

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