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WorkCentre 5335 Family Service Documentation

Service Documentation

WorkCentre 5335 Family Service Documentation

705P01303

Initial Issue

07/2011

***Xerox Private Data***

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 personnel only. Xerox does not warrant or represent that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or modules, components, or parts of such equipment may affect whether Xerox is responsible to fix machine defects under the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third-party provided service.

If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold xerox harmless from any third party claims which arise directly or indirectly for such service.

While Xerox has tried to make the documentation accurate, Xerox will have no liability arising out of any inaccuracies or omissions. Changes are periodically made to this document. Changes, technical inaccuracies, and typographical errors will be corrected in subsequent editions.

Prepared by Creative and Technical Communications – North America

800 Phillips Road, Building 218-01A

Webster, New York 14580

ISO9001 and ISO27001 Certified

©2011 by Xerox Corporation. All rights reserved.

XEROX® and XEROX and design® are trademarks of Xerox Corporation in the US and/or other countries.

Changes are periodically made to this document. Changes, technical inaccuracies, and typographic errors will be corrected in subsequent editions.

CAUTION

This equipment generates, uses and can radiate radio frequency energy, and if not installed and used in accordance with the instructions documentation, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to subpart B of part 15 of FCC rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference in which case the user, at his own expense, will be required to correct the interference.

About this Manual

This Service Manual is part of the multinational documentation system for this copier/printers. The Service Documentation is used in order to diagnose machine malfunctions, adjust components and has information which is used to maintain the product in superior operating condition. It is the controlling publication for a service call. Information on its use is found in the Introduction of the Service Documentation.

This manual contains information that applies to NASG (XC) and ESG (XE) copiers.

Service Manual Revision

The Service Manual will be updated as the machine changes or as problem areas are identified.

Organization

The titles of the sections and a description of the information contained in each section are contained in the following paragraphs:

Section 1: Service Call Procedures

This section contains procedures that determine what actions are to be taken during a service call on the machine and in what sequence they are to be completed. This is the entry level for all service calls.

Section 2: Status Indicator RAPs

This section contains the diagnostic aids for troubleshooting the Fault Code and non-Fault Code related faults (with the exception of image quality problems).

Section 3: Image Quality

This section contains the diagnostic aids for troubleshooting any image quality problems, as well as image quality specifications and image defect samples.

Section 4: Repairs/Adjustments

This section contains all the Adjustments and Repair procedures.

Repairs

Repairs include procedures for removal and replacement of parts which have the following special conditions:

When there is a personnel or machine safety issue.

When removal or replacement cannot be determined from the exploded view of the Parts List.

When there is a cleaning or a lubricating activity associated with the procedure. When the part requires an adjustment after replacement.

When a special tool is required for removal or replacement.

Use the repair procedures for the correct order of removal and replacement, for warnings, cautions, and notes.

Adjustments

Adjustments include procedures for adjusting the parts that must be within specification for the correct operation of the system.

Use the adjustment procedures for the correct sequence of operation for specifications, warnings, cautions and notes.

Section 5: Parts Lists

This section contains the Copier/Printer Parts List.

Section 6: General Procedures/Information

This section contains General Procedures, Diagnostic Programs, and Copier/Printer Information.

Section 7: Wiring Data

This section contains drawings, lists of plug/jack locations, and diagrams of the power distribution wire networks in the machine. Block Schematic Diagrams are found in pdf format in the SGS.

How to Use this Documentation

The Service Call Procedures in Section 1 describe the sequence of activities used during the service call. The call must be entered using these procedures.

Use of the Block Schematic Diagrams

Block Schematic Diagrams (BSDs) are included in Section 7 (Wiring Data) of the SGS. The BSDs show the functional relationship of the electrical circuitry to any mechanical, or nonmechanical, inputs or outputs throughout the machine. Inputs and outputs such as motor drive, mechanical linkages, operator actions, and air flow are shown. The BSDs will provide an overall view of how the entire subsystem works.

It should be noted that the BSDs no longer contain an Input Power Block referring to Chain 1. It will be necessary to refer to the Wirenets in order to trace a wire back to its source.

Symbology and Nomenclature

The following reference symbols are used throughout the documentation.

Warnings, Cautions, and Notes

Warnings, Cautions, and Notes will be found throughout the Service Documentation. The words WARNING or CAUTION may be listed on an illustration when the specific component associated with the potential hazard is pointed out; however, the message of the WARNING or CAUTION is always located in the text. Their definitions are as follows:

WARNING

Do not perform repair activities with the power on or electrical power supplied to the machine. The machine could activate and cause serious personal injury when the power is on or electrical power is supplied.

DANGER: Ne pas effectuer de dépannage avec le contact principal activé ou avec l’alimentation électrique appliquée à la machine: celle-ci pourrait démarrer et causer de graves blessures.

AVVERTENZA: Non effettuare alcuna riparazione con la macchina accesa o con l’alimentazione elettrica inserita. La macchina potrebbe avviarsi all’improvviso e causare gravi ferite.

VORSICHT: Es dürfen keine Reparaturarbeiten durchgeführt werden, solange das Gerät eingeschalten oder mit der Stromquelle verbunden ist. Das Gerät kann u.U in den AktivZustand übergehen und somit erhebliche körperliche Schäden verursachen.

AVISO: No realice reparaciones con la máquina encendida o conectada a la corriente. La máquina podría activarse y ocasionar daños personales graves.

CAUTION

A Caution is used whenever an operating or maintenance procedure, a practice, condition, or statement, if not strictly observed, could result in damage to the equipment.

NOTE: A Note is used whenever it is necessary to highlight an operating or maintenance procedure, practice, condition, or statement.

Machine Safety Icons

The following safety icons are displayed on the machine:

WARNING

Use extreme care when replacing the Raster Output Scanner (ROS) or touching the high voltage lead. Discharge the laser assembly by touching the high voltage lead to the machine frame. The ROS utilizes a laser assembly that stores a high voltage charge after the power has been removed and represents a shock hazard that could cause serious personal injury if not discharged.

DANGER: Faire très attention lors du changement du générateur de balayage (ROS) ou lors de la manipulation du câble de haute tension. Décharger le système laser en touchant le câble HT au bâti machine: le ROS utilise un système laser qui retient une haute tension après la coupure de l’alimentation, représentant un risque de choc et de graves blessures.

AVVERTENZA: Fare estrema attenzione nel sostituire il Raster Output Scanner (ROS) o nel toccare il cavo di alta tensione. Scaricare il complessivo laser collegando il cavo di alta tensione col telaio della macchina. Il ROS utilizza un complessivo laser che ritiene una carica di alta tensione dopo il taglio dell’alimentazione con conseguente grave pericolo di scossa elettrica e serie ferite.

VORSICHT: Beim Ersetzen der Lasereinheit (ROS) und beim Umgang mit Hochspannungsleitern ist äußerste Vorsicht geboten. Die Lasereinheit muss durch Berühren des Hochspannungsleiters mit dem Gehäuse des Geräts entladen werden. Nach Betrieb der Lasereinheit (ROS) bleibt immer eine Hochspannungsladung zurück, welche ein hohes Elektroschockrisiko darstellt. Äußerste Vorsicht ist geboten.

AVISO: Use extrema precaución para sustituir el Escáner de salida ráster (ROS) o tocar el cable de alto voltaje. Descargue el sistema láser tocando el cable de alto voltaje del bastidor de la máquina. El ROS utiliza un sistema láser que retiene carga de alto voltaje después de interrumpir la alimentación de energía y representa un grave peligro que puede ocasionar daños personales graves si no se descarga.

Figure 1 Laser Hazard Symbol

Laser Hazard Statement

DANGER INVISIBLE LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO BEAM.

CAUTION

The use of controls or adjustments other than those specified in the Laser Safety Training Program may result in an exposure to dangerous laser radiation.

For additional information, review the Laser Safety Training program.

An arrow points to the location to install, to gain access to, or to release an object.

Figure 2 Customer Access Label

WARNING

Do not defeat or electrically bypass the ROS Safety Interlock Switch for any reason. The ROS emits an undetectable laser beam that could cause serious permanent damage to the eyes if directly viewed or viewed from a surface that may have reflected the laser beam.

DANGER: Ne pas shunter le contact de sécurité du ROS, quelle que soit la raison. Le ROS émet un rayon laser indétectable qui peut causer de graves blessures permanentes aux yeux s’il est regardé directement ou par le biais d’une surface qui le réfléchit.

AVVERTENZA: Non ostacolare o bypassare elettronicamente l’interruttore blocco di sicurezza ROS per nessun motivo. Il ROS emette un raggio laser invisibile che può causare gravi ferite permanenti agli occhi se viene guardato direttamente o attraverso una superficie riflettente.

VORSICHT: Den ROS (Rasterausgabescanner)-Sicherheitssperrschalter auf keinen Fall vernichten oder elektronisch umgehen. Der ROS sondert einen nicht feststellbaren Laserstrahl ab, der irreparable Augenschäden verursachen kann, wenn direkt oder über eine Spiegelfläche hineingesehen wird.

AVISO: No intente modificar o desviar electrónicamente el interruptor de seguridad por ningún motivo. El ROS emite un rayo láser que no se puede detectar, que podría puede causar grave daño permanente a los ojos si se lo mira directamente o desde una superficie que refleja el rayo láser.

This symbol indicates that a surface can be hot. Use caution when reaching in the machine to avoid touching the hot surfaces.

Figure 3 Heated Surface Label

Danger label indicates where electrical currents exist when the machine is closed and operating. Use caution when reaching in the machine.

Figure 4 Shock Hazard Label

These symbols indicate components that may be damaged by Electrostatic Discharge (ESD).

Figure 5 ESD warning Label

Electrostatic Discharge (ESD) Field Service Kit

The purpose of the ESD Protection Program is to preserve the inherent reliability and quality of electronic components that are handled by the Field Service Personnel. This program is being implemented now as a direct result of advances in microcircuitry technology, as well as a new acknowledgment of the magnitude of the ESD problem in the electronics industry today.

This program will reduce Field Service costs that are charged to PWB failures. Ninety percent of all PWB failures that are ESD related do not occur immediately. Using the ESD Field Service Kit will eliminate these delayed failures and intermittent problems caused by ESD. This will improve product reliability and reduce callbacks.

The ESD Field Service Kit should be used whenever Printed Wiring Boards or ESD sensitive components are being handled. This includes activities like replacing or reseating of circuit boards or connectors. The kit should also be used in order to prevent additional damage when circuit boards are returned for repair.

The instructions for using the ESD Field Service Kit can be found in ESD Field Service Kit Usage in the General Procedures section of the Service Documentation.

Illustration Symbols

Figure 6 shows symbols and conventions that are commonly used in illustrations.

Signal Nomenclature

Refer to Figure 7 for an example of Signal Nomenclature used in Circuit Diagrams and BSDs.

Figure 7 Signal Nomenclature

DC Voltage Measurements in RAPs

The RAPs have been designed so that when it is required to use the DMM to measure a DC voltage, the first test point listed is the location for the red (+) meter lead and the second test point is the location for the black meter lead. For example, the following statement may be found in a RAP:

There is +5 VDC from TP7 to TP68.

In this example, the red meter lead would be placed on TP7 and the black meter lead on TP68.

Other examples of a statement found in a RAP might be:

•There is -15 VDC from TP21 to TP33.

•-15 VDC is measured between TP21 and TP33.

•In these examples, the red meter lead would be placed on TP21 and the black meter lead would be placed on TP33.

•If a second test point is not given, it is assumed that the black meter lead may be attached to the copier frame.

Service Call Procedures

Service Strategy

The service strategy for the WorkCentre 5335 Family is to perform any High Frequency Service Item (HFSI) actions before attempting to repair any problems. Some problems will be corrected by this strategy without the need to diagnose them. The Repair Analysis Procedures (RAPs) will be used for any remaining problems.

Problems that occur in the Basic Printer mode will be repaired before problems that occur when using the accessories.

Image Quality problems should be repaired after all other problems are repaired.

Service Call Procedures

The Service Call Procedures are a guide for performing any service on this machine. The procedures are designed to be used with the Service Manual. Perform each step in order.

Initial Actions

The Initial Actions gather information about the condition of the machine and the problem that caused the service call.

Call Flow

Call Flow summarizes the sequence of the Service Call Procedures.

Detailed Maintenance Activities

Detailed Maintenance Activities section provides the information needed to perform the High Frequency Service Item (HFSI) actions.

Cleaning Procedures

The Cleaning Procedures list what needs to be cleaned at each service call.

Final Actions

The Final Actions will test the copier/printer and return it to the customer. Administrative activi-

ties are also performed in the Final Actions.

Initial Actions

Purpose

The purpose of the Initial Action section of the Service Call Procedures is to determine the reason for the service call and to identify and organize the actions which must be performed.

Procedure

1.Gather the information about the service call and the condition of the copier/printer.

a.Question the operator(s). Ask about the location of most recent paper jams. Ask about the image quality and the copier/printer performance in general, including any unusual sounds or other indications.

b.After informing the customer, disconnect the machine from the customer’s network.

c.Check that the power cords are in good condition, correctly plugged in the power source, and free from any defects that would be a safety hazard. Repair or replace the power cords as required. Check that the circuit breakers are not tripped.

d.Inspect any rejected copies. Inquire as to, or otherwise determine, the paper quality and weight, the specified paper for optimum Image Quality, 24# Xerox Color Expressions (NASG) or ColorTech+90gsm (ESG). Look for any damage to the copies, oil marks, image quality defects, or other indications of a problem.

e.Record the billing meter readings.

f.Access Diagnostic Routines (Accessing UI Diagnostics)..

NOTE: If a fault code is displayed while performing a diagnostics procedure, go to that fault code RAP and repair the fault. Return to Diagnostics and continue with the dC procedure that you were performing.

g.Print the HFSI Report and determine what HFSI action is required based on the customer output volume. Refer to the Detailed Maintenance Activities section for the detailed HFSI information. Record any items that require action.

h.Display and record the information in the Jam Counter, Fault Counter, and Shutdown History. Classify this information into categories:

Information that is related to the problem that caused the service call.

Information that is related to secondary problems.

Information that does not require action, such as a single occurrence of a problem.

i.Check the Service Log for any recent activities that are related to the problem that caused the service call or any secondary problem.

2.Perform any required HFSI activities identified above. Refer to the Detailed Maintenance Activities section.

3.Exit diagnostics. Try to duplicate the problem by running the same jobs that the customer was running.

4.Check the Image Quality in the Basic Copier Mode. Select the tray that is loaded with 11 x 17 or A3 paper, if unable to complete tray selection, go to Call Flow.

Set the copier/printer to the following setup:

• Output Color — Auto

• Original Type — Photo and Text Halftone

•R/E — Auto

•Lighter/Darker — Auto Contrast

•Sharpness — Normal

•Preset Color Balance — Normal

•Color Shift — Normal

•Color Saturation — Normal

•Copy Position — No Shift

•Variable Color Balance — Normal

Run four copies of the Color Test Pattern.

Check the Image Quality. If the customer has identified any Image Quality Defects or problems, go to IQ1 IOT Image Quality Entry RAP.

5.Go to Call Flow.

Call Flow

This procedure should be performed at every service call.

Initial Actions

Ask the operator about the problem. If the problem appears to be related to operator error, or an attempt to perform a job outside of the machine specifications, assist the customer in learning the correct procedure.

Procedure

Ask the operator about the problem.

•If the problem is identified by a fault code (including Paper/Document Jams), refer to Section 2 for the procedure and then proceed with servicing.

•If the problem is noise or smell, select a mode (1 Sided/2Sided, Finisher etc.), find the cause of the problem and proceed with servicing.

The operator operated the machine correctly.

YN

Explain to the operator how to operate the machine correctly.

The UI display is normal.

YN

Go to Machine Not Ready RAP. Refer to BSDs (CH2.1-CH2.4).

The problem occurs only in Print mode.

YN

The problem occurs only in Copy mode. Y N

The problem occurs only in Fax mode. Y N

There is an error message displayed. Y N

Refer to Table 1 Other Faults and identify the problem and follow the corrective action.

Refer to Table 2 Error Messages and identify the message and follow the corrective action.

The problem occurs only in certain modes such as Broadcast transmission.

YN

Perform a transmission test with the call center or station. The problem reoccurs.

Y N

Ask the customer for permission to establish communications with the remote machine that is causing the problem. Perform a Send transmission test with the remote machine. Transmission was normal.

Y N

Print the protocol trace to identify whether it is the remote machine or the machine that is causing the problem.

•If the problem lies in the machine:

A B C D E

Analyze the protocol trace, refer to Section 2 and then proceed with servicing.

•If the problem appears to lie in the remote machine:

Ask the customer to check the status of the remote machine.

There is a problem with Receive transmission test. Perform Receive transmission tests with other stations within the company. Check that there is no problem with the machine and then ask the customer to check the status of the remote machine.

Analyze the protocol trace, refer to Section 2 and then proceed with servicing.

Check the machine settings and if necessary, ask the customer for permission to test the machine in the mode in which the problem occurs.

Analyze the protocol trace when the problem reoccurs, for FAX problems go to GP 13 FAX Diagnostics, or go to Section 2 to proceed with servicing.

There is an image quality problem.

YN

If there is an alignment problem, obtain separate Platen/DADF output samples, refer to Section 4 Adjustments and then proceed with servicing.

Refer to Section 3 IQ1 IOT Image Quality Entry RAP and then proceed with servicing.

There is a problem with the network.

YN

There is a problem with the USB connection. Y N

There is an image quality problem. Y N

The problem lies in a certain Client PC. Y N

There is a problem with a certain application or programming language A. Obtain the latest information on restrictions and technical information. Proceed accordingly.

Check the settings of that particular Client PC and if necessary ask the user to reinstall the printer driver.

Refer to IQ1 IOT Image Quality Entry RAP and then proceed with servicing. If the problem persists, ask the user to reinstall the printer driver.

Check the machine settings and if necessary ask the user to reinstall the printer driver.

F

If the problem continues, replace the network cable. If the problem persists, replace the USB cable. Check the machine settings and discuss the problem with the customer’s network administrator.

Detailed Maintenance Activities (HFSI)

Procedure

1.Access Diagnostic Routines (Accessing UI Diagnostics).

2.Select NVM Read/Write.

3.Refer to Table 1 and enter a counter number for any High Frequency Service Item (HFSI) counters to be checked. Use the customer’s output volume numbers to help determine which HFSI components should be serviced. Consider components near threshold as candidates for service.

4.Refer to Cleaning Procedures for detailed cleaning instructions.

Table 1 High Frequency Service Items

Cleaning Procedures

Purpose

To provide cleaning procedures to be performed at every service call.

Procedure

CAUTION

Do not use any solvents unless directed to do so by the Service Manual.

General Cleaning

Use a dry lint free cloth or a lint free cloth moistened with water for all cleaning unless directed otherwise by the Service Manual. Wipe with a dry lint free cloth if a moistened cloth is used.

1.Feed Components (Rolls and Pads)

Follow the General Cleaning procedure above.

2.Toner Dispense Units

Vacuum the Toner Dispense units.

3.Jam Sensors

Clean the sensors with a dry cotton swab.

4.Scanner

a.Switch off the power and allow the Exposure Lamp to cool off.

b.Using the optical Cleaning Cloth, clean the front and rear of the Document Glass, Document Cover, White Reference Strip, Reflector, and Mirror.

c.Clean the Exposure Lamp with a clean cloth and Film Remover.

d.Clean the Lens with Lens and Mirror Cleaner and lint free cloth.

5.DADF

Check the paper path for debris or damage. Clean the rolls with a clean cloth and Film Remover as required.

6.Document Glass and Constant Velocity Transport Glass

Follow the General Cleaning procedure above.

7.Finisher

Check the paper path for debris or damage. Clean the Finisher with a dry lint free cloth.

Final Actions

Purpose

To provide a guide for procedures to be done at the end of every service call.

Procedure

1.Ensure that the exterior of the copier/printer and the adjacent area are clean. Use a dry cloth or a cloth moistened with water to clean the copier/printer. Do not use solvents.

2.Check the supply of consumables. Ensure that an adequate supply of consumables is available according to local operating procedures.

3.Complete the Service Log.

4.Perform the following steps to make a copy of the Demonstration Original for the customer:

a.Load Tray 1 with 8.5 x 11 inch (A4) or 11 x 17 inch paper.

b.Place the Color Test Pattern on the glass with the short edge of the test pattern registered to the left edge of the glass. Select Tray 1 and make a single copy.

c.Print out the Machine Settings (Configuration Report). Store this report with the service log in the Inner Cover.

d.Ask the customer to verify the Print and Scan functions.

e.Present the copies to the customer.

5.Reconnect the machine to the customer network. Verify the function.

6.Issue copy credits as needed.

7.Discuss the service call with the customer to ensure that the customer understands what has been done and is satisfied with the results of the service call.

Service Call Procedures

Final Actions

Chain 003 — Controller

010 Fuser

Chain 012 (Integrated Finisher)

Chain 012 (Finisher LX)

Chain 013 (Finisher LX)