c35_tech_info_manual.pdf

®

Xerox® C-35 & DC535 styles * TECH-INFO. MANUAL

Supplemental Technical Information for:

(CopyCentre®) C35, C45, C55,

(WorkCentre®) M35, M45, M55, Pro35, Pro45, Pro55 (DocumentCentre®) DC535, DC545, DC555

(CopyCentre®) C165, C175, (CC)232, (CC)238, (CC)245, (CC)255, (CC)265, (CC)275 (WorkCentre®) M165, M175, (WC)232, (WC)238, (WC)245, (WC)255, (WC)265,

(WC)275, Pro165, Pro175, Pro232, Pro238, Pro245, Pro255, Pro265, Pro275 (WorkCentre®) WC5030, WC5050, WC5632, WC5638, WC5645, WC5655, WC5665,

WC5675, WC5687

* The name Xerox and all of the model designations in this book are trademarks of Xerox Corporation. Xerox is in no way affiliated with the production of this book.

Service-Excellence C35 style Tech Info Manual

(Section A – Introduction) p.A-2

INDEX Section A – Introduction p.A-4 to A-5 Introduction to the C35 style machines p.A-5 to A-6 Disclaimer and Warnings p.A-7 Model Names, Numbers & Pseudonyms p.A-8 Machine Specifications p.A-9 Machine Options & Configurations p.A-10 Dimensions & Space Needed p.A-11 to A-12 Supplies & CRU’s (Customer Replaceable Units) p.A-13 Acronyms & Abbreviations Section B – Fault Codes & Troubleshooting p.B-1 Reading Status or Fault Codes p.B-1 to B-6 Fault / Status Code List p.B-7 to B-13 Troubleshooting for specific Faults Section C – Diagnostic Adjustments & Tests p.C-1 Entering Diagnostic Mode p.C-2 to C-7 Memory Adjustments – NVM Read / Write (Dc131) p.C-8 User Interface Test (dC305) Network Echo Tests (dC312) Network Connectivity Tests (dC314) p.C-9 Component Tests (dC330) p.C-10 to C-13 Input Component Test List p.C-13 to C-14 Output Component Test List p.C-15 Registration Setup (dC604) p.C-16 Developer Calibration (Dc905) p.C-17 to C-18 Optional Feature Reinstallation Codes



Section D – Part Replacement Procedures p.D-1 Orientation Photo (front view) LCSS (Large Capacity Stacker / Stapler) p.D-2 Network Module Document Feeder (DADF) Fuser Module Xerographic Module (Drum Cartridge) Transfer Corotron Assembly p.D-3 Developer Unit Toner Dispense Assembly p.D-4 Toner Waste Bottle Door Power & Control Module p.D-5 Feed Rolls Tray 1 & 2 Feed Head Assemblies p.D-6 Tray 3 & 4 Feed Head Assemblies Image Processing Board Module p.D-7 Control Console Scanner Bed Assembly Raster Output Scanner (ROS or Laser Unit) p.D-8 Fuser Latch & Xerographic Latch Erase Lamp p.D-9 Main Drives Module p.D-10 Duplex Transport Module p.D-11 Short Paper Path p.D-12 Registration Transport p.D-12 to D-13 Inverter Module

Section E – Module Repair & Rebuilding p.E-1 to E-4 Fuser Module Repairs & Rebuilding p.E-5 to E-8 Xerographic Module Repairs

Section F – Sourcing Parts



p.F-1 to F-8 C35 style Part #’s & The Parts Drop INTRODUCTION The C35 style and the DC535 style machines are part of a rapidly proliferating series of Xerox black and white digital copier / multifunction machines. They are fast for their size and capable of making some of the most impressive copy quality out there… Our test machine produced extremely solid black areas. Options include a High Capicity Feeder which holds up to 3000 sheets of paper, a Large Capacity Stacker / Stapler / 3-hole punch, and a Network Module. The networking machines can scan, print, email… you name it. They turn out to be relatively friendly to work on too which is a huge plus. There are a few exceptions… the OEM kit for the Fuser Latch is very time consuming to replace (figure on 1 to 1 ½ hours) when it looks at first like it would be a very quick fix. Fortunately, there is now an aftermarket Latch Kit which includes hardware which makes it unnecessary to remove the Scanner Assembly (that makes the replacement quick again). Xerox has chosen not to spare most of the fuser parts except as a complete Fuser Module. If you wish to repair or rebuild the fusers, you can find quality replacement parts on p.F-7. There are a few other things which turn out to be tricky. For one, the machine requires that something be plugged into the Exit end of it. If the machine does not have an OCT (Oscillating Catch Tray ) nor a Finisher, it will refuse to print or copy until you plug something into it. The logic list shows an option for “Simple Catch Tray” but that setting did not work on the machines we tested. A generic Simple Catch Tray Enabler Plug is available for this purpose (p.F-8). At first glance, the first bunch to have been released (DC535, DC545, DC555) look very different from the machines which were released after them. The C35 and all of the others in this series have different covers… they have that sculptural front cover which looks almost like the machine is smiling at you. Inside, it turns out that the C35 and DC535 are in fact the same



engine. Just goes to show that you can’t judge a copier by its covers. Newer models keep coming out… Most recently the WorkCentre 5030, 5050, 5665, 5675, & 5687 models, . Some of the newcomers are considerably faster machines. The Pro275 boasts 75 pages per minute… over twice the speed of the C35. There are differences from model to model, but a majority of the diagnostics and repair procedures appear to be consistent throughout the series. The newest models being introduced may have yet unforeseen differences, but they are likely to follow fairly closely. This ‘Tech-Info Manual’ is best used as a quick-reference guide & supplement, in conjunction with the full OEM Service Manual. It turned out to be impractical to include the fax related codes and adjustments in this book (the service manual has hundreds of codes relating to faxing… they are simply too long to list here). If you need details on the fax capabilities or other advanced functions, you’ll need to pick up a full Service Manual. If you are working on these machines regularly, we highly recommend that you invest in the full Service Manual from Xerox using their part number: 708P88169 (It sold for $360.06 as of Feb. 2007… It covers: C35/45/55, M35/45/55, Pro35/45/55, DC535, DC545, & DC555). See the OEM Documentation website: www.xdss.com (enter the part number into their search field to find it). This book was compiled by referring to the Service Manual for the C35/45/55, M35/45/55, Pro35/45/55, DC535/545/555, by listening to field experience, and by studying a DC555 machine. The photos are of our own, beloved DC555. DISCLAIMER & WARNINGS: YOU MUST TAKE 100% RESPONSIBILITY: The information presented herein is designed to be used by a trained, qualified copier technician. Without the knowledge which comes with training & experience, you risk your own safety and could cause more damage than good to the machine. Unless you

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are willing to take 100% responsibility for your actions, do not use the information in this book. ELECTRICAL SAFETY: Always power down and unplug the machine from the wall outlet before working on any of the internal parts of the machine. Potentially deadly electrical voltages may be present even if the machine is turned “off”. Also moving mechanical parts can cause serious injuries. STATIC / ESD (Electrostatic Discharge) SAFETY: Many of the electrical components in these machines are highly sensitive to static discharge. Use standard industry ESD practices when handling any boards or electrical components. A wrist ground strap is recommended. Electronic components should always be stored and shipped in Anti-Static bags and packaging. EXTREMELY HOT PARTS: Some parts, particularly in the Fuser Module can be extremely hot and may take quite some time to cool down. To avoid a serious burn, don’t touch anything until you are sure that the machine has had enough time to thoroughly cool off. THE PUBLISHER IS NOT LIABLE FOR ERRORS: Neither the publisher nor the seller of this book can be held liable for any misprints or errors contained in this book. We welcome feedback if you find an error so that we can make corrections in future publications, but we do not in any way guarantee the accuracy of the information presented here. Neither the publisher nor the seller of this book can be held liable for any problems or damages, technical or otherwise, resulting from someone using the information presented in this book. Again, if you are not willing to take 100% responsibility for your actions, do not use this book.



MACHINE SPECIFICATIONS:

Model Names, Numbers & Pseudonyms: It has become more important than ever to pay close attention to the exact model name and number on the machine you’re working on. Many of these model numbers are used in other series of Xerox equipment and confusion is almost by design. Two examples:

• WorkCentre 265 (covered in this book) vs. DocumentCentre 265 (a larger machine from the DC265 style)

• DocumentCentre 555 (covered in this book) vs. WorkCentre Pro555 (a much smaller fax machine not covered here)

DC555 style (DC535F (family))models and pseudonyms: DocumentCentre 535 (DC535, DC535F), DocumentCentre 545 (DC545), DocumentCentre 555 (DC555, DC555F) Models which do NOT belong to this “style”(even though they sound like they fit): (WorkCentre) Pro545, Pro555 C35 style models and pseudonyms: CopyCentre - C35, C45, C55, (also called CC35, CC45, CC55), C165, C175, 232, 238, 245, 255, 265, 275 (also called CC232, CC238, CC245, CC255) WorkCentre – 232, 238, 245, 255, 265, 275, 5030, 5050, 5632, 5638, 5645, 5655, 5665, 5675, 5687, M35, M45, M55, M165, M175, (also called WCM35, WCM45, WCM55, WCM165, WCM175) WorkCentre - Pro35, Pro45, Pro55, Pro165, Pro175, Pro232, Pro238, Pro245, Pro255, Pro265, Pro275 (also called WCP35, WCP45, WCP55, WCP165, WCP175, WCP232, WCP238, WCP245, WCP255, WCP265, WCP275) Models which do NOT belong to this “style”(even though they sound like they fit): 5665 (earlier copier in the 5340 style), (DocumentCentre) DC 255, DC 265

Specifications: Pages Per Minute (ppm): last 2 digits are the speed: DC535, C35, M35, Pro35 = 35ppm, DC545, C45, M45, Pro45 = 45ppm, DC555, C55, M55, Pro55 = 55ppm



C165/265, M165/265, Pro165/265 = 65ppm C175/275, M175/275, Pro175/275 = 75ppm Stated Duty Cycle: 35ppm machines = up to 100,000 pages per month 45ppm machines = up to 150,000 pages per month 55ppm machines = up to 200,000 pages per month 65ppm machines = up to 250,000 pages per month 75ppm machines = up to 300,000 pages per month 87ppm machine = up to 400,000 pages per month First-Page-Out Time: For 35 ppm machines: 4.6 seconds For 45 or 55 ppm machines: 3.4 seconds For 65 - 87 ppm machines: 2.7 seconds Power On Time: 99-105 seconds (around 2 minutes) for fuser to warm up. 200-300 seconds (4-5 minutes) for Network Controller to initialize. Memory: 128 MB or 256 MB Standard (expandable to 512 MB) Resolution: 600 x 600 dpi x 8 bit Reduction / Enlargement: 25 – 400% (in 1% increments)… 6 User Programmable Set Points. OEM Stated Paper Specifications… It is helpful to know what is reasonable to expect from a particular machine in regards to paper sizes and weights. Paper Sizes: 8 1/2 x11 (or A4) ok in all trays… 8 1/2 x 14 or 11 x 17 (or A3, A5, or A6) in Trays 1, 2, bypass and duplex. (not in tray 3 or 4). Light paper (16 lb.): From all trays: “Good performance (good image quality, some jams and poor stacking)” Regular paper (20 lb. – 32 lb.) From all trays: “Excellent performance” Heavier paper (34 lb. – 53 lb.) From all trays: “Good performance (good image quality, some jams and poor stacking)” Cardstock (57 lb.): Bypass and Duplex only: “Good performance (good image quality, some jams and poor stacking)” Labels: Bypass only. Transparencies: Bypass only (do not use white strip or paper backed transparencies at all).



Note: Use good paper… Encourage your customer to use quality paper… it helps with copy quality, reduces jamming, and produces less paper dust which cuts down on other potential failures. Document Feeder capacity = 75 or 100 originals (13-32 lb paper) Options & Configurations: Document Handling: Flat Top Platen or DADF (Duplexing Auto. Document Feeder) Stand: Machines which are without the HCF (High Capacity Feeder) are available with or without a stand. Paper Tray Options & Capacities: Tray 1 & 2: two 550 sheet capacity cassettes (drawers) (Standard) Bypass Tray: 100 sheet capacity (fold down tray) HCF (High Capacity Feed Module… also called the High Capacity Tandem Tray on some models) (Optional - Trays 3 & 4): Tray 3 = 1600 sheet capacity Tray 4 = 2000 sheet capacity drawer. Tray 5 High Capacity Feeder (4000 sheet capacity) this one is found on the left side of the machine in a separate module. Envelope Feeding Kit (Optional - fits into Tray 2). Output options: Simple Catch Tray – the OEM parts list does not show this option. An aftermarket option is available which includes a Simple Catch Tray Enabler Plug (you’ll need that plug to run the machine without the Finisher or OCT plugged in). See p.F-8 OCT (Offsetting Catch Tray) holds 300 sheets LCSS (Large Capacity Stapler Stacker) Top Tray holds 250 sheets, Stacker holds 2000 sheets Stapling - 50 sheets max for Automatic Stapling… 40 sheets max for convenience stapling. Hole Punching (optional for LCSS): 2 or 3 holes for US, 2 or 4 holes for Europe. Note that the Parts List does not show a “Simple Catch Tray” as being an option. Oddly enough, however, there is a memory setting for “Finisher Type” which has as one of the choices “No Finisher” (dC131 NVM code 12-001)… so something could probably be rigged if you were stuck without an Output device. Basic Office Finisher – This type does not touch the floor.



Advanced Office Finisher – Top Tray holds 250 sheets, Stacker holds 3000 sheets…available on the newer models such as C165/175, C232/238/245/255/267/275 etc Professional Office Finisher – also only on the newcomers… does saddle stitching etc. HVF (High Volume Finisher) – Top Tray holds 25 sheets, Stacker holds 3,000 sheets… only sold with the newest models. Network Controller: Optional… A box which hangs off of the lower rear cover of the machine. 433 MHz Intel Celeron Processor 64 MB of RAM (upgradeable to 128 MB) Newer, faster models: 1.46 MHz AMD Athion dedicated Processor 128 MB of RAM (upgradeable to 512 MB) Dimensions & Space Needed:

Weight of machine: Approx. 295 lbs (standard config w/ Doc Feeder & Net Controller) Add 63 lbs for Office Finisher, or 168 lbs for Advanced Office Finisher or Professional Finisher. Height of machine (on cabinet or High Capacity Feeder): Height with Flat Top Platen: Height with DADF (document feeder) : 44 inches Height with DADF raised: 57 inches Depth of machine: 26 inches (or 33 inches for the Pro35/45/55 which have an extra curved “Rear Wall” piece). + 4 inches: Always allow a minimum of 4 inches clear at the rear for the machine to circulate air and cool itself properly. Width of machine: 38 inches for machine with OCT (Oscillating Catch Tray) 48 inches for machine with LCSS (Large Capacity Stapler Stacker) 59 inches for Pro35/45/55 with LCSS (these have an extra document work shelf to the left) Working Width: It is recommended that you allow room for operation / service as follows: 77 inches clear for proper operation of a machine with an OCT. 87 inches clear for machines with an LCSS. 95 inches clear for machines with an Advanced Office Finisher. 98 inches clear for machines with a Professional Finisher.



Supplies & Customer Replaceable Units (CRU’s)

Toner: (Cases of 2 Cartridges with one Waste Toner Bottle) For: DC535/545/555, C35/45/55, M35/45/55, Pro35/45/55, CC-232/238/245/255, WC-232/238/245/255, Pro232/238/245/255, WC-5030/5050, WC-5632/5638/5645/5655 6R1046 = Yield = 28-30,000 copies per Cartridge (at 6% cover) For: CC-C165/175, CC-265/275, WC-M165/175, WC-265/275, WC-Pro165/175/265/275, WC-5665/5675/5687 6R1146 = Yield = 45,000 copies per Cartridge (at 6% coverage) Staple Cartridges: 108R493 – For LCSS, Office Finishers & Advanced Office Finishers Box of 3 Ctgs… (5,000 staples per ctg.) 108R682 / 108R535 – For Basic Office Finisher 108R682 = Box of 1 Ctg… (3,000 staples per ctg.) 108R535 = Box of 3 Ctgs… (3,000 staples per ctg.) 8R12897 – For Saddle Stitcher Head on Professional Finisher. Box of 8 Ctgs. (2,000 staples per ctg.) 8R12964 – Ctg (w/ body)…For Convenience Stapler 1 Ctg. (w/ ctg body) (3,000 staples) 8R12941 – 3 Ctg Refills (for replenishing 8R12964 body) (3,000 staples per refill) Fuser Modules: (ozone filter included) For: DC535/545/555, CC-C35/45/55, WC-M35/45/55, WC-Pro35/45/55, WC-5030/5050 (Yield = 350K) 109R636 (110 volt – U.S.) 109R634 (220 volt – Europe) 109R750 (220 volt – Swedish) For: CC-232/238/245/255, WC-232/238/245/255, WC-Pro232/238/245/255, WC-5632/5638/5645/5655 109R752 (110 volt – U.S.) 109R751 (220 volt – Europe) For: CC-C165/175, CC-265/275, WC-M165/175, WC-265/275, WC-Pro165/175/265/275



109R723 (110 volt – U.S.) 109R724 (220 volt – Europe) For: WC-5665/5675/5687 109R773 (110 volt – U.S.) 109R772 (220 volt – Europe) Xerographic Modules (Drum Ctgs.) (Transfer Corotron Assembly included) For DC535/DC545/DC555, CC-C35/45/55, WC-M35/45/55, WC-Pro35/45/55, CC-232/238, WC-232/238, WC-Pro232/238, WC-5030/5050, WC-5632/5638 : (Yield = 200,000) 113R608 (U.S. or Europe “Metered” version) 113R610 (U.S. “Sold” version) 113R607 (Europe “Sold” version) For CC-C165/175, CC-245/255/265/275, WC-M165/175, WC-245/255/265/275, WC-Pro165/175/245/255/265/275, WC-5645/5655/5665/5675/5687 : (Yield = 300,000) 113R672 (U.S. “Metered” version) 113R674 (U.S. “Sold” version) 113R673 (Europe “Sold” version) Document Feed Heads: (Yields = 150,000 pages) For: DC535/545/555, C35/45/55, M35/45/55, Pro35/45/55 : 113R497 / 113R651 For: C232/238/245/255, M232/238/245/255, Pro232/238/245/255 : 113R686 For: WC-5632/5638 113R717 For: WC-5645/5655/5665/5675/5687 : 113R718 Note: The two tires and the Retard Roll are the same for the different types of Document Feed Heads.

Service Manual: 708P88169 = covers the DC535/545/555, C35/45/55, M35/45/55, Pro35/45/55…. Sells for around $360.- from Xerox (www.xdss.com). An excellent, and extremely detailed book. They have plenty of illustrations and wiring diagrams in there. Other models… the service manuals have not yet been found to be available.

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(Section B - Fault Codes & Troubleshooting) p.B-1

STATUS & FAULT CODES:

Reading the Status or Fault Codes: Often the Fault Code is not displayed at first… Customers will likely call with vague messages which show up on the screen. User Interface “Active Faults” and “Error Log”: You might want to ask your customer to go into the User Interface Tools and have them look at the “Active Faults” and / or the “Error Log”. This is done by pressing ‘Access’ and entering the default passcode ‘1111’ followed by ‘Enter’… Once in the “User Tools” menu, have them press the “Machine Status” button on the Control Console (it has an icon next to it which looks like an illustration of the machine with a question mark on it). Have them press the ‘Fault’ tab on the touchscreen and then press ‘Active Messages’ Ask them to read the codes and messages which are shown. They can also choose ‘Error Log’ to see a bit of the Fault History. If they report a code which has a ‘5’, or ‘9’ starting the second part of the code (xx-5xx … for example: 02-530), these types of codes will only give you a vague hint as to what is really going on in the background. Look up the “Chain” on the list below (the first two digits in the code) to get an idea which part of the machine is causing the fault. Fault History / Last 40 Faults from Diagnostics: When you get on-site, you’ll want to enter Diagnostic Mode (from the powered-on state, press and hold down the ‘#’ button and then press the ‘Access’ button. Enter the default password ‘1934’ followed by ‘Enter’). Once you are in Diagnostics, press ‘Fault History’ and then choose “Last 40 Faults”. Read the most recent bunch of Status Codes to see what’s really going on.

Fault Code Listings: * Codes with an asterisk are covered in more detail in the Troubleshooting section of this book. Some may require resetting from Diagnostics. Chain 01 01-xxx Codes

Interlock problems.

* 01-300 Front Door Interlock Opened during a copy run.*(See p.B-7) * 01-305 Left Door interlock Opened during a copy run.*(See p.B-8) Chain 02 02-xxx Codes

UI (User Interface) Control Console problems.

02-309 UI (User Interface) Control Panel or Touchscreen failed the UI test.

02-320 / 380 UI communications failure… between the UI and the Image Processor or the main controller.

02-390 / 391 / 704 / 706

UI software error… This can mean that one or more of the Services which the UI is programmed to expect are not present and stable within 5 minutes.

02-705 / 707 / 709 / 715

UI component failures have been detected… such as buttons, audio, LCD or LEDs.



FAULT / STATUS CODES (Continued) Chain 03 03-xxx Codes

These relate to Communication Errors between the boards… It may be worth trying to power down the machine, unplug it from the wall and check for any loose or damaged wires or connectors.

03-300 / 306 / 370 / 461 / 805 / 870

Communication error between the Image Processing Board and the IOT (Main) Board.

03-310 / 317 Communication error between the Imaging Processing Board and the User Interface (control console). Check wiring and connections between the two boards… also between the User Interface and Power Distribution Boards.

* 03-315 / 325 / 347 / 348 / 349 / 355 / 400 / 411

Communication error within the Image Processing Board… check for loose connections & make sure the Image Processing Board’s Cooling Fan is working. *(See p.B-8)

03-320 / 322 / 323 / 324

Communication error between the Image Processing Board and the DADH (Duplexing Automatic Document Handler).

* 03-330 / 462 Communication error between the Image Processing Board and the Scanner Driver Board or CCD Board. *(See p.B-8)

* 03-331 / 340 / 416

Communication error between the Image Processing Board and the Network Controller. *(See p.B-9)

03-336 Fax Card self test failed. 03-338 Image Processor to Fax Card communication failure. Try

removing the Fax Card and reinstalling it after about 3 min. 03-350 / 351 / 354

Communication error between the Main Board (IOT) and the Tray 1 & 2 Control Board.

03-359 / 407 Communication error between the High Capacity Feeder (HCF, Trays 3 & 4) and the Tray 1 & 2 Control Board… or the HCF is not detected when it is expected.

03-360 / 408 / 410 / 418

Communication error between the Main Board (IOT) and the Output Device (either an OCT Oscillating Catch Tray or an LCSS Large Capacity Stacker Stapler).

* 03-365 Main Board (IOT) bus failure. This code can show up due to electrical noise in the machine among other possibilities. *(See p.B-9)

03-371 Fuser CRUM Connector Communication Failure. Watch for a broken Fuser Latch first or a damaged CRUM socket in the machine. Could also be the CRUM connector on the Fuser is damaged or defective and should be replaced.

03-372 Xerographic Module Connector (CRUM) Communication Failure. Make sure the Xerographic Module (drum ctg) is able to seat properly and that the cartridge latch is not broken. If all else checks out, replace the CRUM Connector on the Xerographic Module.

* Read more about these codes in “Troubleshooting” (p.B-7 to B-12)



03-374 Power Off failure. 03-395 / 396 / 852 / 853

Main Board (IOT) faults… Check all connections at the Main Board. Ground problems can cause these faults.

03-397 Main Motor Control logic failure. 03-401 / 403 Fax Card not detected. 03-412 Foreign Device problem. (coin-op or card reader, or other). 03-417 Incompatible Fax software. 03-419 Incompatible software between the Image Processing Board

and either the Main Board (IOT) or the DADH (Duplexing Automatic Document Feeder).

03-423 / 424 / 433 / 434 / 821 / 822 / 831 / 832

Print command late… does not usually prevent the machine from running… sometimes a blank sheet may be delivered to the output tray. Delete the job and turn the machine off and back on.

03-480 Main Board detects failure on the 24 volt line. Could be a Power Supply or Power Distribution failure.

03-700 / 780 / 785 / 790

Power on or off Status Codes. (Codes logged normally when the machine’s power is turned on or off)

03-770 Main Board (IOT) Software Reset. Does not prevent the machine from running… this code is logged into the fault history whenever the IOT is reset due to a software fault.

03-777 Power loss detected. (from the wall) Chain 05 05-xxx Codes

DADH Problems (Duplexing Automatic Document Handler).

* 05-300 DADH opened during a copy run. *(See p.B-9) 05-305 DADH top cover is open. 05-310 Document too short (under 110mm). 05-330 DADH misfeed – Lead edge of document not detected. 05-331 DADH misfeed – Trail edge of document not detected in

time. 05-335 DADH jam – The document Takeaway Sensor didn’t detect

the document’s lead edge. 05-340 DADH jam – The document Registration Sensor didn’t

detect either the document’s lead edge or the trail edge. 05-345 / 346 DADH Exit Jams – The document exit sensor didn’t detect

the lead edge of the document in time or the trail edge. 05-350 / 352 DADH Continual Velocity Transport (CVT) jam. The CVT

sensor failed to see either the lead edge of the document in time or the trail edge.

Chain 06 06-xxx Codes

ROS (Raster Output Scanner or Laser Unit) Problems.

06-020 ROS Motor Failure. * 06-340 / 350 ROS Laser failures. *(See p.B-10)



FAULT / STATUS CODES (Continued) Chain 07 07-xxx Codes

Tray Interlock or Lift Problems.

* 07-301 Tray 1 opened during a copy run.* (see p. B-10) * 07-302 Tray 2 opened during a copy run.* (see p. B-11) * 07-303 Tray 3 opened during a copy run.* (see p. B-11) * 07-304 Tray 4 opened during a copy run.* (see p. B-11) 07-355 Tray 3 Elevator Lift problem. 07-360 Tray 4 Elevator Lift problem. Chain 08 08-xxx Codes

Misfeeds & Paper Jams.

08-100 Wait Sensor Jam. 08-101 / 111 Tray 1 Misfeeds. 08-102 / 112 Tray 2 Misfeeds. 08-103 / 113 Tray 3 Misfeeds. 08-104 / 114 Tray 4 Misfeeds. 08-106 Sheet late to Tray 1 Feed Sensor when fed from another tray. 08-107 Tray 3 Paper Feed Jam. 08-108 Tray 4 Paper Feed Jam. 08-150 / 151 Registration Jam. 08-155 / 156 Bypass Tray Registration Jam. 08-160 / 161 Duplex Paper Path Jam. 08-171 Unexpected time-out… A jam was detected in the machine at

power on. 08-174 Missing Pre-release sheet. 08-181 Unexpected time-out in simplex inverted mode. 08-182 Unexpected time-out in duplex mode. 08-190 Post Jam clearance initialization. Chain 09 09-xxx

Xerographic problems… High Voltages, Toner dispense or Developer problems.

09-060 High Voltage problem… can be caused by an arcing transfer corona or arcing charge grid on the drum cartridge.

09-310 / 390 The Toner Dispense Motor continued to run after the low toner sensor detected that the toner dispense module is full.

* 09-350 Erase Lamp problem.*(See p.B-11) * 09-360 / 361 / 362 / 363

Toner Concentration Sensor problems… These Faults must be cleared from Diagnostics by resetting NVM Memory Codes: 09-001, 09-115, & 09-276 to ‘0’. Read the “Troubleshooting” section of this book for details about these Fault Codes including how to clear them.*(See p.B-11)

* 09-365 Relative Humidity Sensor problem. (* Read below in “Troubleshooting” for information on how to clear this code… See p.B-12)

* Read more about these codes in “Troubleshooting” (p.B-7 to B-12)



* 09-370 Developer Temperature Sensor failure.

(* Read below in “Troubleshooting” for information on how to clear this code… See p. B-12)

* 09-375 Ambient Temperature Sensor failure. (* Read below in “Troubleshooting” for information on how to clear this code… See p. B-12)

09-380 Waste toner door opened during a copy run or the waste bottle is detected as being missing.

09-390 Low Toner sensed. 09-399 Incompatible Xerographic Module (wrong Connector CRUM

detected on the Drum Cartridge). For example: in a C35, this code would result if you install a 113R608 version of the Drum Cartridge Connector in a machine which has previously had the 113R610 version installed in it.

Chain 10 10-xxx Codes

Fuser Problems.

10-101 / 102 / 103

The Lead-Edge is late arriving to the Fuser Exit Switch.

10-107 / 108 / 109 / 110

The trail edge was late leaving the Fuse Exit Switch.

10-120/121 /126 Exit Jams. 10-315 / 320 / 321 / 323 / 340 / 350 / 360 / 380

Fuser Over Temperature problems.

10-322 / 324 / 325 / 330 / 370

Fuser Under Temperature…

10-399 Wrong Fuser CRUM connector detected (wrong market: Europe vs. US vs. Developing Markets)

Chain 11 11-xxx

Finisher Problems.

11-005 / 006 / 310 / 311

LCSS Front Tamper position failure.

11-007 / 008 / 312 / 313/ 319

LCSS Rear Tamper home position failures.

11-024 / 025 LCSS Paddle Roll failures 11-030 / 334 / 335 / 336 /

Stacker Tray movement failures.

11-043 / 350 Hole Punch operation failure. 11-050 / 360 Staple head operation failure. 11-053 / 370 Staple head movement failure. 11-100 LCSS Paper Entry (sheet entry to the Output Device). 11-110 Sheet is late to the hole punch. 11-130 / 132 Sheet is late to the upper exit of the LCSS. 11-140 / 142 Sheet is late to the stacker (lower) tray.



FAULT / STATUS CODES (Continued) 11-300 The Large Capacity Stapler Sorter (LCSS) docking interlock

was opened during a copy run. 11-302 The top cover interlock opened during a copy run. 11-303 The Front Door Interlock opened during a copy run. 11-320 / 322 Ejector movement failure. 11-364 Stapling failure. (staples in the staple head are not primed). 12-301 OCT (Oscillating Catch Tray) failure. Chain 14 (14-xxx Codes)

Scanner (reading) and Exposure problems.

* 14-110 Scan carriage home sensor failure. *(See p.B-13) 14-310 CCD (Charge Coupled Device or Lens assyembly) Board not

detected. 14-703 / 704 / 705 / 706 / 712 / 714 / 716 / 718

Failure to calibrate the scanning of the image.

14-710 NVM Value for scanner is out of range. 14-720 Scan length out of range. 14-730 Scanner application card failure. 19-xxx Codes Reading / video problems. 19-401 / 402 / 403

Out of memory resources.

19-404 Video Compressor time–out. 19-406 See 03-315 information. 19-407 / 408 Middle Function DVMA time-out. 19-409 Video job integrity fault. If the job has mixed originals,

make sure the “mixed originals” option is selected . Read also about Code 03-315.

20-xxx Codes Fax Problems. 20-302 / 303 Fax Reset failure. (problem with embedded fax board.) 20-305 Fax system low memory unrecoverable. 20-320 / 322 Fax system NVM device not present. 20-323 / 324 Fax system memory low. 20-327 Fax extended card failure. 20-331 / 339 / 341

Fax Network line 1 fault.

20-332 / 340 Fax network line 2 fault. 20-342 Fax file integrity fault. 20-701 Fax phone book download failed. 22-xxx Codes Installation or option-not-present faults. * Read more about these codes in “Troubleshooting” (p.B-7 to B-12) Note: Powering the machine off and back on… To clear some of the faults, you can power the machine off and back on. Don’t simply unplug the machine, it can cause memory corruption and headaches of all sorts.



TROUBLESHOOTING Many of the Status Codes are pretty self explanatory to troubleshoot, but there are some which have a trick to them, or they may have some unusual cause behind them, which would make it more difficult to figure out without guidance. Following are some notes on how to troubleshoot some of the less intuitive codes and symptoms you may run across (these are the codes which are marked by an asterisk * in the Fault / Status Code Listings earlier in this section). Other codes will be added to our website as more information and experience becomes available down the road. Go to www.partsdrop.com and click on the link for “Tech Info Menu” in the left column , then scroll down to “C35 style” and look for the Tech Info Sheets… See if you can find your specific Status Code or symptom in the Troubleshooter list. If not, write to us and we’ll get you the information… and we’ll add it to the website too. 01-300 (Front Door Interlock opened during use): Check the front door interlock circuit from diagnostics. Use “dC330 Component Control” (see p.C-9), Test Code = 01-300. From this test, actuate and deactuate the Interlock Switch (located near the top, just to the right of the Fuser Latch) and see if the state of the switch changes on the display. If the switch tests good from diagnostics, check that all of the many latches and catches inside the front door are in the correct positions. Check out the condition of the Jam Clearance Latch, Short Paper Path / Transfer Latch, Fuser Latch, Xerographic Latch, Post Fuser Jam Clearance Latch, and Cam Handle. Broken or loose latches can prevent the door from remaining securely closed. If the switch does not work from diagnostics, here are some details to troubleshoot by: The circuit first goes through a loop from the Low Voltage Power Supply (LVPS) where the 12 volts are generated, through the Main Drive Board (on the Main Drive Module) and then through the Xerographic CRUM link (the connector CRUM on the Drum Cartridge). The loop ends at the same connector it started from. After it passes through all of that, it goes back out from the LVPS again, to pass through the Front Door Interlock Switch. Finally, the signal wire runs from the LVPS back out to the IOT Main Board where the logic sees the 12 volts showing that the CRUM is in place and the door is closed. The best place to start is to check the circuit which actually goes to the Door Interlock Switch. Go to P/J-17 (Plug/Jack-17) on the LVPS, disconnect the jack from the board and measure between Pins 1 & 2 on the harness side for continuity (with the Door Interlock Switch actuated). If that circuit measures good, then you’ll check the circuit which goes through the Main Drive Board and the Xerographic CRUM. Go to P/J-16 (found on the lower right of the LVPS) and measure on the harness side between pins 3 & 4, again for low resistance / continuity (make sure the Xerographic Module is in place and seated properly when you measure this circuit). If continuity isn’t there, you’ll want to inspect the Connector CRUM on the Xerographic Module and the CRUM socket in the machine for damage or contamination. Then check the harness between the LVPS, P/J-16 (pins 3 & 4)

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TROUBLESHOOTING (Continued) 01-300 (Continued) and the Main Drive Board, P/J-147 (pins 3 & 4) for continuity and make sure neither wire is shorted to ground. From here the wiring disappears to go in front of the Main Drives Module where it passes through P/J-144 (pins 1 & 2). That plug is not accessible unless you remove the Main Drives Module (leave that for a last resort). If both of the circuits test good, you would want to check that the 12 volts (DC) for this circuit are present on the LVPS at the beginning of the circuit (at pin 3 of P/J-16). If not, replace the Low Voltage Power Supply (LVPS). If the voltage is present and the entire circuit has checked out ok so far, then go to the signal line which enters the IOT Main Board at P/J-26 (pin 8). Check on the plug side to see if the 12 volts is arriving there… if so, the problem is logic related. The IOT Main Board is probably at fault. 01-305 (Left Door Open): Test the Left Door Interlock from Diagnostics. Use “dC330 Component Control” (see p.C-9), Test Code = 01-305. The switch is located near the top front corner of the door. Check out the door’s hinge pin and latch. Check P/J-56 (Plug / Jack 56) on the interlock switch and the wires going to the IOT Main Board at P/J-7 (pins 11 & 12). Pin 11 should show +3.3vdc and pin 12 is the return line for the circuit. 03-315 / 325 / 347 / 348 / 349 / 400 / 411 (Image Processing Board Failures): Check that the Cooling Fan for the Image Processor Module (the drawer at the top rear of the machine) is working. Check all connectors on the Image Processing Board to be certain they are seated and in good condition. Make sure the EPC Memory Boards (or board) are securely seated… these are the cards standing up (there are 3 slots available). Use some ‘Stabillant 22’ to improve electrical card contacts. If the code is an 03-411 (Image Processing Board did not detect the Image Disk at power on) then you will also want to check memory location 17-001 (see “dC131 NVM Adjustments” on p.C-2) and ensure that the value is set to ‘0’. 03-330 / 462 (Image Processor to Scanner faults) If the fault is an 03-462 (speed mismatch between the Image Processor and Scanner) and a new scanner is being installed, double check the speed of the new scanner. Scanners which are designed for 35ppm have serial #’s beginning with a ‘3’ while 45 or 55 ppm scanners start with a ‘5’. Check P/J-135 (pins 1-4) on the Power Distribution Board and the wires going to P/J-455 (pins 1-4) on the Scanner Driver Board (located under the lens cover next to the lens) as well as P/J-450 (pins 1-4). Also check out the large ribbon-cable which goes from P/J-110 on the Image Process Board (pins 1-34) to P/J-125 (pins 1-34) CCD Board (lens reading board).



03-331 / 340 / 416 (Image Processor to Network Controller communication failure) Check the Connector P/J-101 which joins the “Riser Board” to the Image Process Board. Check that the Firewire Board is properly seated in the Riser Board. The Firewire Board should always connect into the lower slot on the Riser Board. Also check the external connections from the Image Processor’s Firewire Board down to the matching Firewire Board in the Network Controller Module. Make sure the Network Controller Firewire Board is seated good at Slot 4 on the Network Controller Board. If the ESS (Controller) reboots constantly and puts 03-321 faults in the Diagnostic Fault History, then the ESS software is corrupted. Turn off the machine and try the 2nd Firewire port. 03-365 (IOT Main Board internal (bus) failure): Check all connectors on the IOT Main Board (check for damaged plugs or pins and reseat all of the connectors). Electrical Noise from a loose ground or loose bias lead can also cause this fault… make sure that the wiring going to the Transfer Corotron on the Short Paper Path is not pinched or broken and that it is routed behind the Short Paper Path…. Also check that the screw which holds the upper and lower registration guides together (near the front of the Registration Module) is tight. It is just above and to the left of the green knob on the registration module (the knob is marked “4c”). Check for continuity to ground between the “Halo Guide” (the metal portion of the transfer corotron assembly) and the Registration Guide. Check the contact between the Halo Guide and the Registration Guide for any damage (it is a small loop of material near the front end of the Registration Guide which makes contact with the Halo Guide when the Short Paper Path is raised up into position). If the problem continues, you’ll want to check out all of the ground points in the machine including the one on the front of the Registration Module and several on the rear frame… make sure they are tight and that there is no corrosion building up. If all of this fails to fix it, you may need a new IOT Main Board. 05-300 (Document Feeder Opened during a copy run): Check the Document Feeder Interlock Magnet on the platen cover to make sure it isn’t missing or out of position. It is located near the front center edge of the platen cover. The magnet triggers a reed-switch (the Document Feeder Interlock Switch) which is hiding just under the cover in front of the platen glass. The Document Feeder Interlock Switch can be tested from Diagnostics using Component Control code: ‘05-300’. If you run code 05-300 (see p. C-9) and open and close the Doc Feeder, the display should change hi / low. The switch’s wiring goes to a “bulkhead” connector located under the Control Console or UI (User Interface) (Remove the control console to get to it) (see p. D-7). Then from the bulkhead connector, the two wires continue back into the scanner module to connect to the Scanner Driver Board at P/J 453 (Pins 1 & 2). It runs on +3.3vdc



TROUBLESHOOTING (Continued) 06-340 (Laser Unit (ROS) Laser Failure): An intermittent or flaky interlock can trigger this code falsely. So… before you panic and start digging the Laser Module or ROS (Raster Output Scanner) out of the machine to replace it… double check the way the Xerographic Module is seated… make sure it is fully pushed home and that it latches properly. Also make sure that the front door is closing fully. If you suspect the interlocks might be responsible, read more about them in the Troubleshooting write up above for the code 01-300 (Front Door Interlock Opened on p. B-8). If the interlocks do not prove to be at fault, you’ll want to check the connector P/J-109 on the Image Processing Board. Also check P/J-18 on the Low Voltage Power Supply (LVPS). This is the harness which supplies +24vdc (for the ROS Motor, pin 1 - orange wire) and +3.3vdc (for the logic, pin 3 - orange wire) to the Laser Module. Another connector relating to this problem is P/J-2 on the IOT Main Board (located near the upper right corner of the board). On this connector, pin 3 (orange wire) carries the +3.3vdc signal wire to turn on the Laser Motor. Pin 7 on the same Connector (violet wire) and pin 3 (red wire) have to do with the sensing of the laser beam. When you go to remove the Laser Module check the 3 plugs on the rear of the unit (P/J 120, 121 & 122) as well. The Service Manual says you need to remove the unit to reach them although if you take out the Xerographic Module (Drum Ctg) and look up, you’ll see all 3 connectors near the rear of the underside of the Laser Module. It’d be a blind reach if you had to disconnect and reconnect them in there but you have enough access to be able to see if they are seated ok. 07-301 (Tray 1 opened during a copy run): You can test the Tray 1 Tray Interlock Switch using Diagnostics. Enter dC330 Component Control (See p.C-9) and choose code 07-301… then open the drawer and close it. If the machine is seeing the switch opening and closing, the display should show the change in state (High / Low). If it doesn’t see it or if the problem is intermittent, you’ll want to have a peek at the switch. Remove the LCSS (Large Capacity Stacker Stapler or finisher) from the machine and take off the right cover to access the Tray 1 & 2 Control Board. You’ll see that there are two groups of 5 switches (one set for tray 1 and another for tray 2). For each, the top switch is the tray interlock switch. The other 4 switches are for size sensing. Check the switches and particularly the actuating leaf springs for anything out of position, bent or broken. Make sure the Tray 1 & 2 Control Board is securely attached (the mounting studs or “stand-offs” are known for breaking which causes the board to shift around and cause an intermittent condition). The switches run on +3.3vdc. Also check the rectangular Actuator Cam on the left side of the tray itself.



07-302 (Tray 2 opened during a copy run): See the procedure for 07-301 Status Codes above, but use code 07-302 to test the Tray 2 Tray Interlock Switch. 07-303 (Tray 3 opened during a copy run): Test the Tray 3 Drawer Interlock Switch using dC330 Component Control – Code 07-303 (See p.C-9). The switch can be found if you remove the bottom rear cover behind the Tray 3 & 4 High Capacity Feeder Module. Looking from the rear, the Tray 3 switch can be found on a bracket mounted to the frame on your left side behind where Tray 3 slides in. A piece of the drawer is what hits the switch’s actuator to tell the machine it is closed. 07-304 (Tray 4 opened during a copy run): See the procedure for 07-303 Code above but use code 07-304 instead to test the Tray 4 Drawer Interlock Switch. 09-350 (Erase Lamp Failure): You can turn on the Erase Lamp from Diagnostics. Before you do so, there are a few things to know. First, the +24vdc voltage needed for the lamp is only enabled if the Xerographic Module is fully seated and the Front Door Interlock Switch is actuated (or cheated). You can take the Fuser Module out to get a better view. Do not light up the Erase Lamp for more than a few seconds at a time because damage to the photoreceptor can result. To turn on the lamp, use “dC330 - Component Control” (see p.C-9), Test Code = 09-022. If the lamp does not light at all, there is an inline fuse to check. The fuse is found along the orange wire going from P/J-17 on the Low Voltage Power Supply (LVPS) to the Erase Lamp. 09-360, 09-361 09-362, & 09-363 (Toner Concentration Fault Codes): Look for problems in the toner dispensing… remove the Toner Cartridge and inspect it to make sure it can rotate freely. You can remove the machine’s left cover to get a really good look in at the dispensing components. Make sure that the toner cartridge’s auger hole seal has not come off and become deposited on the toner dispense auger tube (it has happened before… the old seal was left behind and it prevented the new toner cartridge from seating properly). Check the connections on the DV (Developer) Unit. Both the Connector and the Developer Bias lug are located on the left side of the DV Unit (behind the left cover of the machine). Consider the possibility of contamination. The Service Manual actually mentions that it would be easy to mistake one of the DC265 toner cartridges for this machine’s and these codes would result as the toner would then be contaminated with the wrong stuff. The C35 toner cartridges have an off-white colored plastic rear end (the end with the hole for the toner dispensing) , while the DC265 has black plastic instead. It would be an easy mistake for a customer to make if both machines are in the same office… especially if they happened to have a DocumentCentre 265 (DC265 style) and a WorkCentre 265 (C35 style) near one another.



09-360, 09-361 09-362, & 09-363 (CONTINUED): To clear toner Concentration Fault Codes, you’ll need to go into diagnostic mode, select “dC Routines” and then touch “Copier Routines" followed by "131 NVM Read / Write” (See p.C-2). Select “Chain” ‘09’ and look for the following 3 memory settings to make sure they are set to ‘0’: 09-001 – TC Lockout Low 09-115 – Sensor Failure Lockout Flag 09-276 – TC Lockout High You can check each by touching them on the display and then touching “Read/Write”. If any of the three say ‘1’ then the machine is in a “Toner Concentration Fault” condition. Change the ‘1’ to a ‘0’ on the display and confirm your selection. Then when you power off and back on, the machine will attempt to establish the proper toner concentration ratio. Keep in mind that if the condition which triggered the code in the first place has not been resolved, the Fault Code will likely return. The machine will run a few copies (3, 4 or 5) after you reset it. If the concentration continues to be sensed as being out of range, the machine will then call the Fault Code again. Because this machine will stop right in the middle of a copy run when it decides to call a Toner Concentration Fault, it’s a good idea to run only one copy at a time If you expect that the machine may go into the fault again. This will save you some time and frustration clearing jammed paper in the machine. 09-365 (Relative Humidity Sensor problem) The Relative Humidity Sensor monitors the machine’s internal humidity inside the cavity. It is coupled with the Ambient Temperature Sensor and located on the inside of the front frame of the machine near the left corner, just above the Registration Module. Try powering off and back on to clear. It may be necessary to reset NVM Memory Code “09-267” to ‘0’ to clear this Status Code (See p.C-2 & C-6 for Memory Adjustment Codes). 09-370 (Developer Temperature Sensor problem) The Developer Temperature Sensor monitors the temperature just above the Developer Unit. It is located on a plate just above the rear of the Developer Unit where it seats into the machine. Try powering off and back on to clear the code. It may be necessary to reset NVM Memory Code “09-268” to ‘0’ to clear this Status Code (See p.C-2 & C-6 for Memory Adjustment Codes). 09-375 (Ambient Temperature Sensor problem) The Ambient Temperature Sensor monitors the machine’s internal temperature inside the cavity. It is coupled with the Relative Humidity Sensor and located on the inside of the front frame of the machine near the left corner, just above the Registration Module. Try powering off and back on to clear the code. It may be necessary to reset NVM Memory Code “09-269” to ‘0’ to clear this code.



14-110 (Scanner Carriage problems) This code usually is accompanied by the Scanner Carriage (exposure carriage) slamming against the inside of the right side of the machine repeatedly, making a sound like a drum-solo. The message which accompanies the code is “Scanner failed to initialize, Copying and Scanning not available”. The 14-110 Status Code’s on-screen description (Scan Home Position Failure) would lead one to believe that the problem is in the Scan Home Position Sensor but this rarely turns out to be the true cause. This problem is most common on the 35 ppm (pages per minute) models. To test the Scan Carriage Home Position Sensor, you can run the diagnostic Code 14-110 from dC330 Component Control (See p.C-9). It is helpful to know that the Platen Angle Sensor is identical to the Scan Carriage Home Sensor (the Platen Angle Sensor is located at the rear left corner of the scanner and a plunger-like actuator pushes down when the platen is closed). So if you believe that the sensor could be bad, try swapping the two to see if the symptom changes. Usually, the sensor itself is fine, but the +5 vdc going to it is not right because of a failure on the CCD board. The CCD Board is supposed to produce the +5vdc for the Scan Home Sensor Circuit. When components on the CCD board overheat, you lose the +5 volts and the scan home sensor circuit fails to work. If you want to verify that the CCD Board is at fault… It is the board which is mounted on the CCD / Lens Assembly. Test for the +5vdc at P/J ___ Pin __. Also inspect the upper left corner of the back of the CCD Board for heat damage. If you do find that the CCD Board is at fault… At first Xerox only spared it as part of the entire Scanner Module (basically the whole top of the machine which sells for $1900.- and then they give 50% back for the old one). More recently, a CCD Board Kit was introduced for around $650.- which is just the board and a bunch of shims with instructions on how to painstakingly install the new board in place of the old one. Fortunately, a less costly and slightly simpler solution is now available as well… a Scanner CCD / Lens Assembly Repair Service is now available (see p.F-8). VERY IMPORTANT : Do not turn any screws on the CCD / Lens Assembly until you prepare the unit as follows: You will want to scribe the outline of the CCD / Lens Assembly’s footprint on the Scanner’s metal base before you turn any screws. This way, you can return the unit to its factory position after it has been repaired. Never turn any of the screws except for the ones which fasten the entire CCD / Lens Assembly to the Scanner’s metal base… if you do, it will be virtually impossible to get the CCD back into the factory-set position, in relation to the Lens.


(Section C - Diagnostic Adjustments & Tests) p.C-1

DIAGNOSTICS:

Entering Diagnostic Mode: To get into Diagnostics; from the powered on state you’ll hold down the ‘#’ button while then pressing the ‘Access’ button… You’ll be asked for a password which you’ll enter using the keypad (default is ‘1934’) followed by ‘enter’. If you get the password wrong 3 times in a row, there will be a 3 minute lock out period after which you can try again. Once you’re in, the Main Menu will show up:

Leaving Diagnostic Mode (Call Closeout). Press the “Call Closeout” button. A screen will ask you if you want to reboot the copier (default is “yes) and also if you want to reboot the controller (default is “no”). Rebooting the copier is necessary if you have made any changes to memory settings. If no changes were made to the Memory settings, you can choose not to reboot the copier and you can also choose not to reboot the Network Controller… this will speed up the shut down / restart process tremendously.

Main Menu: Service InfoTab: For reading software versions, billing counters, serial number, prints since last call, and the Network IP address. Fault History Tab: Last 40 faults & fault counters. Diagnostic Routines Tab: Most of the diagnostic functions are found in the Diagnostic Routines tab, including NVM (memory) Adjustments and Component Control codes. Usually, you’ll then be touching “Copier Routines” followed by the dC Routine number / description (i.e. 131 NVM Read / Write).



Memory Adjustments – 131 NVM Read / Write: (dC131) (NVM means: Non Volatile Memory) To get into the Memory Adjustments (Non Volatile Memory or NVM), enter Diagnostic Mode and select “Diagnostic Routines”. Then touch “Copier Routines" followed by "131 NVM Read / Write”. The codes are arranged like many of the Xerox models… they have 2 digits called the “Chain” followed by 3 digits which are referred to as the “Function” (for example 01-001). At this point, you’ll see a screen with a menu of the different “Chains” which are available.

The menu items are mostly self-explanatory. One which might not jump out at you is chain “14 RIS”. RIS stands for Raster Input Scanner (the exposure / scanner part of the machine) and possibly “06 ROS” which is the Raster Output Scanner (the laser module). Touch the Chain / menu item which you want to enter. Then a new menu will appear:

You can get to a code either by pressing ‘Find’ and entering it in the code entry box which appears on your right, or you can scroll down through the list of available codes. When you see the code you want to read or change at the top of the screen, press the code's description to highlight it. To read the current value for that code, touch the “Read/Write” button.



The list of codes is extensive… there is a lot of stuff you probably won’t ever play around with. Some will no doubt prove to be “read-only”. Following is a list of the codes from the copier options (chains 01 through 19 and 28) which are likely to be important to most of us… We don’t have the space to include the fax related codes (Chain 20). You can find your way around in there if you choose “Other Routines” instead of “Copier Routines”. You can then scroll through the Chain 20 choices and find whatever you are looking for. Memory Adjustment Codes (NVM):

Code Description Default 01-001 Power Save Enable (0 to disable) 1 02-001 Printer Language 0 02-002 Edit E-mail From (for editing the “From” field in

outgoing emails) DC535/545/555 only- ‘1’ enables 0

02-003 Enable job delete (set to ‘1’ to allow customer to delete jobs)

1

02-004 Edit From Guest (set to 1 to enable editing of e-mail from guest on DC535/545/555 only)

1

03-001 Foreign Interface Enable (set to 1 when installing an external device such as a card counter or coin-op)

0

03-003 Market region… 0 = US, 1 = XCL (Canada), 2 = FX (Fuji Xerox - Asia), 3 = FXAPO (Fuji Xerox Asia Pacific Operations), 4 = ACO (Americas Customer Operations), 5 = XE (Xerox Europe) **Password: 2845490**

0

03-004 System Configuration: 0 = digital copier, 1 = Multifunction Devlice, 2 = Printer, 3 = Scan Server, 4 = OEM Scanner, 5 = OEM Printer, 6 = OEM Multifunction, 7 = Atlanta only

0

03-006 Auto-Configuration Enable (to stop auto configuration at start up, set it to ‘0’)

1

03-008 Product Identifier (used to ID the machine type over the network). Newer models are not covered in the Manual which this book is based on. The newcomers will no doubt have their own codes. **Requires Password: 2845490**

WCP35=48 WCP45=49 WCP55=50

WC35=51 WC45=52 WC55=53 ST535=33 ST545=35 ST555=37 DC535=32 DC545=34 DC555=36

03-010 Service Copy Mode Password for making copies from the diagnostic mode (normally it is the reverse of the Diagnostic Password)

4391

Code Description Default 03-011 Hold job queue if resources are not available. (Set to 1



‘0’ if you don’t want jobs to be held in queue) 03-012 Product Configuration (Copier Speed) 35, 45, or 55

cpm (image processing speed… 08-001 must be set to the same setting). Newer models with faster speeds will undoubtedly have new values for this memory setting. **Requires Password: 2845490** Note: There are physical differences between the 35ppm and the 45 or 55 ppm machines including gearing on the Main Drive Motor… you can not simply change these settings to speed up a machine.

45

03-013 Doc Handler config (with or without Duplexing Automatic Document Handler)… 0= DADH present, 1= flat top

Auto select

03-014 Inverter Switch (0= paper exits face up, 1 = paper exits face down / inverted)

1

05-001 DADH Feed Head Count 0 05-002 CRU Days (day count for the Customer Replaceable

Unit or Drum Cartridge) 0

06-001 Light Level (Laser Light Level for 600dpi laser) 3721 06-003 ROS motor time out (Raster Output Scanner),

determines how long the machine will wait before calling a ROS motor fault

5000

07-001 Feeder Module Type (High Capacity Feeder, HCF present (Tray 3&4) or not… 67 = No HCF, 68 = With HCF present)

67

08-xxx Codes

Registration Values … Too many various adjustments to list here, Use: “dC604 Registration Setup” procedure. (See p. C-15)

08-001 Print Rate (prints per minute… 0 = 35, 1= 45, 2 =55 ppm (value must agree with 03-012). Newer models with faster speeds will undoubtedly have new values for this memory setting. **Requires Password: 2845490** Note: There are physical differences between the 35ppm and the 45/55, & 65+ ppm machines including gearing on the Main Drive Motor… you can not simply change these settings to speed up a machine.

2

09-001 TC (Toner Concentration) Low - Fault State (value=1 if fault is declared) Reset to ‘0’ to clear some Toner Concentration Faults

0

09-002 Charge Corotron (Charge corona voltage in micro Amps, true value is negative)

800

09-003 Charge Grid (Charge Grid voltage in microAmps, true value is negative)

430

Code Description Default 09-004 Chute Bias (lead edge) 501



09-005 Chute Bias (mid document) 501 09-006 Chute Bias (trail edge) 501 09-007 Transfer Corona Voltage – lead edge of side 1 350 09-008 Transfer Corona Voltage – middle of side 1 350 09-009 Transfer Corona Voltage – trail edge of side 1 350 09-010 Transfer Corona Voltage – lead edge of side 2 350 09-011 Transfer Corona Voltage – middle of side 2 350 09-012 Transfer Corona Voltage – trail edge of side 2 350 09-013 Detack Corona Voltage – side 1 4200 09-014 Detack Corona Voltage – side 2 4200 09-015 Detack Corona Voltage – lead edge of side 1 130 09-016 Detack Corona Voltage – middle of side 1 160 09-017 Detack Corona Voltage – trail edge of side 1 199 09-018 Detack Corona Voltage – lead edge of side 2 145 09-019 Detack Corona Voltage – middle of side 2 165 09-020 Detack Corona Voltage – trail edge of side 2 199 09-021 Developer Bias Print Level (the actual voltage is the

negative of what the value in memory is set to) 350

09-069 Toner Concentration Sensor Control Voltage (a value of 800 = 8 volts) Note: Read later in this book for the proper way to Calibrate this Sensor for Developer replacement (See dC905 on p.C-16)

800

09-090 Waste Bottle Full print count at which ‘Bottle Full’ status id confirmed

100

09-096 Developer Temperature reading (degrees C) 09-097 Humidity %RH 09-098 Altitude adjustment in meters (0=0-749, 1=750-

1499, 2=1500-2249, 3=2250-2999, 4=3000+) 0

09-101 Ambient Temperature (degrees C) 09-110 Toner capacity (grams) 1188 09-111 Toner Dispense Rate (grams per minute) 50 09-112 Total Toner Dispense Time (in minutes…read only) 0 09-115 Toner Concentration Sensor Fault state (value=1 if

fault is declared) Set to ‘0’ to reset some Toner Concentration Faults

0

09-120 Ozone Filter Life (In thousands)… Read about ozone filter reset procedure in the Troubleshooting section of this book)

350(k)

09-121 Charge Scorotron Cleaning Message interval (copies between messages for customer to clean the scorotron manually… in thousands of copies)

25(k)

09-123 Image count 0

Code Description Default 09-267 Humidity Sensor Fault state (value=1 if fault is 0



declared) Supposed to reset by powering off and back on.

09-268 Developer Temp. Sensor Fault (value=1 if fault is declared) Supposed to reset by powering off and back on.

0

09-269 Ambient Temp. Sensor Fault (value=1 if fault is declared) Supposed to reset by powering off and back on.

0

09-271 Developer Material Age (Read Only) 0 09-273 OCT (Oscillating Catch Tray) 90% Full page count 30 09-274 Inter-image Chute Bias (for actual voltage, subtract

500 from the value shown on the screen). Normal range is from -500 to +900 volts.

0

09-275 TC (Toner Concentration) Setup Target Voltage (185=1.85 volts)

185

09-276 TC (Toner Concentration) High - Fault State (value=1 if fault is declared) Set to ‘0’ to reset some Toner Concentration Fault Codes

0

09-278 Automatic Charge Scorotron Cleaning (1=enabled) 1 09-279 Charge Scorotron Cleaning Counter (1=enabled) 0 10-028 Fuser Standby Temperature (35 cpm = 177 degrees

Celcius, 45/55 cpm = 188 degrees C) 177 or

188 10-029 Fuser Run Temperature (35 cpm = 172 degrees C,

45/55 cpm = 183 degrees C) 172 or

183 10-030 Fuser Low Power Temp (Power Save Mode temp.) 135 10-063 Fuser Web Counter – resets to ‘0’ when a new fuser

CRUM Connector, with a new web is installed (Read Only)

0

12-001 Finisher Module Type 65 = Oscillating Catch Tray (OCT), 67 = Simple Catch Tray (SCT), 110 = Large Capacity Stapler Stacker (2K) (LCSS2K), 120 = Large Capacity Stapler Stacker (1K) (LCSS1K), 130 = High Capacity Stapler Stacker (HCSS), 140 = High Cap. Stacker Booklet Maker (HCSBM), 150 = High Cap. Stapler Stacker Booklet Maker (HCSSBM) 160 = Binder, 170 = Booklet Maker, 100 = No Finisher Note: Newer configurations will no doubt have their own settings for this code.

65

Code Description Default 12-002 OCT (Oscillating Catch Tray) 90% full timer 2500



(milliseconds) 12-050 Finisher cycle out time (in seconds) 30 14-001 Duplexing Auto. Document Handler (DADH)

Continual Velocity Transport (CVT) Center Registration (pixels)

2376

14-002 Duplexing Auto. Document Handler (DADH) Lead Edge Registration (in scan lines)

70

14-003 Platen Top Edge Registration (in pixels lines) ** 4747 14-004 Platen Lead Edge Registration (in scan lines) ** 70 14-012 Scanner to Document Feeder’s Constant Velocity

Transport (CVT) Position (0.1mm Increments) 4988

14-013 Scanner to Document Size Detection Position (0.1mm increments)

700

14-014 Scanner Lead Edge start (“active hotline”) in 0.1 mm increments **

350

14-027 Scanner Magnification Adjustment - Adjusts platen scan speed (lead to trail edge to help you compensate for magnification errors)

100

15-007 CVT (Constant Velocity Transport) Document Transport roll… scanning image gain adjustment

0

17-001 Disk present or not present (1 = enabled, 0 = disabled)

0

19-001 Megs of installed Memory (Read Only) 16 20-xxx Codes

Fax related memory settings… Too many to list here (nearly 400 codes). Fortunately, you can scroll through the list on screen to find what you need.

28-001 Embedded Extended Fax Presence (0=Extended Fax Not Present… 1= Extended Fax Present)

Read Only

28-002 Embedded Fax Presence (0=No Fax Present, 1=Fax Present, 2=Fax install in progress)

Read Only

28-003 Fax modem version (0 = No Fax, 1 = Embedded Fax, 2 = Server Fax)

Read Only

** Registration Adjustments are all best approached using a special procedure explained on page C-15 called “dC 604 Registration Setup”… this process sets up all of the various registration adjustments in a handy and systematic way.

User Interface (UI / Control Console) Test (dC305)



Enter Diagnostic Mode, select “Diagnostic Routines”, then “Copier Routines”, followed by “dC305 UI Tests”. You can then select from the following tests and follow the onscreen instructions 1. User Interface Button Test (tests the hard buttons) 2. Tone Test (produces the audio tones) 3. LED test (turns on all LED’s on the panel) 4. Touch Area Test (tests sensitivity of the touchscreen’s grid) 5. Display Pixel Test 6. Video Memory Test (checks SRAM used on the Console) 7. Communications Self Test (communication between Image Processor Module and UI) 8. Reset User Interface (rebuoots the UI) 9. Application Checksum Verification displays checksum and displays any errors which are detected. Network Echo Tests (dC312) From Diagnostic Mode, choose “Diagnostic Routines”, and select “Network Routines”, followed by “dC312 Echo Test”. This choice will be “grayed out” if the Network Controller is not available. Choose from the available list of tests, press ‘Start Test’ and follow the instructions on the touchscreen. Following are the available tests: • TCP/IP • Novell or IPX • NetBIOS / NetBEUI • Apple Talk • Internal TCP/IP (sends a ‘Ping’ to the IP device “localhost”)

Network Connectivity Tests (dC314) Enter diagnostic mode, choose “Diagnostic Routines” and select “Network Routines”, then “dC314 Network Connectivity Tests”. If the Network Module is not available, this button will be “grayed out”. Select the test you want to run from the list below and follow the instructions on the touchscreen. This list shows each option and what information the copier will give you on each. 1. TCP/IP - Network Controller Interface where host was discovered - Device Name - Device Subnet Mask - Device IP Address - Device Media Access Control (MAC) Address - Gateway IP Address 2. Novell ® or IPX - Frame Type - Server Name - Print Queue Name - Server Internal Network Number



- Server Node (MAC) Address - Server NOS Version Number - Hop Count to Device (local net), extended test - Printer Attached to File Server: Status - Printer Attached to Print Queue: Status - NDPS Enabled 3. NetBIOS / NetBEUI - No data is collected because the Network Controller has a Dynamic Internal Name Table stored in RAM 4. Apple Talk ® - ESS Port ID - Device Type (router, print server, file server, etc.) - NBP Registered Device Name - Device NBP Protocol Address - Device Media Access Control (MAC) Address - Network Number - Zone Name - Sub Zone Name - Device Operating System Version Number Diagnostic Component Tests (dC330): The next thing you’ll want to know about will be how to test switches, motors, solenoids, etc from Diagnostics. This is done from “dC330 Component Control” (from Diagnostics, touch the “Diagnostic Routines” tab, then “Copier Routines”, followed by “330 Component Control”). This will bring you to a screen where you select one or more components which you wish to have on a short “ready” list. You can choose up to 6 components at a time (as long as the components are allowable together). You'll find both Input Codes and Output Codes all together in here. Input codes are for testing sensors, switches, etc and output codes allow you to run motors and solenoids, clutches and so forth. Here’s the Component Selection screen:



One nice thing is that if you don’t have your book handy, you can still find component codes from the touchscreen, as they are available in a scrollable menu. When you see a code you wish to have ready to go, touch that Component’s Name and then touch “Select”… this will add the code to your short list of up to 6 readied codes (The word "yes" will appear next to that code's description). Touch “Save” to save your list which will then bring up the "Component Control Screen" which is the short list of up to 6 components which you’ve selected. Here’s a sample Component Control Screen:

Touch a control code to highlight it and then touch “Start” to start that component’s test. If it’s an input code, the state of the code will show up to the right side of the component code's description (it'll say "High" or "Low" for most of the codes). For Output codes, the state of the code will also show up to the right side of the code’s description (it will say “on” or “off”). Below is a listing of many of the useful codes available to you… we’ve chosen to leave off chain “20” which is the fax related stuff because it is an extremely long list. Fortunately, if you ever need to find something in the way of fax tests, you can go into chain ‘20’ and scroll through all of the options. The first list shows the “Input Component Codes” (codes for testing switches & sensors). Then you’ll find the “Output Component Codes list (codes for motors, lamps, clutches, solenoids, etc.) INPUT COMPONENT CODES: Code Description Notes & Details 01-300 Front Door Interlock Switch High = closed 01-305 Left Door Interlock Switch High = closed 05-300 DADH Closed Switch (Duplexing

Automatic Document Handler) High = closed

05-305 DADH Cover Interlock High = closed 05-310 DADH Document Present Sensor High = Document

sensed



05-315 DADH Length Sensor 1 High = Document Present

05-320 DADH Length Sensor 2 High = Document Present

05-325 DADH Width Sensor (potentiometer) millimeters 05-330 DADH Takeaway Sensor High = Document

Present 05-335 DADH Takeaway Roll Sensor High = Document

Present 05-340 DADH Registration Sensor High = Document

Present 05-345 DADH Exit Sensor High = Document

Present 05-350 DADH CVT (constant velocity transport)

Sensor High = Document Present

06-320 ROS (Raster Output Scanner or Laser Unit) Motor Ready Sensor – sensor detects when the ROS motor is at the required speed

High = ready Run the ROS motor (06-020) at the same time to test sensor.

06-340 ROS (Laser Unit) laser intensity and motor are both up to speed and working.

High = ready Run the ROS motor (06-020) to test the sensor.

07-301 Tray 1 Home Switch High = home 07-302 Tray 2 Home Switch High = home 07-303 Tray 3 Home Switch High = home 07-304 Tray 4 Home Switch High = home 07-311 Tray 1 Paper Size Switch 1 High = switch made 07-312 Tray 1 Paper Size Switch 2 High = switch made 07-313 Tray 1 Paper Size Switch 3 High = switch made 07-314 Tray 1 Paper Size Switch 4 High = switch made 07-315 Tray 1 Paper Size Switch 5 High = switch made 07-321 Tray 2 Paper Size Switch 1 High = switch made 07-322 Tray 2 Paper Size Switch 2 High = switch made 07-323 Tray 2 Paper Size Switch 3 High = switch made 07-324 Tray 2 Paper Size Switch 4 High = switch made 07-325 Tray 2 Paper Size Switch 5 High = switch made 07-331 Tray 1 Paper Empty Sensor High = out of paper 07-332 Tray 2 Paper Empty Sensor High = out of paper 07-333 Tray 3 Paper Empty Sensor High = out of paper 07-334 Tray 4 (HCF, High Cap Feeder) Paper

Empty Sensor High = out of paper

07-335 Bypass Empty Sensor High = Paper Present 07-341 Tray 1 Paper Low Switch (senses when the

stack height of Tray 1 is >25%) High = >25% paper stack



07-342 Tray 2 Paper Low Switch (senses when the stack height of Tray 2 is >25%)

High = >25% paper stack

07-350 Bypass Width Sensor (analog width sensor) Width (in mm / inch) 07-383 Tray 3 Stack Height Sensor High = stack is in

feed position 07-384 Tray 4 (HCF) Stack Height Sensor High = stack is in

feed position 08-100 Wait Sensor for Paper Feed Module (PFM

- Tray 1/ 2) High = Paper Present

08-101 Tray 1 Feed Sensor High = Paper Present 08-102 Tray 2 Feed Sensor High = Paper Present 08-103 Tray 3 Feed Sensor High = Paper Present 08-104 Tray 4 Feed Sensor High = Paper Present 08-150 Registration Sensor High = Paper Present 08-160 Duplex Paper Path Sensor High = Paper Present 09-310 Low Toner Sensor (the ultrasonic sensor in

the replenisher sump) High = toner present

09-350 Waste Toner Full Sensor High = full 09-360 Toner Concentration Sensor (shows %

concentration in developer unit) % is shown

09-365 Humidity Sensor (RH – Relative Humidity) in Paper Path

% humidity is shown

09-370 Developer Temperature Sensor (in Paper Path above the Xerographic Module)

Degrees C (to nearest degree)

09-375 Ambient Temperature Sensor (near the Front Door)

Degrees C (to nearest degree)

09-380 Waste Toner Door Switch … sees if the waste toner bottle is present or not

High = bottle is present

10-100 Fuser Exit Switch High = Paper present 10-120 Exit Sensor (from machine) High = Paper present 10-300 Fuser Temperature Sensor ‘A’ Degrees C (0-255

degrees) 10-310 Fuser Temperature Sensor ‘B’ Degrees C (0-255

degrees) 10-315 Fuser Thermistor failure sensing High = fault detected 11-xxx Codes

Chain 11 is all relating to Finisher sensors and switches… you can go to Chain 11 and then scroll through the available tests.

12-300 OCT level sensor (detects when the tray is 90% full)

High = 90% full

12-301 OCT Index position sensor High = at index position

14-100 Exposure Lamp Carriage Home Sensor Note: Sensor is identical to the DADH Angle Sensor

High / Low



14-310 DADH Angle Sensor (sees if DADH is at 30% angle or not) Note: Sensor is identical to the Exposure Carriage Home Sensor

High / Low

14-315 DADH Document Size Sensor 1 High / Low 14-320 DADH Document Size Sensor 2 High / Low That does it for the “Input Component Codes”… now on to the “Output Codes” (motors / solenoids, clutches, etc)…For some of the codes, we’ll include only the “Chain” or first part of the code and you can scroll through the options. A majority of these components will run for a default time-out of 90 seconds although some will be on for a shorter period of time. OUTPUT COMPONENT CODES: (motors, clutches, solenoids, etc.) Code Description Notes & Details 04-010 Main Motor On / off 05-010 DADH Feed Solenoid On / off 05-020 DADH Feed Motor On / off 05-025 DADH Feed Roll Clutch On / off 05-030 DADH CVT (constant velocity transport)

motor On / off

05-050 DADH Duplex Solenoid On / off 06-020 ROS (Raster Output Scanner / Laser Unit) On / off 06-025 ROS (Raster Output Scanner / Laser Unit)

at Standby Speed On / off

07-030 Tray 3 elevator motor Up (Warning: Only energize with Tray OUT)

On / off

07-040 Tray 4 (HCF) elevator motor Up (Warning: Only energize with Tray OUT)

On / off

08-010 Tray 1 Feed Motor (Warning: Only energize with Tray OUT)

On / off


On / off

08-025 Tray 1 & Tray 2 Vertical Transport Motor On / off 08-030 Tray 3 Feed Motor (Warning: Only

energize with Tray OUT) On / off


On / off

08-045 Tray 3 & Tray 4 Transport Motor On / off 08-050 Bypass Feed Solenoid Default = not

engaged in standby 08-060 Duplex Motor Slow speed On / off 08-062 Duplex Motor Fast speed On / off 08-070 Registration Clutch Default = not

engaged in standby



09-010 Photoreceptor Drive Motor On / off 09-022 Photoreceptor Erase Lamp On / off 09-030 Ozone Fan (operation times out 20 seconds

after run is finished) On / off

09-035 Photoreceptor Cooling Fan On / off 09-040 Toner Dispense Motor On / off 09-045 Toner Cartridge Motor (spins the toner

cartridge) On / off

09-060 HVPS Fault check High = fault 09-061 Charge Scorotron (Warning: make sure

09-010 (photoreceptor motor) is running before you run this test to avoid damage to the drum)

On / off

09-062 Charge Grid (Warning: make sure 09-010 (photoreceptor motor) is running before you run this test to avoid damage to the drum)

On / off

09-063 Transfer Corotron (Warning: make sure 09-010 (photoreceptor motor) is running before you run this test to avoid damage to the drum)

On / off

09-064 Detack Corotron (Warning: make sure 09-010 (photoreceptor motor) is running before you run this test to avoid damage to the drum)

On / off

09-065 Chute Bias On / off 09-066 Developer Bias (Warning: make sure 09-

010 (photoreceptor motor) is running before you run this test to avoid damage to the drum)

On / off

10-010 Fuser Web Motor On / off 10-030 Inverter Motor Forward (slow speed) On / off 10-035 Inverter Motor Reverse (process speed) On / off 10-040 Inverter Motor Reverse (duplex speed) On / off 10-045 Inverter Path Solenoid (diverter

mechanism ) Default is off (sends sheet to the inverter)

10-050 Inverter Nip Solenoid Default is “nip open” or solenoid off.

10-065 Vacuum Transport Fan - Short Paper Path On / off 11-xxx Finisher tests of motors, solenoids, etc. 12-005 OCT (Oscillating Catch Tray) Motor Drives the tray

between the two off-set positions.

14-005 Exposure Lamp (on for 90 sec. normally) On / off 20-xxx Fax related tests



Registration Setup (dC604): The process for setting up the Registration is really quite ingenious. First make sure that 8.5x11 paper (or A4) is loaded in Tray 1 with the 11 inch edge being the lead edge. Enter the Diagnostic Mode (hold down the “#” button while then pressing the ‘Access’ button… the machine will prompt you for a passcode… use the default: ‘1934’). Select the ‘Diagnostic Routines’ tab on the touchscreen, then press ‘Copier Routines’, followed by ‘604 Registration Setup’. Choose “Image Output Terminal Registration Side 1”, then “Setup All Trays”, then “Print Test Samples” and follow the prompts. Look at the 3 test sheets which print out. The scale marked Zone ‘D’ on the test prints shows you the Lead Edge Registration (20mm is ideal) and Zone ‘A’ represents the setting for the “Top Edge” or Front Edge Registration” (20mm is ideal). Press “Ok” to continue. On the screen which comes up, use the up & down arrows to input the average measurement you see in ‘Zone A’ and ‘Zone D’ to the nearest 0.5mm., then press ‘Save’. New test patterns with the corrected registration will print out. The same process can be used to check and adjust side 2 of duplexed copies (choose “Image Output Terminal Registration Side 2” this time). You can also then adjust the Scanner and Document Registration from this same procedure. Print Test Patterns (dC606): Another goodie is the ability to run Test Pattern Prints from diagnostics. This is extremely useful in troubleshooting copy quality problems. When you run a Test Pattern from the machine’s logic, you eliminate the optics / reading part of the machine from the equation. You’ll go into diagnostics and choose “Other Routines”, select “Image Quality Test Patterns 1-19”, & select: your desired features, 1 or 2 sided print and the paper size to use for the pattern. You then also choose if you want a label or a border on the sheet. Then select “Save” followed by the “Start Test” button.



Developer Calibration (dC905) (Toner Concentration Sensor Calibration): For the Developer Calibration, you’ll go into Diagnostics and select “Diagnostic Routines” followed by “Copier Routines”, and then “dC 905 TC (Toner Concentration) Sensor Calibration”. Touch the ‘Start’ button to begin. The message will remind you to only run the routine if new developer has been installed… and to make sure that the developer unit is cammed in before starting. The routine will energize all the needed components simultaneously in order to tone up and calibrate the sensor for the new developer. Let it go through its entire setup. If any of the Toner Sensor Failure codes come up: 09-360, 09-361, 09-362, or 09-363, the message “Toner Concentration Setup Failed” will show up. In that case, you’ll need to figure out why the machine is having trouble setting up the Toner Concentration Sensor (make sure toner dispensing is working properly). You may also need to clear the Toner Control Faults from Diagnostics (See Troubleshooting details on p.B-11).



Options Re-enablement Codes: If the machine was originally set up for having certain options and all of the hardware is in place, and the machine has the necessary Firmware version, optional services can be reinstalled. This would be necessary during recovery from an NVM memory failure for example. Each group of models has different sets of enablement codes. D535 Family (DC535/545/555) To install an optional service… • Press ‘Access’, enter the Password (default = ‘1111’), touch ‘Enter’ • Touch “Go to Tools”… touch “More”, followed by “Optional

Services”, touch the name of the service you are adding from the menu.

• Enter the proper code from the list below and touch ‘Enter’ Touch “Exit Tools” and the machine will reboot automatically… Do not interrupt the machine during the reboot process which takes about 5 minutes.

Scanning Kit Scan to File: 40260 Scanning Kit Scan to Email: 41123 C35 Family (WC-M35/45/55, Pro35/45/55, 5030 / 5050) To install an optional service… • Press ‘Access’, enter the Password (default = ‘1111’), touch ‘Enter’ • Touch “Go to Tools”… touch “More”, followed by “Optional



Scanning Kit Scan to File: 25711399 Scanning Kit Scan to Email: 92315358



WC-232 Family (232/238/245/255/265/275, 5130/5150) To install an optional service… • Press ‘Access’, enter the Password (default = ‘1111’), touch ‘Enter’ • Touch “Go to Tools”… touch “More”, followed by “Optional



Kit Part# = 604E16931 Scanning Kit Scan to File: 18482948 Scanning Kit Scan to Email: 42512933 WC-5632 Family (5632/5638/5645/5655/5665/5675/5687) To install an optional service… • Press ‘Access’, touch “Login” … Defaults are: Username = admin,

Password = ‘1111’, touch ‘Enter’ • Touch “Tools Pathway”… touch “More”, followed by “Optional

Service”, touch the name of the service you are adding from the menu.


Scanning Kit Scan to File: 52396012 Scanning Kit Scan to Email: 21857286 Server Fax Kit (498k15150): 31498300 Internet Fax Kit (498K15140): 28007962


(Section D - Part Replacement Procedures) p.D-1

Photo 1 – Inside the Front Door…

PART REMOVAL PROCEDURES:

ORIENTATION Photo 1…

LCSS (Large Capacity Stacker / Stapler): The finisher on this machine is called the “LCSS”. It stands on the floor and is nearly as tall as the machine itself. It is latched by two hooks on a single mechanism. You can separate it from the machine by opening the LCSS front door and reaching in, to pull on the latch assembly (it slides forward to release the two hooks). There is a metal indexing pin on a plate on the LCSS which indexes it into a hole on the machine. A flat plastic actuator (snapped in place on the machine) is what touches a switch in the LCSS to make the interlock. Interestingly there is a latch release handle down low on the front of the LCSS which apparently had been intended to release the LCSS more easily, but on the machines which we have seen, there is no connection between the release handle and the latches themselves. Best guess is that the handle was engineered, and then the idea was abandoned for some reason. Some are equipped with an automatic hole-punch and you can use the finisher as a convenience stapler.



Network Controller Module: Unplug any network cables going from the Network Module to the machine and also any which go to other computers. There is then one large thumb-screw to release and then the module will slide to your right and lift off the back of the machine easily.

DADF (Duplexing Automatic Doc. Feeder): The DADF comes off easily by unplugging it, removing two thumb screws which secure the hinges and then sliding it forward a little and lifting off.

Fuser Module: (Read details about the fuser rebuild process on p.E-1) Open the front door, flip up the Fuser Latch (yellowish orange color). Slide the fuser out the front. Watch out… it can be extremely hot and it takes a long time to cool off. Pay attention to the condition of the Fuser Latch. The latch is known to break and a loose latch can cause all sorts of problems as the electrical connections to the fuser would then be loose and intermittent.

Xerographic Module (Drum Cartridge): Open the front door and flip up the Xerographic Module Latch (yellowish orange color). This action also retracts the Developer Unit away from the Drum. Slide the Xerographic Module out the front… be very gentle with it and shield it from prolonged exposure to light. Never let sunlight touch the drum… not even for a second or the drum will get light-shocked. (Read the cartridge reconditioning instructional on p.E-5)

Transfer Corotron: When you buy a Xerographic Module, it also comes with a Transfer Corona Assembly in the box. The Transfer Corotron is designed to be replaced without any tools. It sits on a long narrow piece called the “Short Paper Path” which is hinged at the rear end so that when you slide the Xerographic Module out, this unit drops down. When you go to put the Xerographic Module back in… you need to remember to raise that Short Paper Path / Transfer Assembly back up so that it latches in the up-position just under the drum (refer to the Orientation Photo 1 on page D-1).



Photo 2 – Developer Unit Removal, Connectors behind the left side cover

Photo 3 – Developer Unit Removal,

Developer Unit: The Developer Unit with its Toner Dispensing Assembly on top is pretty easy to get out as well, although it does require a technician. First remove the Xerographic Module (Drum Cartridge) and put it someplace safe from light such as a black bag. Next you’ll remove the left side panel to gain access to two connectors. There is a main connector and a developer bias lug to unplug (see Photo 2). Then remove two screws from the front end and the unit will slide out the front of the machine. Toner Dispense Assembly: The Toner Cartridge sits on the top of the Developer Unit. The Toner Dispense Assembly is the piece mounted to the rear end with the dispense motor, cartridge motor and the dispense gears. To get the Toner Dispense Assembly off of the Developer Unit you’ll unplug the connector for the two motors at the rear end of the unit (one drives the toner dispense auger and the other spins the toner cartridge itself to keep the toner flowing into the dispense auger). Then remove two screws from the left side of the Toner Dispense Assembly. The Assembly will then slide off to the left.



Photo 4 - Waste Toner Door Removal.

Photo 5 - Remove one screw & move

the Power & Control Module to the left

Toner Waste Bottle Door: Take off the rear cover. Open the Waste Bottle Door and remove it by pressing down a little clip to give you clearance to slide the plastic hinge towards the rear (to the right in the photo) and off. Power & Control Module: (power supplies & Main IOT Board) The “Power & Control Module” is a module which includes the HVPS (Hi Voltage Power Supply), the LVPS (Low Voltage Power Supply) and the Main Board (IOT PWB or Image Output Board). Releasing and shifting the Power & Control Module aside is necessary to get-to many of the other parts in the machine although for most repairs it is not necessary to actually remove this module. There is only one screw to remove, from near the center of the machine (See Photo 5 above). Then you can move the whole module to the left so that it’s out of your way. If you actually need to remove the module, there are a whole host of connectors and ground straps to release or disconnect before the module will come off for you.



Photo 6 – Five Screws removes the

Tray 1 & 2 Feed Module

Feed Rolls: Now … lets go down to the Feed Rolls. All 4 trays use the same basic idea for the feed rolls although trays 1&2 and trays 3&4 use rollers with different part numbers. Getting the Feed Rolls off of the feed heads is easy enough to do… but requires some care. The Feed Heads are extremely fragile. One problem you are likely to run into, is damaged feed heads which result when the paper stack hits the feed head and tears stuff apart. If the customer overloads the paper tray, this can happen. A kit which was introduced later on, puts a “ramp” on the front end of the feed roll so that the feed head is less likely to get damaged in this manner.

Tray 1 & 2 Feed Head Assembly: You’ll get at the Feed Heads from the rear of the machine. Pull out and remove Tray 1 and Tray 2. Take off the rear cover and the Waste Toner Door (read about the Waste Toner Door on the previous page). Then remove one screw from near the center of the “Power and Control Module” (refer to Photo 5 above) and move it to the left & out of your way. Now from the rear you can remove the cover for the Tray 1 & 2 Feed Assembly. There are a few connectors to disconnect and the feed drive belt needs to be disengaged. Then there are 5 screws from the rear (see Photo 6) . Extract the entire Feed Assembly through the rear of the machine taking care that the Feed Sensor Actuators do not get caught on the Feed Sensors. Just be gentle and take your time here… The individual Feed Heads are set away from the rest of the module on fragile plastic “stand-offs”. Each Feed Head is held onto the Feed Assembly by 3 screws. The OEM Parts List which we have,



spares the entire Feed Assembly and does not spare the Tray 1 & 2 Feed Heads individually.

Tray 3 & Tray 4 Feed Head Assemblies: Tray 3 & 4 are considered the “HCF” or High Capacity Feeder option on these machines. The tray 3 & 4 Feed Assemblies are spared separately and are the same as one another. You’ll get at these from the rear of the machine too. First remove the Network Controller from the lower rear of the machine (as explained earlier, it is a self-enclosed plastic box which is easy to take off by unplugging it, releasing one thumb screw and then sliding it over to your right and lifting it off). Then take off the lower rear cover. Slide the drawer you are working on all the way out so that it will be out of your way. For the Tray 4 Feed Assembly, you also need to remove an internal cover from the rear (2 screws). After that, the two come out the same way. Unplug the ribbon cable, taking notice of how the blue strip is positioned on the cable so you know which way it should go when you plug it in again. You’ll remove two screws (the one at the bottom and the one at the upper right). Then lift a tab at the bottom of the feed assembly and move the assembly to the left so that it can be extracted. When you are reinstalling the Tray 3 or 4 Feed Assemblies, you need to hold down the feed head shaft to avoid catching the feed head on the inside of the machine (the shaft is visible protruding out the rear in a slot near the top of the assembly). A more recent version of the feed head has an extra plastic plate on the rear which makes it necessary to use a tool to hold down the feed head shaft (they recommend using a tiny flat head screwdriver with paper wadded around it to protect the shaft).

Image Processing Board Module: Preparing for removing the Image Processing Module, you’ll first take off the Document Feeder. It comes off easily by unplugging it, removing two thumb screws which secure the hinges and then sliding it forward a little and lifting off. The Image Processing Board Module is a big drawer-like tray which sits just below the scanner. You’ll loosen a pair of thumb screws and then disconnect a bunch of connectors, then the unit will slide out the rear for you.



Photo 7 – Preparing to remove

the Scanner Assembly.

Control Console: To remove the Control Console or UI (User Interface) as they call it, remove two screws from the bottom of the console… then tilt the console up and unplug it.

Scanner Bed Assembly: In preparation for removing the Scanner Bed Assembly, you’ll first remove the Xerographic Module (put it in a black bag in a safe place). Then take off the Document Feeder, the Image Processing Board Module, and the Control Console (read earlier for more details on these three items). Remove the upper rear cover of the machine and the large black fan & duct (see Photo 7). Use the red Scanner Latch Bolt to lock the scan carriage so that it doesn’t move around when you remove the scanner. Looking at the rear of the machine, the Scanner Latch Bolt is stored in a little cubby on the upper left corner (see Photo 7). Remove two screws and two spacers from the front of the Scanner Bed Assembly. Some more recent build machines also have two more screws and spacers from the bottom (located near the rear corners). Unplug the harness. Now slide the entire assembly back to disengage the two latches and lift the Scanner Assembly off.

Raster Output Scanner (ROS or Laser Unit): The ROS or Laser Unit can be removed once the Scanner Bed Assembly is off (read above). There are different versions of the ROS depending on the speed of the machine. There’s a Serial # label on the bottom front end of the ROS (visible without removing the ROS if you take the Drum Cartridge out of the



Photo 8 – ROS (Laser Unit)

Screw and Serial # Label

machine (see Photo 8). The first 2 digits in the ROS serial number indicates the machine speed it is designed for (35, 45, or 55). Once you have the Scanner Assembly off, there is one screw from the front end (see Photo 8) which holds the ROS in place. With that one screw gone, you can slide the ROS to the rear to align a cutout & lift the rear end, taking particular care not to hurt the wiring on the rear end of the ROS (it is very vulnerable). If you take the ROS out and you choose to open it for cleaning … keep in mind, aside from the 5 torx screws which hold the top cover on, you should not turn any other screws inside the ROS. The manual says it is ok, if you are extremely gentle, to clean the mirrors including the polygon mirrors but do not clean the laser diode itself. You can use a vacuum inside there but beware that the mirrors and slit glass are extremely delicate and may snap if the vacuum nozzle gets too close to them (canned air might be a better choice for this cleaning process).

Fuser Latch & Xerographic Latch: Removing either the Fuser or Xerographic Module Latches looks easy at first glance, however both are screwed from the inside of the frame of the machine. This means you have to remove the Scanner Bed Assembly (refer to p.D-7). There is an aftermarket Fuser Latch Kit which allows you to install a new Fuser Latch from the outside (saves about an hour). (see p.F-8)

Erase Lamp: Remove the Xerographic Module (drum ctg). The Erase Lamp is just to the right of it. Remove one screw from the front end and the lamp assembly will slide out the front.



Photo 9 – Seven silver screws.

Main Drives Module: The Main Drives Module includes the Xerographic Drive Motor and a rather massive flywheel which is mounted to the spline of the motor (it is designed to make the turning of the drum cartridge as smooth and consistent as possible). The module also includes the Main Drive Motor, which is responsible for driving much of the rest of the machine. Also spared only as part of this larger module, is the waste toner auger assembly and its gearing. To remove the Main Drives Module from these machines takes a little effort. You’ll start by taking out the Xerographic Module (drum ctg.) and the Fuser Module. You’ll also want to release the Developer Unit and slide it out about 4 inches. Here’s a quick refresher: remove the machine’s left cover and unplug a wiring harness on the DV Unit and a bias lug. Then remove two screws from the front end of the DV Unit. The unit can slide out at that point. At the rear of the machine, remove one screw from the Power & Control Module so that it can be shifted back and then towards the exit side of the machine. Disconnect P/J24 (Plug / Jack 24) from near the top of the Power & Control Module. Disconnect the Main Frame Ground Wire. Remove the Waste Toner Full Sensor, and P/J57 (Plug / Jack 57) from the Waste Toner Door Switch. Release the clip holding a wiring harness (see Photo 9) (make sure you don’t trap this harness behind the Main Drives Module when you go to put it back on later). Disconnect P/J147, P/J148, & P/J149 from the Main Drives Module. Now… finally you can remove the 7 silver screws which keep the Main Drives Module in place (see Photo 9), and slide it off of its locating dowels. If you are replacing the module, you’ll want to pay attention to the color of the gears. There are



Photo 10– Releasing the Transports

Photo 11– Duplex Transport (Correct positioning of rail)

different versions of the Main Drives Module based on the speed of the machine. The 35ppm machine’s version which has black drive gears and the 45/55ppm machine’s version has white drive gears. The newer faster machines probably will have other colored gears although that remains to be seen. When you are ready to reinstall the Main Drives Module, it is important that you first go to the front of the machine and support the Short Paper Path in the “up” position (that is the piece with the Transfer Corona Assembly on it). Use a piece of string or a long rubber band to gently hang it from the Xerographic Latch which is directly above it. The Service Manual also advises that you lubricate the Developer Unit support pin on the Main Drive Module. Once the module is in place, rotate the motor by hand to engage the drive to the inverter transport before tightening the 7 screws back up. Duplex Transport: Before you can remove many of the modules from the body of the machine, you will first need to remove the Duplex Transport (marked “2a” on its green handle). This is easily accomplished… First get the Fuser and Xerographic Modules out. Next remove 1 screw (5.5mm Hex Drive) from the front (See Photo 10). Pull the transport out 3 inches and disconnect its wiring harness. Then it’ll slide out the front to you. When you are reinstalling it… make sure that the rail of the Duplex Transport is properly positioned on the metal rail in the machine (see Photo 11)



Photo 12 – Transfer (T) &

Detack (DT) Leads

Photo 13 – Short Paper Path Removal

Short Paper Path: The “Short Paper Path” is the assembly which holds the Transfer Corotron (it’s marked ‘4b’ on its green handle). It also houses the vacuum transport fan and the vacuum transport roller. It’s hinged at the rear end so that it can drop down to allow the Xerographic Module to be removed. Be gentle… this piece is fragile. To get the Short Paper Path out; first take out the Fuser and Xerographic Modules, the Duplex Transport, and the Transfer Corona Assembly (push it towards the rear and raise up the front to remove). Go to the back of the machine and remove the rear cover. Here you’ll need to move the Power & Control Module to the left and a little bit outward (Refer to p.D-4 and see Photo 5). Disconnect the Transfer and Detack Leads from the High Voltage Power Supply. The Transfer Lead (marked with a “T”) goes on the right side and the Detack (marked with a “DT”) goes to the left (See Photo 12). Now go to the front of the machine and pull the 2 leads through the round hole in the frame. Disconnect the Vacuum Transport Fan’s connector. Next from inside the machine, you’ll remove one screw with its ground lead, from the lower left of the Short Paper Path’s hinge bracket and a second screw from the right side of the same bracket



(see photo 13). When reinstalling, take care to route the wires properly so that nothing gets caught behind the assembly. Registration Transport: The Registration Transport has a green knob on it which is marked with the number “4c”. This will be necessary if you ever need to get to the Registration Roller and the Registration Clutch. Start by removing the Fuser and Xerographic Modules. Also remove the Developer Unit, Duplex Transport and the Short Paper Path. Open the left door and remove 2 screws. Also, from the front, release the registration retainer bracket and the ground wire trapped beneath one of the screws (Refer to Photo 10 on p.D-10). Disconnect the connector and the spade lug terminal (red) at the front end of the assembly. Move the Registration Transport frame forward slightly and lift it to unlock the transport from the base. When you go to reinstall the Registration Transport, make sure that the ground wire is reattached properly and double check for a low resistance path (under 4 ohms) between the registration / pre-registration rollers and the machine’s ground (any uncoated metal frame will serve as a ground test point). After the Registration Transport is reinstalled, you will want to check the Registration and make adjustments if need-be. See p.C-15 for details on how to do the Registration Adjustment (dC604 Registration Setup). Inverter Module: The Inverter Module handles duplexing and paper exit transport. You’ll need to take out the Fuser Module, and Duplex Transport. Also remove whichever Output Device the machine is equipped with… either the Oscillating Catch Tray (OCT) or the Large Capacity Stacker Stapler (LCSS). Take off the right hand cover (2 screws). Now remove the Inverter Support (2 screws from the front and turn clockwise to extract) and the “Tie Bar” which is a metal plate from the front frame to the rear frame (see Photo 14). The Tie Bar is held in by 4 screws; 2 from the front and 2 from the rear. There are a pair of connectors to release on the Inverter Drive Board on the Tie Bar. Disconnect (Plug / Jack 49) which is for the



Photo 14 – Inverter: Front Photo 15 – Inverter: Rear

Inverter Gate Solenoid. You can now lift the Inverter Frame slightly at the front end and move it towards the front of the machine until the idler shafts at the rear of the unit clear their holes (see Photo 15). Once you’re certain the shafts are all the way out,

you can turn the rear end of the Inverter to the right and remove the module through the right side of the machine. When you reinstall the Inverter Transport, make sure the wiring harness for the Inverter Gate Solenoid is behind the unit so that there is no chance of it getting into the paper path. Once the idler shafts are fully seated; rotate knob 3c clockwise to engage the drive coupling. This helps to locate the Inverter in the machine’s frame. The Inverter is a relatively complex unit. Inside you’ll find the Fuser Exit Roll, a lower transport roller and the Final Exit Roll as well as “Gravity Fingers”. An Inverter Repair Kit is available which includes the Fuser Exit Roll, the lower transport roll, the Inverter Gravity Fingers, and the Inverter Gate Cam (from the rear of the gate). (see p.F-8)


(Section E – Module Rebuilding / Repairs) p.E-1

FUSER REPAIRS & REBUILDING:

Below are the part numbers for the various Fuser Modules for the specific models within the “C35 style”.

For: (DocumentCentre) DC535/545/555, (CopyCentre) C35/45/55, (WorkCentre) M35/45/55, Pro35/45/55, WC-5030/5050 109R636 (110 volt – U.S.) … 109R634 (220 volt – Europe) For: (CopyCentre) C232/238/245/255, (WorkCentre) WC-232/238/245/255, Pro232/238/245/255, WC-5632/5638/5645/5655 109R752 (110 volt – U.S.) … 109R751 (220 volt – Europe) For: (CopyCentre) C165/175 (WorkCentre) WC-165/175/265/275, Pro165/175/265/275 109R723 (110 volt – U.S.) … 109R724 (220 volt – Europe) For: (WorkCentre) WC-5665/5675/5687 109R773 (110 volt – U.S.) … 109R772 (220 volt – Europe)

This book is based on the original version: 109R636 / 109R634. Other fusers in this series come apart in a similar manner with some minor differences. There are physical differences between the parts in the fuser modules beyond just the Connector CRUM. The heat lamps change from model to model and the heat and pressure rollers turned out to change as well from fuser version to fuser version. Fortunately, the webs are consistent throughout and the fingers, gears, bearings and bushings are as well. You can easily extend the life of a fuser by replacing the Connector and the web. You may want to simply replace the fuser the first time you run across a need for one and then keep the core. This way you can repair it and offer a rebuilt unit at a better price to the next customer who needs one. This is where the Service Industry is going it seems… if you’re not repairing the modules of the machines, you’ll miss out on a good part of the work. The Connector or CRUM on the rear of the Fuser Module keeps track of the copy count for the fuser. The 109R636 is set to run 350K copies before it times out at which point the machine will lock you out till it sees a new Connector (CRUM) on the fuser. Naturally, if the fuser runs into other difficulties such as an overheat, it will end its life early. Interestingly the Service Manual acknowledges that it is possible for the Fuser Cleaning Web to run out before the Fuser Copy Count runs out if the client runs an



unusually high ratio of long sheets (14” or 17” paper)… so the fuser reset Connector CRUM will be extra important on this series. This Fuser Module is rather simple to disassemble: 1.) Remove the upper Picker Finger Assembly (2 screws) which also houses the Fuser Exit Switch. This is on the right hand side of the fuser. Disconnect the Exit Switch’s connector at the rear end. 2.) Remove the Top Cover (4 screws) to gain access to the Fuser Cleaning Web Assembly. 3.) Remove the Cleaning Web

Assembly. There is one screw near the front end (from the top) and a second screw near the rear end. The rear screw also retains a metal clip which serves to prevent the Web Take-up Gear from turning backwards. 4.) Next you’ll go after the Thermistor / Thermal Fuse Assembly (2 screws from the left side). This assembly also includes the electrical connector for most of the circuits of the fuser. You’ll need to disconnect the two front fuser lamp connectors. Disconnect also

Remove the Top Cover to reveal

the Cleaning Web Assembly.

The Thermistor / Thermal Fuse Assembly.

Remove the Upper Picker

Finger Assembly.

Rear Fuser Lamp Holder Bracket.



the two rear Fuser Lamp connectors and the green ground wire (1 screw). Then remove the rear lamp holder bracket which is trapping the lamp connectors (2 screws). Now you can get to both Thermal Fuses and the two Thermistors easily. In the C35 version of the fuser shown in the photos, it appears that the two thermistors would be interchangeable if it were not for the length of their wires. The two Thermal Fuses are identical to one another. Replacing one of the Thermal Fuses would be a piece of cake. To replace the thermistors you’ll need to release molex pins from the fuser’s Electrical Connector. It’ll be important to know which wire goes to each pin on that Electrical Connector (see the pinout for the AC Connector after this procedure). 5.) Now for the lamps… you’ve already removed the Rear Lamp Holder Bracket. Now remove the front lamp holder bracket (1 screw). Be very gentle sliding out the two Fuser Lamps as they tend to want to get hung up on one another on the way out. In the C35 version (109R636), the two lamps are identical to each other, later models also have two lamps, but of a different wattage. 6.) Before you start removing the upper Heat Roll, release the tension from the Pressure Roller… There is an adjusting screw on the front end and one on the rear end which suspend ‘L’ brackets which have the pressure springs attached to them. Mark how each is positioned before you start so that you can later return them to

Front Fuser Lamp

Holder Bracket

Releasing the tension on

the Pressure Roller.



the same tension. Now you can remove the ‘C’ clips from the Heat Roller. One from the outer rear end allows you to slide off the Fuser Drive Gear, Upper Fuser Bearing, and Heat Sleeve. Similarly the front end can be dismantled. The Heat Roll can now come out and the lower roller with its bearings can then be lifted out of its cradle. Notice for reassembly later, that the flanges from the lower bearings are positioned on the inside of their metal cradles so that they can’t walk off the ends of the roller. 7.) Once you’ve cleaned everything up and replaced any bad parts, its time to reassemble. Everything goes back pretty much the way it came apart. Make sure to clean the faces of the Thermistors. Also, once the Cleaning Web Assembly and its metal clip (the piece on the rear end which engages the web Take-up Drive Gear) are in place, turn the take-up gear (counterclockwise when viewed from the rear) to remove any slack on the web. Its also helpful to remember to reconnect the Exit Switch’s connector before you install the top cover (while it is still accessible). 8.) If you wish to reset the Fuser’s Copy Count, you will need to replace the Connector (or CRUM) from the rear of the fuser module. (see p. F-7 for CRUMs and lots of other parts for the fusers) Here’s the pinout for the Fuser’s Electrical Connector:

Pin #1: Red Wire to Rear Thermal Fuse Pin #2: Red Wire (short) to Rear Red Connector Fuser Lamp Pin #3: White Wire (short) to Rear White Connector Fuser Lamp Pin #4: White Wire to Front Thermal Fuse Pin #5 & 6: Rear Thermistor Pin #6 & 7: Front Thermistor Pin #8: Green Ground Lug Wire Pin #9 & 10: Exit Switch

Fuser Connector

(CRUM)

Fuser Electrical Connector

(Pinout)



XEROGRAPHIC MODULE RECONDITIONING (Drum Cartridge): For (DocumentCentre) DC535/545/555, (CopyCentre) C35/45/55, (WorkCentre) M35/45/55, Pro35/45/55, (CopyCentre) C232/238 (WorkCentre) WC-232/238, Pro232/238, WC-5030/5050, WC-5632/5638 113R608 (U.S. or Europe Type ‘B’ version) (Yield = 200,000) 113R610 (U.S. Type ‘A’ version) (Yield = 200,000) 113R607 (Europe Type ‘A’ version) (Yield 200,000) For (CopyCentre) C165/175, (WorkCentre) WC-165/175, WC-245/255/265/275, Pro245/255/265/275, WC-5645/5655/5665/5687 113R672 (U.S. Type ‘B’ version) (Yield = 400,000) 113R674 (U.S. Type ‘A’ version) (Yield = 400,000) 113R673 (Europe “Sold” version) (Yield = 400,000) The Xerographic Module is designed to have an estimated yield of 200K on some models and 300K on many of the newest models… this means the drum itself is made of some pretty good stuff and the 113R608 / 113R610’s drum will undoubtedly be capable of running a second cycle. You’ll want to be prepared to service the unit to repair drum cleaning problems and other issues which may arise during the life of the cartridge. Think of the Xerographic Module as just another part of the machine which requires regular service and you won’t miss out on that part of the action. A new Xerographic Module has a retail price tag in excess of $400.- from Xerox. This book is based on the 113R610 (Type ‘A’) and 113R608 (Type ‘B’). Some of the faster and newer models use a slightly different cartridge. The repair procedure will be extremely similar, but the cartridges do have some substantial differences which go beyond just the Connector CRUM.



These cartridges come with a Transfer / Detack Corona Assembly in the box as well. The machines which are still set up for the “Metered” plan are ones which were sold with a Field Service Maintenance Agreement (FSMA)… the cartridges are included with the deal while they are under that maintenance agreement. The first time that a “Sold” version of the Drum Cartridge is installed in a “metered” plan machine, the machine changes to the “Sold” plan and will need to get the 113R610 ‘Sold’ (Type ‘A’) version of the cartridge from then on or else the Status Code “09-399” “Incompatible Xerographic Module” will show up. That Status Code will also appear if you try to install a cartridge from a different market. For example a European cartridge (113R607) would also result in a Status Code. The key to all of these market differences is held in the small Connector on the rear of the cartridge… the “CRUM” (Customer Replaceable Unit Monitor) which is programmed differently for each market. You’ll need a replacement Connector CRUM to reset the drum count. (see p.F-8) These cartridges are pretty straight forward with the exception of a trick being necessary to remove the Drum Hubs… 1.) You’ll want to remove the Top Cover first (4 screws from the top) then clean out whatever waste toner is easily reached from there. 2.) Next lay the unit on its Right Side… the drum will not be in danger of touching your work surface if the cartridge is in this position so you’ll want to keep it sitting like this for most of the balance of this procedure. Remove the Front Cover (1 screw from the front near the bottom… 5.5mm nut driver) 3.) Take notice of where the spring for the Stripper Finger Bracket attaches. Slide the Finger Bracket forward until the rear pin

Rear View

CRUM Connector



comes clear of the rear frame and remove the Finger Bracket and its spring. You will want to take care not to scratch the drum’s surface with the fingers (it might be wise to slide a piece of paper between the fingers and the drum before you slide the finger Bracket over).

4.) Here’s the tricky part… the Drum Hubs. We’ll start with the Rear Hub. Get a pair of pliers and get a firm grip on the rear hub and rotate the hub about ¼” counterclockwise… it will resist and then suddenly “pop” into a

new position. Then it can be extracted. The hubs each have a pair of hooks with wedge shaped tips (one at the top, one at the bottom). The hooks prevent the hubs from being able to slide out unless they are turned to the removal position where there is clearance for the hooks. The wedge shapes at the tips of the hooks are indexed into a hole in the cartridge’s frame such that you need substantial force to rotate the hub into the removal position. … The author broke one trying to figure this out. The Front Hub

Drum Hub

Drum Hub Clearance / Removal Position

Rear Drum Hub Removal

(shown with hub in removal position)



works much the same way (except that you rotate the hub clockwise). When you remove the second hub, make sure the drum doesn’t drop out on you as it is only lightly retained when the hubs are out. The drum will now be removable from its cradle.

5.) The Cleaning Blade can be removed now (2 screws … 5.5 mm Nut Driver needed). Be very gentle with the mylar seal blade below the cleaning blade… if it gets damaged, the cartridge will likely drop sprinkles of toner into the paper path when you reinstall it. 6.) To remove the Charge Corona Assembly, pry the indented portion of the spring metal holding clips (one on the front end, and one on the rear) till you can slide the clip out away from the cartridge’s frame to release the Corona Assembly. 7.) Clean everything up really good… Reassemble the unit. Pay attention to the position of the large toothed mylar piece attached to the top cover… its teeth need to slide all the way down into the waste toner auger (it prevents the auger from clogging up). It is possible to position it against the drum instead which would obviously be bad news. 8.) Replace the Connector CRUM to reset the drum count. That should do the trick. Eventually Cleaning Blades and replacement Drums will no doubt become available. A generic replacement Connector CRUM is already available.

Corona Removal…

Release the metal clip.

Cleaning Blade and Recovery Blade


(Section F – Sourcing Parts) p.F-1

SOURCING PARTS & SUPPLIES: Sourcing parts can be a challenge at times, however there are an increasing number of places to look these days. You can buy directly from Xerox if you have an account or if you provide the serial number of the machine when you call (800)-828-5881 or you can call an alternative Parts Supplier. (see P.F-7)

Supplies / Customer Replaceable Units - Part #’s: A complete listing of all of the part numbers for the Customer Replaceable Units (CRUs) can be found on p.A-11 & A-12. That list includes the part #’s for all of the models in this series to date (as of Dec. 2007). That list includes: Xerographic Modules, Toner Cartridges, Document Feed Heads, Fuser Modules and Staple Cartridges.

Parts: Things to keep in mind: • Order by exact model designation… even if you think you

know the part number … Remember that while some parts cross over between models, there are many variations within this series, so don’t take compatibility for granted.

• Not spared by Xerox?… Many many parts are simply not spared except as a larger module or assembly. For example, very few parts in the fuser are spared. For these non-spared items you’ll need to find some good generic parts or find someone who sells used parts. (See p. F-7)

• Changing Part Numbers: Part Numbers get replaced with new ones from time to time. So in some cases, there may be multiple part numbers for the same part.

• Pay attention to “Tag” changes… Xerox calls their field changes “Tags” (other makers call them “mods”). The Tag matrix for the main machine is located just inside the front door of the machine on the frame. Other parts of the machine such as the Doc Feeder or Finisher will have their own Tag matrix. The matrix will look like a grid of numbers with some either “blacked out” or “punched out” or other-wise marked to indicate that modification has been done to the machine. Many parts in the parts list will show more than one variety… one may be “W/ Tag xxx” (With Tag xxx) and another version will be “W/O Tag xxx”(Without Tag xxx)



Parts Listing for DC535 family and C35 family: Below is a list of some of the modules and important parts from the Parts List in the DC535 Service Manual. That book covers the following models: (DocumentCentre)DC535, DC545, DC555, (CopyCentre) C35, C45, C55, (WorkCentre) M35, M45, M55, Pro35, Pro45, Pro55. Read also the Alternative List which follows. It includes some of the parts which are now available from your sponsoring Parts Dealer which are not spared by Xerox according to their parts list. You’ll also an innovation kit or two which can save you either time or money. Keep in mind that the OEM part numbers may change over time. Parts may or may not be compatible with newer models in the series. Acronyms / abbreviations used in the list: CC35-WCP55F = CopyCentre 35 – WorkCentre Pro55 Family DADH = Duplexing Automatic Document Handler DC535F = DocumentCentre 535 Family HVPS = High Voltage Power Supply IOT = Image Output Terminal (the main part of the machine) LCSS = Large Capacity Stacker Stapler (finisher) LVPS = Low Voltage Power Supply NASG = North American Service Group (US) NSX = Not Spared by Xerox (at least not in the list we have been provided with) PPM = Pages per minute (some parts are 35 ppm vs. 45/55 ppm) PWB = Printed Wire Board ROS = Raster Output Scanner (laser unit) UI = User Interface (control console) W/ TAG = With Tag (field modification) W/O TAG = Without Tag (field modification) XCL = Xerox Canada Limited

OEM Part # Part Name

Electrical Components (main machine / IOT) 160K96201 Main Board (IOT PWB) 604K18591 Low Voltage Power Supply (LVPS) & BASE MODULE 160K97152 High Voltage Power Supply (HVPS)

101K56940 Control Console Assembly / UI (User Interface Assy.) (US - NASG/XCL) (CC35-WCP55F)

123K07092 Control Console Assembly / UI (User Interface Assy.) (US - NASG/XCL) (DC535F) (W/TAG 002, TAG 038)

960K11571 Power Distribution PWB (W/TAG 001) 160K96540 Firewire PWB (W/OTAG TAG N003) 960K1 3691 Firewire PWB (SMART) (WC35- WCP55F) W/TAG N003



Drive Components (main machine / IOT) 007K13485 Main Drive Module (35 PPM) 007K13495 Main Drive Module (45/55 PPM) 127K42780 Main Drive PWB (35 PPM) 127K42800 Main Drive PWB (45/55 PPM) 127K42870 Fuser Web Motor Laser Modules 604K18500 ROS (Laser Unit) (35 PPM) (W/TAG 019) 604K12990 ROS (Laser Unit) (45/55 PPM) Feed Components 160K92822 Tray 1 and 2 Control PWB 050K54361 Tray 1 or 2 Paper Tray Assembly 050K54181 Tray 3 Paper Drawer Assembly 050K54191 Tray 4 Paper Drawer Assembly

059K30390* Feed Roll (Tray 1 or 2) (*See also alternative listing to follow for Feed Tire Kits)

059K39200* Feed Roll (Tray 3 or 4) (*See also alternative listing to follow for Feed Tire Kits)

604K31370 Tray 1 & 2 Multifeed Improvement Kit 059K30542 Tray 1 and 2 Paper Feed Assembly (includes for both trays) 059K30552 Tray 3 or 4 Paper Feed Assembly (1 assy per tray) 059K30381 Bypass Feed Roll and Retard Pad Kit 050K54933 Bypass Feed Module Assembly 498K06280 Envelope Feed Kit, C10 (NASG/ XCL) (CC35WCP55F) Paper Transport modules and parts 059K50500 Registration Transport (W/TAG 008, TAG 033) 059K33951 Duplex Transport Module 059K33981 Short Paper Path Assembly 112K00701 lnverter Complete Assembly (WI /TAG 039) Developer Unit, Toner Dispense & Waste Toner See p.A-11 Toner Cartridges (2 versions… depending on model) 6041K 3620 Toner Dispense Module Kit

NSX Developer (Not spared in our parts list, however it turns out that it is obtainable under a non-published part number… see the alternative list to follow.)

604K13411 Developer Module Kit (includes Developer) 604K18510 Toner Cartridge Latch Repair Kit

008R12896 Toner Waste Bottle (one is includes with each case of Toner, either 6R1046 or 6R1146)

802E45131 Waste Toner Door



Xerographic Components See p.A-12 + alternative list to follow

Xerographic Modules (Drum Ctgs.) (many versions… depending on exact model) For Drum Cartridge Parts, refer to the alternative list to follow.

003K17600 Xerographic Module Latch Kit 122K02300 Erase Lamp

504K11510 Transfer/Detack Corotron (note: one included with each new Fuser Module)

Fuser Modules See p.A-11 + alternative list to follow

Fuser Modules (many versions… depending on exact model) For Fuser Parts, refer to the alternative list to follow.

604K17672* Fuser Latch Kit (*Note that there is an aftermarket innovation kit which saves time for installation, see alternative list to follow)

Output / Finisher (LCSS or OCT) Components

- Simple Catch Tray (not an option according to the OEM parts list, but a generic product is available)

See p.A-11 Staple Cartridges 604K31360 Oscillating Catch Tray (OCT) Kit 050K55021 Finisher (LCSS) Top Tray Assembly 050K54132 Finisher (LCSS) Stacker Tray 110K13980 Finisher (LCSS) Interlock Switch I20K02590 Finisher (LCSS) Interlock Actuator 003K18510 Finisher (LCSS) Latch Assembly 160K92710 Large Capacity Stacker Stapler (LCSS) PWB 105K26331 LCSS Power Supply Module Scanner Components (Exposure) 062K13792 Scanner Module (35 PPM) (CC35- WCP35) 062K13802 Scanner Module (45/55 PPM) (DC535F) 062K21931 Scanner Module (35 PPM) (DC535F) 062K21941 Scanner Module (45/55 CPM) (CC45-WCP55F) 090K02381 Document Glass (DC535F) 090K02451 Document Glass (CC3S-WCP55F) 122K02290 Exposure Lamp (REP 14.9)

130K67500 Scan Carriage Home Sensor (same part# for Input Module Angle Sensor)

127K42750 Scan Drive Motor (for Exposure Carriage) 960K20412 Scanner Driver PWB (W/TAG 048, TAG 049, TAG 050) 160K92770 Scanner Driver PWB (W/O TAG 048, TAG 049, TAG 050) NSX CCD PWB (Spared only as part of the Scanner Module)



Document Feeder (DADH)

See p.A-12 Document Feed Head Assy. (See also alternative listing to follow for Document Feed Repair Kit)

036K01326 Document Right Hinge (Counterbalance) 036K01336 Document Feeder Left Hinge (Counterbalance) 160K65887 Document Feeder Board (DADH PWB) 084K08896 Document Feeder (DADH) - Complete (DC535F) 084K17497 Document Feeder (DADH) - Complete (CC35- WCP5SF) 022 K69682 Document CVT Roll (Constant Velocity Transport)

Network Controller Components & Upgrade Kits (optional) 160K96540 Firewire PWB (W/OTAG TAG N003) 960K13691 Firewire PWB (SMART) (WC35-WCP55F) (W/TAG N003) 498K01982 Network Controller Kit (US) (DC535F) 498K04600 Network Controller Kit (US) (CC35-WCP55F) 498K02030 Internet Fax Kit (DC535F) 498K04250 Internet Fax Kit (CC35-WCP55F) 498K02060 Scanning Kit (DC535F) 498K04270 Scanning Kit (CC35-WCP55F) 498K02080 Server Fax Kit (DC535F) 498K04300 Server Fax Kit (CC35-WCP55F) 498K02170 Network Accounting Kit (DC535F) 498K04260 Network Accounting Kit (CC35-WCP55F) 498K02710 Security Kit (DC535F) 498K04290 Security Kit (CC3S-WCP55F)



ALTERNATIVE PARTS LIST: Parts from the sponsor of this book:

The Parts Drop www.partsdrop.com Tel#: (201)387-7776 We’ve been working on this series in preparation for all of your needs… including the publication of this book. We hope that we can serve you well. If you don’t see something you need, please ask us, we probably have it… and if we don’t, we can usually come up with it in a reasonable amount of time.

Rebuilt Modules and Good Used Parts: We have carefully qualified & cleaned used parts. This helps us to have on-hand many of the little rare parts which no one in their right mind would stock new. It also allows us to get you decent pricing on some of the more expensive parts such as boards or modules. Let us know your exact model and the part you need and we’ll get you pricing and availability.

Not Spared? No problem… You’ll find in the list which follows that we went and found, or had-made, many parts which are “Not Spared by Xerox” (NSX).

The Parts Drop’s Wholesale Pricing: log into our website (www.partsdrop.com) and get us to approve your account for Wholesale Status… then enter Our Part number or a model number and a description into the Keyword Search (in the left column of our website). Or give us a call! We would love to hear from you: (201)387-7776. Always order by Exact Model Number so we can be sure to get you the right part for your particular machine.





The Parts Drop: Regular Catalog Items As of May 2008 (we are adding new stuff all the time):

OurPart# XPart# Description

FUSER MODULES & FUSER PARTS… Refer to p. A-11 to see which Fuser Module fits which model numbers.

C35FM 109R636 Fuser Module (N. America) C35FME 109R634 Fuser Module (Europe) New in a plain box 232FM 109R752 Fuser Module (N. America)

C35FCN NSX Fuser Connector (CRUM) for fuser count reset (For 109R636)

C35FCNE NSX Fuser Connector (CRUM) for fuser count reset (For European 109R634, 220 volts)

232FCN NSX Fuser Connector (CRUM) for fuser count reset (For 109R752)

232FCNE NSX Fuser Connector (CRUM) for fuser count reset (For European 109R751, 220 volts)

C35FHR NSX Fuser Heat Roll C35FPR NSX Fuser Pressure Roll C35UPF 604K24990 Fuser Picker Finger (we sell them individually) C35UFB NSX Fuser Heat Roll Bearing (Upper Fuser Bearing) C35LFB NSX Fuser Press Roll Bearing (Lower Fuser Bearing) C35HS NSX Fuser Heat Roll Bushing / Heat Sleeve (each) C35FDG NSX Fuser Heat Roll Gear (46T) C35FW NSX Fuser Web (pd Brand) C35FL NSX Fuser Heat Lamp (pd Brand) (110 volts) C35FL2 NSX Fuser Heat Lamp (pd Brand) (220 volts) C35FES 110E14650 Exit Switch (w/ actuator) C35THR NSX Fuser Thermistor C35THF NSX Fuser Thermostat (2 per fuser) C35FWG NSX Fuser Web Drive Gear

C35FEIK 604K22070

Fuser Exit Improvement Kit (ribs which strengthen the exit baffle to reduce paper downward curl exiting fuser)

XEROGRAPHIC MODULES & PARTS: See p. A-12 to see exactly which models each cartridge fits. Also read up on p.E-5 to E-6 for an explanation of what Type A vs. Type B means.

C35XM 113R608 Xerographic Module (Type ‘B’) C35XMG 113R610 Xerographic Module (Type ‘A’) C35DB NSX Drum Cleaning Blade (Coming Soon)

C35CN NSX Xerographic Connector CRUM (Type A) (resets 113R610 drum count)

C35CNB NSX Xerographic Connector CRUM (Type ‘B’) (resets 113R608 drum count)



DEVELOPER MODULE / TONER HANDLING PARTS: C35DU Reconditioned Developer Unit C35D Developer LATCH KITS:

C35FLK

Fuser Latch Kit… Innovator Kit includes OEM kit + hardware to install it without having to remove the Scanner Module.

C35XLK

Xerographic Latch Kit (for drum cartridge latch)… requires removal of the Scanner Module (figure on a couple of hours to play it safe).

C35TLK Toner Latch Kit (Secures the Toner Ctg.).

C35TCL

Transfer Corotron Carrier Latch (from the “Short Paper Path” which holds the Transfer (says ‘4b’ on it) includes flat spring).

C35IJCL Inverter Jam Clearance Latch (green latch, says ‘3d/4d’ on it).

PAPER FEED PARTS: C35BFRK 059K30381 Bypass Feed Roll Kit (roll and retard pad)

C35PFTK 059K30390 / 059K39200 Feed Tire Kit (3 tires) fits Trays 1-4

C35PFHA3 059K30552 Paper Feed Head Assembly (for Tray 3 or 4) EXIT / OUTPUT PARTS & KITS:

C35SCTK NSX

Simple Catch Tray Kit (includes a Paper Exit Tray, a Simple Catch Tray enabler plug, and stacking Fingers)… an Innovator Kit.

C35OCTA 604K31360 Oscillating Catch Tray (OCT) Assembly… call for availability.

C35FIA I20K02590 Finisher Interlock Actuator

C35FINLK 003K18510 Finisher Docking / Latch Kit (includes the latch hooks, docking pin, etc.)

C35FIS 110K13980 Finisher Interlock Switch C35FERRK Exit Roll Repair Kit (4 tires & paddle wheel) SCANNER REPAIR SERVICE & PARTS:

C35CCDR NSX

CCD / Lens Assembly Repair Service … for 35ppm Scanners. See p.B-13 for trouble-shooting info also read critical information about how to properly handle the CCD / Lens Assembly.

C35SHS 130K67500

Scan Home Sensor … Read about Scan Home Sensor Failures (14-110) on p.B-13 often the problem is not the sensor, but the power to the sensor (see the Scanner Repair Service above).

DOCUMENT FEEDER PARTS:

C35DFRK 113R497 / 113R686

Document Feed Repair Kit (1 Feed Tire, 1 Nudger Tire & 1 Retard Roll)

C35DER Document Exit Roll (or Takeaway Roll)

c35_tech_info_manual.pdf

Documents