Xerox Docucolor 2240 User manual

701P39969

February, 2003

DocuColor 3535/2240/1632

Service Manual

THE DOCUMENT COMPANY

XEROX

CAUTION

Certain components in the DocuColor 3535/2240/

1632 are susceptible to damage from electrostatic

discharge. Observe all ESD procedures to avoid

component damage.

WARNING

This equipment generates, uses and can radiate radio frequency energy, and if not

installed and used in accordance with the instructions documentation, may cause inter-

ference to radio communications. It has been tested and found to comply with the limits

for a Class A computing device pursuant to subpart J of part 15 of FCC rules, which are

designed to provide reasonable protection against such interference when operated in

a commercial environment. Operation of this equipment in a residential area is likely to

cause interference in which case the user, at his own expense, will be required to cor-

rect the interference.

DANGER: Cet équipement génère, utilise et peut émettre des fréquences radio, et, s'il

n'est pas installé et utilisé selon les recommandations du manuel d'instructions, peut

causer des interférences aux communications radio. Il a été testé et jugé conforme aux

limites des systèmes de catégorie A, conformément à la partie 15 de l'alinéa J des règle-

ments FCC, établis pour protéger contre de telles interférences pendant le fonctionne-

ment en milieu commercial. Dans une zone résidentielle, il peut causer des

interférences; dans ce cas, l'utilisateur devra corriger le problème à ses propres frais.

WARNING

This machine contains an invisible laser. There is no visual indication that the laser

beam is present. During servicing, the machine is a Class 3B product because of the

invisible laser. the laser beam could cause eye damage if looked at directly. Service pro-

cedures must be followed exactly as written without change. The service representative

must observe the established local laser safety precautions when servicing the

machine. Do not place tools with a reflective surface into the ROS opening. Do not look

in the area of the ROS window if the power is On and the laser is energized.

DANGER: L'équipement contient un faisceau laser invisible et aucune indication visible

signale la présence du faisceau laser. De ce fait le produit est classé 3B pour tout ce qui

concerne la maintenance. L'exposition directe des yeux au faisceau laser peut entraîner

des lésions visuelles. Les procédures de maintenance doivent être réalisées sans

aucun changement comme indiqué dans la documentation. Le représentant Xerox lors

d'interventions sur l'équipement doit respecter les consignes de sécurité locales con-

cernant les faisceaux laser. Ne pas placer d'objet réfléchissant dans la zone du ROS

quand il est ouvert. Ne pas regarder dans la zone du ROS lorsque la machine est sous

tension et que le laser est en fonctionnement.

repare

Xerox Corporation

Global Knowledge & Language Services

800 Phillips Road Bldg. 845-17S

Webster, New York 14580-9791

USA

right protection claimed includes all forms and matters of copyrightable

material and information now allowed by statutory or judicial law or hereinaf-

ter granted, including without limitation, material generated from the soft-

ware programs that are displayed on the screen such as styles, templates,

icons, screen displays, looks, etc.

***XEROX DocuLock Protect Until Forever***

XEROX®, The Document Company®, the stylized X and the identifying

product names and numbers herein are trademarks of XEROX CORPORA-

TION. Other company trademarks are also acknowledged.

NOTICE

While every care has been taken in the preparation of this manual, no liabil-

ity will be accepted by Xerox Corporation arising out of any inaccuracies or

omissions. NOTICE

ll service documentation is supplied to Xerox external customers for infor-

mational purposes only. Xerox service documentation is intended for use by

certified product trained service personnel only. Xerox does not warrant or

represent that such documentation is complete, nor does Xerox represent

or warrant that it will notify or provide to such customer any future changes

to this documentation. Customer performed service of equipment, or mod-

ules, components or parts of such equipment may affect the warranty

offered by Xerox with respect to such equipment. You should consult the

applicable warranty for its terms regarding customer or third party provided

service. If the customer services such equipment, modules, components or

parts thereof, the customer releases Xerox from any and all liability for the

customer actions, and the customer agrees to indemnify, defend and hold

Xerox harmless from any third party claims which arise directly or indirectly

from such service.

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Introduction

Initial issue

Introduction

About this Manual ........................................................................................................... iii

Organization....................................................................................................................iii

How to Use this Documentation...................................................................................... iii

Symbology and Nomenclature........................................................................................ iii

Translated Warnings....................................................................................................... vii

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Introduction

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DC 3535/2240/1632

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Initial issue

About this Manual

This Service Manual is part of the multinational documentation system for DocuColor 3535/

2240/1632 copier/printers. The Service Documentation is used in order to diagnose machine

malfunctions, adjust components and has information which is used to maintain the product in

superior operating condition. It is the controlling publication for a service call. Information on its

use is found in the Introduction of the Service Documentation.

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

Service Manual Revision

The Service Manual will be updated as the machine changes or as problem areas are identi-

fied.

Organization

This Service Manual is divided into seven sections. The titles of the sections and a description

of the information contained in each section are contained in the following paragraphs:

Section 1: Service Call Procedures

This section contains procedures that determine what actions are to be taken during a service

call on the machine and in what sequence they are to be completed. This is the entry level for

all service calls.

Section 2: Status Indicator RAPs

This section contains the diagnostic aids for troubleshooting the Fault Code and non-Fault

Code related faults (with the exception of image quality problems).

Section 3: Image Quality

This section contains the diagnostic aids for troubleshooting any image quality problems, as

well as image quality specifications and image defect samples.

Section 4: Repairs/Adjustments

This section contains all the Adjustments and Repair procedures.

Repairs

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

special conditions:

When there is a personnel or machine safety issue.

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

Parts List.

When there is a cleaning or a lubricating activity associated with the procedure.

When the part requires an adjustment after replacement.

When a special tool is required for removal or replacement.

Use the repair procedures for the correct order of removal and replacement, for warnings, cau-

tions, and notes.

Adjustments

Adjustments include procedures for adjusting the parts that must be within specification for the

correct operation of the system.

Use the adjustment procedures for the correct sequence of operation for specifications, warn-

ings, cautions and notes.

Section 5: Parts Lists

This section contains the Copier/Printer Parts List.

Section 6: General Procedures/Information

This section contains General Procedures, Diagnostic Programs, and Copier/Printer Informa-

tion.

Section 7: Wiring Data

This section contains drawings, lists of plug/jack locations, and diagrams of the power distribu-

tion wire networks in the machine. Individual wire networks are shown in the Circuit Diagrams

contained in Section 2. This section also contains the Block Schematic Diagrams.

Section 9: Installation

This section contains installation information for various machine components.

How to Use this Documentation

The Service Call Procedures in Section 1 describe the sequence of activities used during the

service call. The call must be entered using these procedures.

Use of the Circuit Diagrams

Circuit Diagrams (CDs) are included in Sections 2 (Status Indicator RAPs) and 3 (Image Qual-

ity RAPs) of the Service Manual. All wirenets, with the exception of power distribution wirenets,

are shown on the CDs. Power distribution wirenets are shown in Section 7 (Wiring Data) of the

Service Manual. The power distribution wirenets on the CDs will end at the terminal board for

the power being distributed. Find the wirenet for that power and locate the terminal board on

the wirenet. Use the wirenet to troubleshoot any power distribution wiring not shown on the

CD.

Use of the Block Schematic Diagrams

Block Schematic Diagrams (BSDs) are included in Section 7 (Wiring Data) of the Service Man-

ual. The BSDs show the functional relationship of the electrical circuitry to any mechanical, or

non-mechanical, inputs or outputs throughout the machine. Inputs and outputs such as motor

drive, mechanical linkages, operator actions, and air flow are shown. The BSDs will provide an

overall view of how the entire subsystem works.

It should be noted that the BSDs no longer contain an Input Power Block referring to Chain 1. It

will be necessary to refer to the Wirenets in order to trace a wire back to its source.

Symbology and Nomenclature

The following reference symbols are used throughout the documentation.

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Introduction

Warnings, Cautions, and Notes

Warnings, Cautions, and Notes will be found throughout the Service Documentation. The

words WARNING or CAUTION may be listed on an illustration when the specific component

associated with the potential hazard is pointed out; however, the message of the WARNING or

CAUTION is always located in the text. Their definitions are as follows:

WARNING

A Warning is used whenever an operating or maintenance procedure, a practice, condi-

tion, or statement, if not strictly observed, could result in personal injury.

CAUTION

A Caution is used whenever an operating or maintenance procedure, a practice, condition, or

statement, if not strictly observed, could result in damage to the equipment.

NOTE: A Note is used whenever it is necessary to highlight an operating or maintenance pro-

cedure, practice, condition, or statement.

Machine Safety Icons

The following safety icons are displayed on the machine:

WARNING

This machine contains an invisible laser. There is no visual indication that the laser

beam is present. During servicing, the machine is a Class 3B product because of the

invisible laser. the laser beam could cause eye damage if looked at directly. Service pro-

cedures must be followed exactly as written without change. The service representative

must observe the established local laser safety precautions when servicing the

machine. Do not place tools with a reflective surface in the area of the ROS opening. Do

not look in the area of the ROS window if the power is On and the laser is energized.

The following symbol and statement appear on a label in the machine. The symbol by

itself, or the symbol and the statement may also appear in the service documentation

and in the training program. When this symbol appears, the service representative is

warned that conditions exist that could result in exposure to the laser beam.

WARNING

Do not try to bypass any laser interlocks for any reason. Permanent eye damage could

result if the laser is accidentally directed into your eye.

Figure 1 Laser Hazard Symbol

Laser Hazard Statement

DANGER INVISIBLE LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO

BEAM.

CAUTION

The use of controls or adjustments other than those specified in the Laser Safety Training Pro-

gram may result in an exposure to dangerous laser radiation.

For additional information, review the Laser Safety Training program.

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

Figure 2 Customer Access Label

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

avoid touching the hot surfaces.

Figure 3 Heated Surface Label

Danger label indicates where electrical currents exist when the machine is closed and operat-

ing. Use caution when reaching in the machine.

Figure 4 Shock Hazard Label

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

Figure 5 ESD warning Label

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Initial issue

Electrostatic Discharge (ESD) Field Service Kit

The purpose of the ESD Protection Program is to preserve the inherent reliability and quality of

electronic components that are handled by the Field Service Personnel. This program is being

implemented now as a direct result of advances in microcircuitry technology, as well as a new

acknowledgment of the magnitude of the ESD problem in the electronics industry today.

This program will reduce Field Service costs that are charged to PWB failures. Ninety percent

of all PWB failures that are ESD related do not occur immediately. Using the ESD Field Service

Kit will eliminate these delayed failures and intermittent problems caused by ESD. This will

improve product reliability and reduce callbacks.

The ESD Field Service Kit should be used whenever Printed Wiring Boards or ESD sensitive

components are being handled. This includes activities like replacing or reseating of circuit

boards or connectors. The kit should also be used in order to prevent additional damage when

circuit boards are returned for repair.

The instructions for using the ESD Field Service Kit can be found in ESD Field Service Kit

Usage in the General Procedures section of the Service Documentation.

Illustration Symbols

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

Figure 6 Illustration Symbols

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Introduction

Signal Nomenclature

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

Figure 7 Signal Nomenclature

Voltage Measurement and Specifications

Measurements of DC voltage must be made with reference to the specified DC Common,

unless some other point is referenced in a diagnostic procedure. All measurements of AC volt-

age should be made with respect to the adjacent return or ACN wire.

Logic Voltage Levels

Measurements of logic levels must be made with reference to the specified DC Common,

unless some other point is referenced in a diagnostic procedure.

DC Voltage Measurements in RAPs

The RAPs have been designed so that when it is required to use the DMM to measure a DC

voltage, the first test point listed is the location for the red (+) meter lead and the second test

point is the location for the black meter lead. For example, the following statement may be

found in a RAP:

There is +5 VDC from TP7 to TP68.

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

Another example of a statement found in a RAP might be:

There is -15 VDC from TP21 to TP33.

In this example, the red meter lead would be placed on TP21 and the black meter lead would

be placed on TP33.

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

the copier frame.

Table 1 Voltage Measurement and Specifications

VOLTAGE SPECIFICATION

INPUT POWER 220 V 198 VAC TO 242 VAC

INPUT POWER 100 V 90 VAC TO 135 VAC

INPUT POWER 120 V 90 VAC TO 135 VAC

+5 VDC +4.75 VDC TO +5.25 VDC

+24 VDC +23.37 VDC TO +27.06 VDC

Table 2 Logic Levels

VOLTAGE H/L SPECIFICATIONS

+5 VDC H= +3.00 TO +5.25 VDC

L= 0.0 TO 0.8 VDC

+24 VDC H= +23.37 TO +27.06 VDC

L= 0.0 TO 0.8 VDC

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Translated Warnings

02/03

viii DC 3535/2240/1632

Initial issue

Introduction

Symbology and Nomenclature WARNING

A Warning is used whenever an operating or maintenance procedure, a practice, condi-

tion, or statement, if not strictly observed, could result in personal injury.

DANGER: Une note DANGER est utilisée à chaque fois qu'une procédure de mainte-

nance ou qu'une manipulation présente un risque de blessure si elle n'a pas été stricte-

ment observée. WARNING