Xerox 3001 User manual

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PartNumber
701 PI 4950
Date
December 1998
Product
3001 EngineeringzCopier (60 Hz/ 50 Hz)
Title
Service Manual
Status
t
INITIAL ISSUE
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XEROX
Xerox 3001 Engineering Copier (60150 Hz)
Service ~anual
-
701PI 4950
December 1998
CAUTION
Certain components in the 3001 Copiers
are susceptible to electrostatic discharge.
Observe
all ESD procedures to avoid
damage.

Publishedby:
XeroxCorporation
Multinational CustomerandServiceEducation
780SaltRoad
Webster, NewYork 14580
@ 1998 by Xerox Corporation. All rightsreserved.
XEROX, 3001 aretrademarks
PrintedinU.S.A.
WARNING
This equipment generates, uses, and can radiate radio
frequency energy, and if not installed and used in
accordance with the instruction manual, may cause
interference to radio communications. It has been tested
and found tocomplywiththe limits for aClassA computing
device pursuant tosubpart
J of Part 15 of FCC Rules, which
are designed to provide reasonable protection against such
interference when operated in a commercial environment.
Operationofthis equipment ina residentialarea
is likely to
cause interference inwhichcase the userathisown expense
will berequiredtocorrect theinterference.
NOTICE
All service documentation is supplied toexternal customers
for informational purposes only. Xerox service
documentation
is intended for use by certified, product
trained service personnel only. Xerox does not warrant or
represent that such documentation is complete, nor does
Xerox represent or warrant that
it will notifyor provide to
such customer any future changes to this documentation.
customer performed service of equipment, or modules,
components, or parts of such equipment may affect the
warranty offered by Xerox with respecttosuch 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 partsthereof, the customerreleasesXerox from any and
all liability for the customer actions, and the customer
agreestoindemnify, defendand holdXerox harmlessfrom
any third party claims which arisedirectly or indirectly from
such service.
Every effort has been made to ensure that this manual is
technically accurate and reflects the configuration of the
3001as of December
1998.
NOTICE
This product will produce ozone during normal operation.
The ozone produced is dependent on copy volume and
is
heavier than air. Providing the correct environmental
parameters as specified in Xerox installations procedures
willensurethatconcentration levelsmeetsafelimits.
(US0 only: If additional information concerning ozone
is
needed, request the Xerox publication 600P83222,
"Ozone", bycalling 1-800-828-6571.)
NOTICE
The appliance coupler (power cord)
is the disconnectdevice
for this equipment. Ensure that installation
is near the
outletand
is easilyaccessible.
"Scotch" and "Magic" aretrademarksofthe3M

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- --
Table of Contents
Title Page
Introduction ...................... vii
About This Manual
................ vii
..................... Organization vii
...
HowtoUse This Manual ........... VIII
... RepairAnalysis Procedures(RAPS) viii
Repair/AdjustmentProcedures
..... viii
ReferenceSymbology
............. x
DC VoltageSpecifications .......... xi
.........
1. Service CallProcedures 1 - 1
..............
SectionContents 1-1
This sectioncontainsthe
following information:
Call Flow Diagram
InitialAction
StatusCode EntryChart
MaintenanceActivitiesChecklist
2. Status IndicatorRAPS .......... 2-1
SectionContents .............. 2-1
This section contains a listing of
the status codes and the Repair
Analysis Procedures,(RAPs).
3. ImageQualityRAPs .............. 3-1
SectionContents ................ 3-1
This section contains the Repair
Analysis Procedures for correcting
thecopyquality problems.
Title Page
RepairIAdjustrnentProcedures .
SectionContents ..............
This sectioncontainsall Repair/
Removal andAdjustment
procedures, ElectrostaticSeries.
Parts List
......................
SectionContents ..............
This section contains the part
numbers for all replaceable
components.
GeneralProcedures/lnformation
SectionContents
..............
This section contains information
about diagnostic procedures,
Drum Maintenance procedures,
tools and supplies, installation
procedures, copier specifications,
andtheChangeTag/ MOD Index.
Wiring Data
...................
SectionContents ..............
This sectioncontainsthe list of
connectorsandtheconnector
locationdrawingsand
informationaboutsome
componentwiring.
Title ..................... Page
8. Accessories/Options ........... 8- 1
This section contains information
about the accessories and options
forthe
2520 copiers.
SectionContents
.............. 8-1
8A
Auto Cut .................. 8A-1
8B
Cut Sheet Feeder ........... 8B-1
12/98
3001
v Table of Contents

Notes:

lntroduction
AboutThis Manual
This manual is part of a documentation
systemthat includesproducttraining.
This manual containsServiceCall Procedures,
Diagnostic Procedures, General Procedures
or Information, Status Indicator Repair
Analysis Procedures, Repair and Adjustment
Proceduresand PartsLists.
This information will help a Service
Representative repair and maintain this
copier.
Organization
This manual is divided intoeightsections:
Section 1. Service Call Procedures
This section contains the following
information:
StatusCode EntryChart
The StatusCode EntryChartshows a list of
status codes, causes, clearance procedures
and instructions on where to go if the
problemcontinues.
MaintenanceActivities Checklist
This
is a list of the items that have to be
checked based on the type of call to be
performed.
Section 2. Status lndicator Repair
AnalysisProcedures
This section contains the Repair Analysis
Procedures (RAPS) that are necessary to
repair the faults other than image quality
defects. When using a RAP, stop the repairs
when the fault
is fixed. Do not perform the
remainingsteps.
Section 4. Repair1Adjustment
Procedures
This section contains the repairs and
adjustmentsfor thecopier.
Section 5. PartsList
This section contains the detailed Parts Lists
for thecopier.
Section 6. General Procedures1
Information
This section contains the Diagnostic
Procedures, Copier Installation and Removal
procedures, Copier Specifications,
Supplemental Tools and Supplies and
ChangeTagIMod Index.
0 Call Flow Diagram
Section 7. Wiring Data
The Call Flow Diagram is a map of the
Section 3. Image Quality Repair
This section hasa list oftheconnectorsinthe
procedurestofollowoneachservice call.
AnalysisProcedures copier and shows the location of the
0 InitialActions This section contains a listing of image Connectors and some of the component
The Initial Actions identify how to collect quality defects to assist in classifying the wiring.
the information necessary toproceedwith defects. Whenthedefect has beenclassified,
theservicecalI. a checklist
is then used torepair the cause of
the defect. The checklists are arranged in
*. Options
the sequence of most probable to least This section contains information about the
probablecause or the ease ofthecheck. accessoriesand options for the
2520 copier.
lntroduction

HowTo UseThis Manual
Always begin withthe Service Call Procedures,
Section
1. Perform Initial Actions to identify
andclassifytheproblem.
Then proceedtoone ofthe following sections
ofthemanualtocorrectthe problem.
Section
2 contains the Status Indicator RAPs.
Use these RAPs ifthe copier
is notoperational,
such as when a Status Code is displayed or
there
is an improper indication, or "blank"
display, etc.
Section
3 is used to troubleshoot Image
Quality problems. If you are not sure of the
type of image quality defect that
is occurring,
use the contents page in Section
3 to find a
defect that best represents the type of defect
that
is onthecopy.
When usingSection
2 orSection 3, you may be
directed to Section 4 to perform repair or
adjustment procedures, or to Section
5, Parts
List.
Next, perform the Normal Call procedures.
Now determine if Extended Maintenance has
tobeperformed.
For an Extended Maintenance Call, perform
the Extended Maintenance Procedures in
Section
1.
After performing Normal Call or Extended
Maintenance, perform Final Actions toensure
thatthecopier meetsthecopyspecifications.
Multinational Configuration
Differences Repair
I Adjustment Procedures
This manual contains information that applies
toUS0 (USA), EO (Europe),
XCL (Canada), and
XLA (Latin America). US0 references usually
apply to XCL and XLA. If a USO, EO, XCL or
XLA copier configuration
is different, the
specific USO, XCL,
RX or XLA information will
beshown by itself.
"Dry Ink" means the same as "Toner" and
"Tag" meansthesame as "Mod".
RepairAnalysis Procedures(RAPs)
A RAP is a series ofsteps designedtolead you
tothe cause of a problem. In each step, you
will perform an action or observe an
occurrence. At each step, astatement
is made
thathasaYes (Y)or No(N) answer.
If the answer
is NO, perform the action
following the NO. If the answer
is YES,
proceedtothenextstep.
Whenseveral itemsare listed, performthem in
theorder listed.
Proceed through the steps only until the
problem is solved. There is no need to
continue with the RAP after the problem
is
corrected.
The repair procedures provide detailed steps
on how to remove and replace components.
The adjustment procedures provide detailed
steps onhowtocheck and adjust components.
Some copiers have been modified by various
design changes. Each change or modification
is labeled with a TaglMOD (modification)
number. The TaglMODnumbersare identified
inthe Change TaglMOD Index in Section
6 of
thisService Manual.
When a modification affects how a particular
procedure is performed, the procedure or
steps are identifiedwith either a WITagIMOD
or a WIO TagIMOO statement.
Each
procedure or step that is affected by a
modification is identified with the statement,
WI TaglMOD followed by the modification
number. The W1 in the statement indicates
that this step must be performed on copiers
that are assembled
yitJ that specific
modification.
When the procedure or steps are not affected
by a particular modification, they are
identified with the statement, WIO TagIMOD
followed by the modification number. The
WIO in the statement indicates that this step
must be performed on copiers that are
assembledwithoutthat specific modification.
(continued)
12198
Introduction viii 3001

Refer to the Change TagIMOD Index
Q for information on how to determine
whether ornota copier hasaparticular
TagIMODnumber.
FOR EXAMPLE:
THERMISTOR(RTI
) REPAIRPROCEDURE
WARNING
1. Switch off the copier and disconnect
thepowercord.
W/TagIMOD
5: Removethe
Xerographic Module.
In the step
1, the WI TaglMOD 5 statement
refers to the modification number
5. If the
copier
that is being serviced does have
TagIMOD
5, performthisstep.
If the copier does not have TagIMOD number
5, ignoretheWITaglMOD 5 instruction. Inthis
situation, do not remove the xerographic
module.
2. Lowerthetransport latchingcover.
3. Lowerthefrontcover
In the steps
2 and 3, no reference is made to
either the with or without TagIMOD
5
modification. Therefore, perform the
instructions whether the copier has or does
nothaveTagIMOD 5.
Introduction

Reference Symbology
The following symbols are used in this
document:
Flags
Indicates that the part has an
This symbol
is used on the circuit
d diagrams and is pointing to a adjustmentprocedureand a repair
procedure listed in the Repair1
wirenet that has to be examined Adjustmentsection ofthis manual.
for a short circuit to frame or an
Q
10.1
0
-L
+ 5 VDC
NOTE
This symbol is used to refer to
notes, usuallyonthesame page.
opencircuit.
Switchesand RelayContacts
Adjustment
This symbol is used toshow that an
adjustment
is required on the
indicated component and there
is
also a referencetothe location of
theadjustmentprocedure.
Voltage Source
This is an indication of the source
voltage that
is used for operation
of a component. This voltage
is
distributed in the PWB and comes
fromthe LVPS.
ComponentControl
1
The code [lo] is the test for the
copier maindrivemotor.
PartsList
PL 1.1
This is the referencetothe parts list
exploded drawing where the spared
component is found.
lndicatesthat the part has a repair
procedure listed in the Repairl
Adjustmentsectionofthis manual.
Safety
-d;;Ti- closed
interlock switch
interlockswitchtha
Switchlrelaycontactswith
/&momentary contactsshown
normallyopen.
that
is
tis
Indicates that the part has an Switch1relaycontactswith
adjustment procedurelisted inthe -momentary~contacts shown
StatusCode
RepairlAdjustment section of this normallyclosed.
The status code
is represented by a manual.
box inthe control logic section of
the circuit diagram. This example
is the code for the fuser
undertemperaturesignal.
12/98
Introduction x 3001

WARNING
A warning is used to alert the
personnel to an operating or
maintenance procedure, practice,
or condition that,
if not strictly
observed, could result in injury or
lossof life.
CAUTION
A caution is used to alert the
personnel to an operating or
maintenance procedure, practice,
or condition that,
if not strictly
observed, could result
in damage
to, ordestructionof, equipment.
TagIMOD Information
This symbol identifies the
component or configuration of
components in a circuit diagram
that are part of a change
identified with this TagIMOD
number.
This symbol identifies an entire
circuit diagram that has been
changed by this Tag/ MOD
number.
TagIMOD Information
This symbol identifies the
component or configuration of
components in a circuit diagram
that are not part of a change
identified with this TagIMOD
number.
This symbol identifies an entire
circuit diagram that has not been
changedbythisTag/MODnumber.
The SignalFlow
This symbol is used on circuit
diagrams to indicate an
interrupted signal in the
horizontaldirection.
This symbol
is used on circuit
< diagrams to indicate a
rec~rculatingsignal.
This symbol
is used on circuit
<< jl~~~~a;;sig~aI.indicate a
SignalName
The signal line is given a namethat indicates
the condition ofthesignal whenthe signal is
present.
Signal name
Voltage levelwhenthe
signal
is present. The
stateofthesignal.
Sourcevoltage.
DC Voltage Specifications
4.75 TO 5.25 VDC
24 VDC 19TO 35VDC
12/98
3001 XI Introduction

Notes:

Service Call Procedures
SectionContents
.....................
Introduction 1-2
................
Call Flow Diagram 1-3
...........
StatusCode Entry Chart 1-4
Maintenance Procedures
.......... 1-8
..........
XerographicModule 1-9
MediaTransport
............. 1-11
............
DeveloperModule 1-12
. ......................
Covers 1 13
..................
FinalAction 1-14
12/98
3001 1-1 Section Contents

Introduction
Use the Service Call Procedures as a
maintenance guide when performing the
service on the copier. The Service Call
procedure has been designed to be used with
the
3001 ServiceManual.
Call Flow Diagram - This diagram outlines
the major activities that are performed
when a service call
is made. The diagram
also outlines how the decision
is made as
to whether an Extended Maintenance
activitywillbeperformed.
Initial Actions - This procedure is designed
to guide the Service Representative
through the customer interface. It also
assists the Service Representative in
preparing the copier for an evaluation of
its performance. The Initial Actions
diagram
is designedtoidentify andclassify
the problem and to refer you to the
appropriate RAP in order to repair the
problem. When the problem has been
repaired, refer to the Call Flow Diagram
and continue the Service Call with the
MaintenanceActivities.
Maintenance Activities - This procedure
contains the activities that are followed
afterthe maincause for theservice call has
been corrected. These activities are
referred to as Normal Call and Extended
Maintenance.
Normal Call
- This is theserviceactivitythat
is performed when less than 30K feet (9K
metres) of media has been run since the
last service call. Normal Call activity is
designedtobe performed onall calls. This
activity includes cleaning and replacing
the parts in areas that require more
frequent cleaning and inspection time.
Normal Call activity
is designed to restore
the copier to an initially clean and
functional condition.
Extended Maintenance
- This is the service
activity that
is performed when greater
than
30K feet (9K metres) of media has
been run since the last service call.
Extended Maintenance
is designed to
restore the copy quality to an initial copy
qualitycondition.
Final Action
- The purpose of this
procedure
is to record the media feet
count and make a record of the service
activities that were performed in the
machine log book. Final Action
is
designed to stress test the image quality
and repairany imagequality problems.
1 2/98
Service Call Procedures 1-2 3001

Call Flow Diagram
Section 2
GT+
Repaired
A
InitialAction
Phone At Account
Precallcustomer Check space meetsrequirements
Use CCA (Customer CallAssistance)
r
Havecustomer operate machineandduplicate
Give EstimatedTimeofArrival) problem(s). Ask aboutadditionalproblems.
Havecustomersave problemcopies Recordcopy meter. check service log&tagmatrix
Inspectsample copieslcredits
Verify, Classify, Repairproblem
Go
To Status StatusCode Indicator
Repaired Code Entry
e, YES
1 Chart NO
I
YES NO
I
1
2
Other Faults
lndicator
YES I
,NO
I CopyQuality I
* -
Go To CQ Faults
Section
3
I
I
Repaired I
I
I
Copy Quality
Section
2
GoToCQ Faults I
I Section 3
I I
(LessThan 5 Maintenance
(30000 FT.)
Daysor 500 ft.)
9000 Meters
CALL COMPLETION
I
12/98
3001 1-3
Call Flow Diagram

Status
Code
A1
A3
A4
A5
A6
A7
A8
A9
Cause Clearance Procedure
Whilethefuser waswarming up, a Removethedocumentfrom thecopier.
documentwasinthecopier. Ensurethatthe
document handler
is correctlyseated.
A documentwas expectedatthefront Removethe mediafromthecopier.
original sensor buttheoriginal hadbeen
removed.
A documentwas expected atthe rear Removethe mediafromthecopier.
original sensor buttheoriginal was
removed.
The documentdidnotreachthe rearoriginal Removethedocumentandthemediafromthecopier.
sensor inthecorrect amountoftime.
Whilethefuser waswarming up, a Removethedocumentfrom thecopier
documentwasatthefrontdocumentsensor.
Ensurethatthedocument handler
is
correctlyseated.
A documentwas either lessthan 12 inches Removethedocumentfrom thecopier.
(305mm)or morethan 54 inches(1372mm)
longandthecopier was
in themultiple
copiesmode.
Whilethecopierwas inthe multiplecopies Removetheseconddocumentfromthecopier.
mode,adocument was atthe rearofthe
copier andanotherdocumentwas inserted
intothecopier.
The documentdidnotreachthefront Removethedocumentandthemediafromthecopier.
documentsensor inthecorrect amount of
time.
Go to RAP in Section 2
A1 Document Handler RAP
A3 Document Handler RAP
A4 Document Handler RAP
A5 Document Handler RAP
A6 Document Handler RAP
A7 Document Handler RAP
A9 Document Handler RAP
12/98
StatusCode EntryChart 1-4 3001

Status
Code Cause
C9
The Auditron is notconnected.
C9
The ForeignAccessory is notconnected.
E 1
Ittooktoo longforthecopy mediatoreach
themotionsensor.
E 2
Whilethecopierwas inthemultiplecopies
mode, themedia
is insertedintothecopier
beforethedocument
is inserted.
E 3
The motionsensor stopsturningwhilethe
copy media
is still causingtheactuator to
blockthe prefeedsensor.
Clearance Procedure
Go to RAP in
Section
2
EnsurethattheAutitron isconnected. Enter avalid user C9 Auditron RAP
number.
EnsurethattheForeignAccessory
is connected.
C9 ForeignAccessory
RAP
Removethemediafromthecopier.
El RAP
Removethemediafromthecopier. E2 RAP
Open thetransport latchingcover and removethemedia
fromthecopier.
E3 RAP
12/98
3001 1-5 Status Code EntryChart

Status
Code
E 5
F1
J 1
J 2
LL
U 1
L9 toLO
Constant
L9 or L8
Constant
P
(USO),
(XLA 6OHz)
Constant
L
(EO),
(XLA 50Hz)
Cause
One oftheinterlockswitches is open.
The fuserthermistordoes notsense a
temperaturechangewithin 20 seconds, or
thefuser does not maintainthecorrect
temperature.
The toner concentration
is toolow.
The toner concentration
is toohigh.
There
is afailure onthe ControlPWB.
The copy countmeter
is disconnected.
Copier
is initswarmupcycle.
Copierdoes notwarm up.
Copier
is inthe powersaver mode.
Copier
is inthe lowpower mode.
Clearance Procedure
Ensurethat allofthe interlockswitchesareclosed.
Switchoffthecopier, thenswitchonthecopier.
Donotinstallanewtoner cartridgeifanewonealready has
beeninstalled.
Switchoffthecopier, thenswitchonthecopier. Replacethe
Control PWB (PL
1.4).
Reconnectthecopy countmeter.
Waitfor fuser towarm up. Displayshouldbecounting
down from L9 toLO.
Switchoffthecopier, then switchonthecopier.
Pressthe
Start button.
Pressthe
Start button.
Go to RAP in
Section
2
E5 RAP
F1 RAP
J1 RAP
J2 RAP
U1 RAP
F1 RAP
1 2/98
StatusCode EntryChart 1-6 3001