Xerox 3050 User manual

XEROX
Xerox 3050 (50160 Hz) Copier
Service Manual
Revisions 700P86582,700P86583,700P86584,700P86585,700P86586, and 700P86587 have
been merged intothis document. Changes bring this document to the
12/97 level.
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700P86580
December 1997
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NOTICE
While every care has been taken in the
preparation of this mantlal, no liability will be
accepted by Xerox Engineering Systems
arising out of any inaccuraciesor omissions.
Prepared by:
MultinationalCustomerand Service Education
Developmentand Manufacturing
Xerox Corporation, Rochester, NewYork
14644
"1992, 1993,
1 994, 1996, and 1997 by Xerox Corporation.
All rights resewed.
XEROX" and allXerox productnames mentionedinthis
publicationare trademarksof the XEROX CORPORATION.
XEROX, and
3050 are trademarksused by Xerox Canada
Ltd. as
a registereduser.
Printedin
USA
MOLEX" isa registeredtrademarkof the Molex
Corporation.

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Table of Contents
Title Page
Introduction ........................ vii
AboutThis Manual .................. vii
Organization ....................... vii
HowtoUse This Manual ............ viii
.... RepairAnalysis Procedures(RAPS) viii
Repair1AdjustmentProcedures
...... viii
ReferenceSymbology
............... ix
DC VoltageSpecifications ............. x
1. ServiceCallProcedures .......... 1 - 1
SectionContents ............... 1 - 1
Thissectioncontainsthefollowing
information:
a Call Flow Diagram
0 InitialAction
StatusCode EntryChart
a MaintenanceActivitiesChecklist
2. StatusIndicatorRAPS ........... 2-1
SectionContents ............... 2- 1
This section contains a listing of
the status codes and the Repair
Analysis Procedures, (RAPS).
.............
3. ImageQuality RAPS 3-1
...............
SectionContents 3-1
This sectioncontainsimagequality
defectsamplesandthe RepairAnalysis
Procedurefor correctingtheproblem.
Title
Page
4. RepairlAdjustmentProcedures . . 4-1
................
SectionContents 4-1
This sectioncontainsallRepairl
RemovalandAdjustment
procedures, ElectrostaticSeries.
.......................
5. .PartsLlst 5-1
...............
SectionContents 5-1
This sectioncontainsthepartnumbers
forallreplaceablecomponents.
6. GeneralProceduresllnformatlon . 6-1
............... SectionContents 6-1
This sectioncontains information
aboutdiagnosticprocedures,
DrumMaintenanceprocedures,
toolsandsupplies, installation
procedures,copier specifications,
andtheChangeTag1
MOD Index.
.................... 7. Wiring Data 7-1
............... SectionContents 7- 1
This sectioncontainsthelistof
connectorsandtheconnector
locationdrawingsand
informationaboutsome
componentwiring.
8. AccessorieslOpt~ons ............ 8- 1
This sectionnotused atthistime.
10192
3050
v Table of Contents

Introduction
About This Manual
This manual is part of a documentation
systemthatincludesproducttraining.
This manual contains Service Call
Procedures, Diagnostic Procedures, Status
lndicator Repair Analysis Procedures, Repair
and Adjustment Procedures, Parts Lists and
GeneralProceduresor Information.
This information will help
a Service
Representative repair and maintain this
copier.
Organization
Thismanual is dlvidedintoeightsections:
Section 1. ServiceCall Procedures
This section contains the following
information:
0 Call FlowDiagram
The Call Flow Diagram
is a map of the
procedurestofollow oneachservice call.
InitialAction
The Initial Actions identify how to collect
the information necessary and how to
verify, classify and proceed with the
servicecall.
0 MaintenanceActivities
The MaintenanceActivities
lists the items
thathavetobe serviced based onthetype
ofcalltobe performed, either NormalCall
or CallBack.
Section 2. Status lndicator Repair
Analysis Procedures
This section contains the Repair Analysis
Procedures (RAPS) that are necessary to
repair the faults other than image quality
defects. When usinga RAP, stop the repairs
when the fault
is fixed. Do notperformthe
remainingsteps.
Section 3. Ima e Quality Repair
Analysis Proce
3 ures
This section contains a listing of image
quality defects and samples to assist in
classifyingthe defects. When the defect has
been classified, a checklist
is then used to
repairthe cause of the defect. The checklists
are arranged in the sequence of most
probable to least probable cause with the
corresponding corrective action for each
cause.
Section 4. Repair/Adjustment
Procedures
This section contains the repairs and
adjustmentsforthecopier.
Section 5. PartsList
This section contains the detailed Parts Lists
forthecopier.
Section 6. GeneralProcedures1
Information
This sectioncontainsthe Diagnostic
Procedures, ProductSpecifications,
SupplementalToolsandSupplies, Generic
RAPS,Installationand Removal procedures,
andother information..
Section 7. Wiring Data
This section contains thePlugNack Locational
Drawings, Electrical Component Wiring
Connections Drawings, and a set of
ComponentDrawings.
Section 8. AccessorieslOptions
Thissection is notused atthistime.
10192
3050 ~ii Introduction

HowToUseThis Manual
Always beginwiththe Service Call Procedures,
Section
1. Perform Initial Actions to identify
andclassifytheproblem.
Then proceed to one of the following sections
ofthemanualtocorrecttheproblem.
Section
2 contains the Status Indicator RAPS.
Use these RAPs ifthecopier
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 imagequality defectthat
is occurring,
use the contents page InSection
3 to find a
defect that best represents the type of defect
that
is onthecopy.
When usingSection
2 or Section 3, you may be
directed to Section
4 to perform repair or
adjustment procedures, or to Section
5, Parts
list.
Next, performtheNormalCallprocedures.
After performing Normal Call or Call Back,
performFinalActionstoensure thatthecopier
meetsthecopyspecifications.
MultinationalConfiguration
Differences
This manual contains informationthat applies
to
US0 (USA), RX (Rank Xerox and Xerox
Engineering Systems Europe),
XCL (Canada),
and
XlA (Latin America). US0 references
usually apply to
XCL and XLA. If a USO, RX,
XCL or XLA copier configuration is different,
the specific USO,
XCL, RX or XLA information
will beshownbyitself.
"Dry Ink" means the same as "Toner" and
"Tag" meansthesame as "Mod".
RepairAnalysisProcedures(RAPs)
A RAP Is a series of steps designed tolead you
to the cause of a problem. Ineach step, you
will perform an action or observe an
occurrence. At each step,
a statement is made
thathasaYes
(Y) or No (N) answer.
If the answer
is NO, perform the action
following the NO. If the answer
is YES,
proceedtothe nextstep.
Whenseveral itemsare listed, performthem in
theorderlisted.
Proceed through the steps only until the
problem
is solved. There is no need to
continue with the
RAP after the problem is
corrected.
Repair / Adjustment Procedures
The repair procedures provide detailed steps
on how to remove and replace components.
The adjustment procedures provide detailed
steps on howtocheck and adjust components.
Some copiers have -beenmodified by various
design changes. Each change or modification
is labeled with a TaglMOD (modification)
number. The TaglMOD numbersare identified
in the Change TagIMOD Index inSection
6 of
thisServiceManual.
When a modificationaffects how
a particular
procedure
is performed, the procedure or
steps are identifiedwith either a
W1 TaglMOD
or a WIO TaglMOD statement. Each
procedure or step that
is affected by a
modification
is identifiedwith the statement,
Wl TaglMOD followed by the modification
number. The WI in the statement indicates
that this step must
be performed on copiers
that are assembled
y& that specific
modification.
When the procedureor steps are not affected
by a particular modification, they are
identifiedwith the statement,
WIO TaglMOD
followed by the modification number. The
WIO inthe statement indicates that this step
must be performed on copiers that are
assembledwithoutthatspecific modification.
(continued)
lo/%?
Introduction viii 3050

Refer to the Change TaglMOD Index
for information on how to determine
whetherornotacopierhasaparticular
TaglMOD number.
FOR EXAMPLE:
THERMISTOR (RTI) REPAIR PROCEDURE
WARNING
1. Switch off the copier and disconnect
thepowercord.
WI TaglMOD 5: Removethe
XerographicModule.
In the step
1, the WI TagIMOD 5 statement
refers to the modification number
5. If the
copier that
is being serviced does have
TaglMOD
5, performthis step.
If the copier does not have TaglMOD number
5, ignorethe WI TaglMOD 5 instruction. Inthis
situation, do not remove the xerographic
module.
2. Lowerthetransport latchingcover.
3. Lowerthe front cover.
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
nothaveTaglMOD
5.
lot92
3050 ix Introduction

ReferenceSymbology
The following symbols are
document:
Flags
Indicates that the part has an
used in this This symbol
is used on the circuit
d diagrams and is pointing to a
adjustmentprocedureand a repair
procedure listed in the Repair/
wirenet that has to be examined Adjustmentsectionofthis manual.
for a short circuit to frame or an
opencircuit.
NOTE
This symbol is used to refer to
notes, usuallyonthesame page.
Switches and RelayContacts
ComponentControl
- Safety interlock switch that is
(om31 The ;ode (04031 is the output -&./*open:
Adjustment
diagnostic test for the copier
10.1
This symbol is usedtoshow that an drumldeveloperandfuser motors.
adjustment
is required on the
indicated component and there
is
also a referenceto the location of
parts ~i~t
Safetyinterlockswitchthat is
theadjustment procedure. PL 1.1 This is the reference to the parts list closed.
exploded drawing where the spared
component
is found.
Voltage Source
/.L
This is an indication of the source Indicatesthatthe part has arepair Switch1relaycontactswith
+svoc voltage that is used for operation procedure listed in the Repair/ /&momentary contactsshown
of a component. This voltage
is Adjustment sectionofthismanual. normallyopen.
distributed inthe
PWB and comes
fromtheLVPS.
Indicates that the part has an Switch1relaycontactswith
adjustment procedure listedinthe -momentary contactsshown
[cl.ol , Statuscode
RepairIAdjustment section of this normallyclosed.
The statuscode
is represented by a manual.
box inthe control logic section of
the circuit diagram.
This example
is the code for the Roll 1 position
sensor.
lo/%?
Introduction x 3050

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 TagfMOD
number.
This symbol identifies an entire
circuit diagram that
has been
changed
by this Tag1 MOD
number.
TaglMOD lnformation
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
changed
by thisTagIMODnumber.
+ + The Signal Flow
This symbol is used on circuit
diagrams to indicate an
interrupted signal
in the
horizontaldirection.
This symbol is used on circuit
+ ;;:9;;ingt;gn;diCate a
This symbol is used on circuit
<< diagrams to indicate a
feedback signal.
SignalName
The signal line
is givena name that indicates
the conditionof thesignal whenthe signal
is
present.
Signal name
Voltage levelwhenthe
signal
Is present. The
stateof thesignal.
Sourcevoltage.
I
DC VoltageSpecifications
10 VFWA
+ 15VDC
+ 26 VDC
DC
COM
2.5 TO 14 VDC
+ 14.25 TO .+ 15.75
VDC
+ 24.7 TO + 27.3
VDC
0.0 TO + 0.8 VDC
10192
3050 XI Introduction

Notes:

1 . Service Call Procedures
SectionContents
.....................
Introduction 1-2
................
I
...........
Call Flow Diagram 1-3
StatusCode EntryChart
1-4
MessageDisplay EntryChart ...... 1-14
MaintenanceProcedures .......... 1-15
...........
DocumentHandler 1-15
..........
I Xerographic Module 1-16
............. .
MediaTransport 1 18
..................
Media Feed 1 . 19
............
DeveloperModule 1-20
......................
Covers 1-21
.......................
Cutter 1-21
..............
MediaDrawers 1-21
........................
I Call Back 1-22
.....................
FinalAction 1-22
31 93
3050 1-1 Section Contents

Introduction
The Service Call Procedures are designed to
assist the Service Representative to identify
copier faults, perform the necessary corrective
action and perform the correct Maintenance
Procedures. The Service Call Procedures are
designed to be used with the
3050 Service
Manual and
is the entry level for all service
calls.
Call Flow Diagram - This diagram outlines
the major activities that are performed
when a service call
is made. The Initial
Actions assist the Service Representative
through the custornar interface and help
toidentifytheproblem.
The diagram also
directs the Representative to verify,
classify, repair the problem and perform
thecorrect MaintenanceProcedure.
Status Code Entry Chart - The chart
containsa
list ofStatusCodes, theirCause,
the corresponding Clearance Procedure
and the Go to RAPS (Repair Analysis
Procedures). The chart
is designed to
direct the Representative to the
appropriate Clearance Procedure. If the
Proceduredoes not clear the Status Code,
the Representativereferstothe Go toRAP
in Section 2 column. This columncontains
the name of the RAP that must be
followed,
in order to repair the problem.
When the Status Code problem has been
repaired, refer to the Call Flow Diagram
andcontinuetheServiceCall.
NOTE: The Status Code Entry Chart includes
statuscodesthatmaybegenerated
by anyone
of several different firmware revisions. The
totalnumber
of statuscodeshasbeenreduced
in later versions of firmware. The chart has
beendesigned as a
cross reference for aN the
firmwarerevisions.
Service Call Procedures
Consequently, the chart contains status codes
listed
in the Status Code column that may be
different thanthe statuscodeslistedintheGo
To RAP
In Section 2 column. For example,
status code
C2.51 is listed in the Status Code
column and
C2.01 is listed in the
correspondingGo To RAP InSection
2 column.
The
C2.01 RAP contains the information
required to isolate and repair the problem
thatcreatedthe
C2.51 statuscode.
a Call Back - After correcting the problem
that resulted
in the call back, go to the
Final Action and perform the activities
indicated.
a Maintenance Procedure - This procedure
containsthetasks thatare performedafter
themaincause for theservicecall hasbeen
corrected. The tasks identified in the
procedure are performed at the Interval
indicated. The Interval may be after
a
specific number of feet, for example 10K.
The lnterval may also be specified as. a
NormalCall(NC).
Normal Call activities are designed
to be
performed onall service calls. The specific
interval and Normal Call activities include
cleaning and replacing parts that require
more frequent service and inspections.
The Maintenance Procedure activities are
designed to restore the copier to an
initiallycleanandfunctional condition.
Final Action - The purpose of this
procedure
is to record the media feet,
countandtomakea record
in themachine
logbook oftheservice activities that were
performed. Final Action
is designed to
stresstest theimagequality and repair any
image quality problems. A copy of test
pattern
82E5980 is made and compared
with the image copy quality specifications
locatedinSection
3 ofthemanual.

InitialAction
Phone AttheAccount
Callthecustomer Checkthatthespace meetstherequirements.
UsetheCCA(Cust0mer CallAssistance). Ask thecustomertooperate machineand
GivetheEstimatedTimeofArrival. duplicatetheproblem(s). Ask about additional
problems.
Ask thecustomertosavesome problem copies. Makearecordofthecopy meterandthestatus
code. Check theservice
log andthe tag matrix
Inspectthesamplecopiesandcredit theaccount
GoToSection 1
StatusCodeEntry
Chart
Call Flow Diagram
MessageDisplay is Go toSection 2
Illuminated 1.1 AC Power
forthecopies .. I
I
I
StatusCode Message is
+ CopyQuality
Displayed Displayed Defect
- -
YES NO YES NO YES NO
-
-
-
I I I
GoTo Section 1
MessageDisplay
EntryChart
Go To Section 3
TableofContents
.I Other Faultlndkators I
ElectricalFaults
DrivesFault
DocumentHandlerFaults
MediaFeedFaults
MediaTransportation Faults
OtherFaults
YES NO
>
I
I
I
I
GoTo Section 2
TableofContents
I
I
I
I
L.llllll
I
v
I I
It hasbeenlessthan 5 Working
Daysorlessthan
500 ft (1 50
metres) sincelastServiceCall
1Olll.r) 71 MaintenanceProcedure
31 93
3050 1-3 CallFlow Diagram

CAUSE
I
CLEARANCEPROCEDURE GO TO RAP IN
I
A1.O1
InsertDocumentSensorwas actuatedat Refertothedisplayonthecontrolpaneland A1
.O1 DocumentHandler
PowerOn. followtheclearanceprocedure. RAP
A1.02
FrontDocumentSensorwas actuatedat Refer tothedisplayonthecontrolpaneland A1.02 DocumentHandler
PowerOn. followtheclearanceprocedure. RAP
A1.03 Rear DocumentSensor was actuatedat Refertothedisplayonthecontrolpaneland A1.03 DocumentHandler
PowerOn. followtheclearance procedure.
RAP
A1.25
DocumentdidnotreachtheRear Document Refertothedisplayonthecontrolpaneland A1.25 DocumentHandler
sensor. followtheclearanceprocedure. RAP
I
DocumentreachedtheRear Document
I
Refer tothedisplay onthecontrolpaneland Document Handler
sensor tooearly. followtheclearanceprocedure.
I
- -
-- - pp pp - -
A1.33 FrontDocumentSensor didnotactuate Refertothedisplay onthecontrolpaneland A1.43 DocumentHandler
duringrescanofthedocument. Document followtheclearance procedure.
RAP
was removedaftercopy scan, butbefore
rescan.
A1.36 Rear DocumentSensor didnotdeactuate Refer tothedisplayonthecontrolpaneland A1.46 DocumentHandler
whenthedocumentwas
in thescan or followtheclearanceprocedure. RAP
rescanmode.
A1.38
Operatordidnotpressthe Partial Copy
Refertothedisplayonthecontrolpaneland Instructthe operator howto
buttonasecondtimeinordertostartor stop followtheclearanceprocedure. use the
Partial Copy feature.
thecopyingof
a partialcopy.
A1.43 FrontDocumentSensor didnotactuate Refertothedisplayonthecontrolpaneland A1.43 DocumentHandler
whenthedocumentexitedoutthefrontof followtheclearanceprocedure. RAP
thecopier.
A1.46
Rear DocumentSensor didnotdeactuate Refertothedisplayonthecontrolpaneland
A1 .46 DocumentHandler
whenthedocument exitedthefrontor rear followtheclearanceprocedure. RAP
ofthecopier.
Note: Fordocumentscanproblemsthatarenotindicated by astatuscodeproceedto OF2 DocumentDoesNotScan RAP
Status Code Entry Chart

STATUS
CODE
GO TO RAP IN
SECTION 2
CAUSE CLEARANCE
Thetimeintervalwas toolongbetweenthe
deactuationof the InsertSensor andthe
deactuationoftheFrontDocumentSensor.
Refertothedisplayonthecontrolpanel
andfollowtheclearanceprocedure. A1.63 Document
HandlerRAP
The FrontDocumentSensordeactuated
beforethe insertdocumentsensor. Refertothedisplayonthecontrolpanel
andfollow theclearanceprocedure. Al.64 Document
HandlerRAP
InsertDocumentsensor deactuatedtoo
early. Documentwas tooshort.
Cutter could not return to the home
position, or did not move off the home
position.
Refertothedisplay onthecontrolpanel
andfollowtheclearanceprocedure.
Refer to the display on the control panel
andfollow theclearance procedure.
Al.65 Document
HandlerRAP
LL.30 Cutter Fault
RAP
The Roll
X PositionSensor didnot actuateor
deactuate. Refer to the display on the control panel and followtheclearanceprocedure. C1.O1 and C1.05 MediaFeedRAP
C2.01 and C2.05
MediaFeed RAP
C3.01 and C3.05
MediaFeed RAP
RefertoNote
1
Media Registration Sensor did not actuate
ordeactuate. Refer to the display on the control panel and followtheclearanceprocedure. C1.O4 MediaFeed
RAP
C2.04 MediaFeed
RAP
C3.04 MediaFeed
RAP
Motion was not detected or the media
stopped moving before
it was scheduled to
stop. Possibly caused by an out of Media
condition.
-
Refer to the display on the control panel
andfollow theclearanceprocedure. C1.05 Media Feed RAP
C2.05 Media Feed
RAP
C3.05 Media Feed
RAP
Roll
3 media is not detected at the Roll 2
PositionSensor. C3.06 Media Feed
RAP
Refer to the display on the control panel
and followtheclearanceprocedure.
NOTE
1: Substituteeither 1,2, or 3 forXdependingonwhichStatusCode isdisplayed.
NOTE 2: Forrollfeedproblemsthatarenotindicatedbyastatuscodeandthemessagedisplayreads, RefeedRolll,%or 3,
proceedtothe RAP thatmatchesthemessagedisplay.
NOTE 3: Formediafeedproblemsthatarenotindicatedbyastatuscodeandthemessagedisplayreads, PleaseOpenThe Cut
SheetFeed-InShelf, proceedtothe
OF3 MediaDoesNotFeed RAP
StatusCode EntryChart

STATUS
CODE
C2.07
C3.07
C1.O9
C2.09
C3.09
C1
.I 1
C2.11
C3.11
C1.12
C2.12
C3.12
C1.15
C2.15
C3.15
C3.16
CAUSE CLEARANCE
GO TO RAP IN
SECTION 2
Roll 2 media is not detected at the Roll 1
PositionSensor.
Roll
3 media is not detected at the Roll 1
PositionSensor.
- --
--
This is a Firmwareproblem.
Motionof the Roll
X was not sensed while Roll
X was tryingto feed the media from the park
position to the cut position. Also, the roll did
notcompletelyrewind.
Note
1
Roll X was trying to feed media forward from
the park positiontothe cut position. The Roll
X Positionsensor never actuated. The rollwas
rewoundbeyondthepark position.
Note
1
The media has passed the Roll X Position
Sensor, but stops before reaching the cut
position. Possibly caused by an out of Media
condition.
Note
1
- --
-
Roll 3 media is not detected at the roll 2
Position Sensor, while tryingto feed media to
thecut position.
Refer to the display on the control panel
and follow theclearanceprocedure.
Refer to the display on the control panel
andfollow theclearanceprocedure.
Press power off
(0) then power on (1). Call
HotlineIfproblempersists.
Refer to the display on the control panel
and followtheclearance procedure.
Refer to the display on the control panel
and followtheclearance procedure.
Refer to the display on the control panel
and followtheclearance procedure.
Refer to the display on the control panel
and followtheclearance procedure.
C2.07 MediaFeed
RAP
C3.07 MediaFeed RAP
None
C1 .O5 and Cl .O1 Media Feed
RAP
C2.05 and C2.01 Media Feed
RAP
C3.05 and C2.01 Media Feed
RAP
C1.O1 MediaFeed RAP
C2.01 MediaFeed RAP
C3.01 Media
Feed RAP
C1 .O5 MediaFeed RAP
C2.05 MediaFeedRAP
C3.05Media Feed RAP
C3.06 MediaFeed RAP
NOTE 1: Substituteeither 1,2, or 3 for X dependingonwhichstatuscode is displayed.
NOTE 2: Forrollfeedproblemsthatarenotindkatedby a statuscodeandthemessagedisplayreads, RefeedRoll 1,2,0r 3, proceedto the RAP that
matchesthemessagedisplay.
NOTE 3: Formediafeedproblemsthatare notindicatedbyastatuscodeandthemessagedisplayreads, PleaseOpenThe CutSheetFeed-lnShelf,
proceedtothe OF
3 Media Does NotFeedRap
3193
Status Code EntryChart 1-6 3050