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C35 Tech Info Manual PDF
C35 Tech Info Manual PDF
C35 Tech Info Manual PDF
TECH-INFO. MANUAL
Supplemental Technical Information for:
(CopyCentre) C35, C45, C55,
(WorkCentre) M35, M45, M55, Pro35, Pro45, Pro55
(DocumentCentre) DC535, DC545, DC555
* 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.
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INDEX
Section A Introduction
p.A-4 to A-5
p.A-5 to A-6
p.A-7
p.A-8
p.A-9
p.A-10
p.A-11 to A-12
p.A-13
p.C-9
p.C-10 to C-13
p.C-13 to C-14
p.C-15
p.C-16
p.C-17 to C-18
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p.D-3
p.D-4
p.D-5
p.D-6
p.D-7
p.D-8
p.D-9
p.D-10
p.D-11
p.D-12
p.D-12 to D-13
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p.F-1 to F-8
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
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
(Section A Introduction) p.A-4
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engine. Just goes to show that you cant 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, youll 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.
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are willing to take 100% responsibility for your actions, do not use
the information in this book.
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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 youre 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)
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
(Section A Introduction) p.A-7
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03-300 / 306 /
370 / 461 / 805 /
870
03-310 / 317
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03-374
03-395 / 396 /
852 / 853
03-397
03-401 / 403
03-412
03-417
03-419
03-423 / 424 /
433 / 434 / 821 /
822 / 831 / 832
03-480
03-700 / 780 /
785 / 790
03-770
03-777
Chain 05
05-xxx Codes
* 05-300
05-305
05-310
05-330
05-331
05-335
05-340
05-345 / 346
05-350 / 352
Chain 06
06-xxx Codes
06-020
* 06-340 / 350
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* 09-370
* 09-375
09-380
09-390
09-399
Chain 10
10-xxx Codes
10-101 / 102 /
103
10-107 / 108 /
109 / 110
10-120/121 /126
10-315 / 320 /
321 / 323 / 340 /
350 / 360 / 380
10-322 / 324 /
325 / 330 / 370
10-399
Chain 11
11-xxx
11-005 / 006 /
310 / 311
11-007 / 008 /
312 / 313/ 319
11-024 / 025
11-030 / 334 /
335 / 336 /
11-043 / 350
11-050 / 360
11-053 / 370
11-100
11-110
11-130 / 132
11-140 / 142
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20-xxx Codes
20-302 / 303
20-305
20-320 / 322
20-323 / 324
20-327
20-331 / 339 /
341
20-332 / 340
20-342
20-701
22-xxx Codes
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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 well get you the
information and well 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 youll 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 isnt there, youll 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 doors hinge pin and latch. Check P/J56 (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).
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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, youll 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, youll see all 3 connectors near
the rear of the underside of the Laser Module. Itd 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 doesnt see it or if
the problem is intermittent, youll 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. Youll 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.
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DIAGNOSTICS:
Entering Diagnostic Mode:
To get into Diagnostics; from the powered on state youll hold down
the # button while then pressing the Access button Youll be asked for a
password which youll 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 youre in, the Main Menu
will show up:
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, youll then be touching Copier Routines
followed by the dC Routine number / description (i.e. 131 NVM Read / Write).
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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.
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Description
Power Save Enable (0 to disable)
Printer Language
Edit E-mail From (for editing the From field in
outgoing emails) DC535/545/555 only- 1 enables
Enable job delete (set to 1 to allow customer to
delete jobs)
Edit From Guest (set to 1 to enable editing of e-mail
from guest on DC535/545/555 only)
Foreign Interface Enable (set to 1 when installing an
external device such as a card counter or coin-op)
Market region 0 = US, 1 = XCL (Canada), 2 = FX (Fuji
Default
1
0
0
1
1
0
0
03-004
03-006
03-008
03-010
Code
03-011
1
WCP35=48
WCP45=49
WCP55=50
WC35=51
WC45=52
WC55=53
ST535=33
ST545=35
ST555=37
DC535=32
DC545=34
DC555=36
4391
Default
1
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03-012
03-013
03-014
05-001
05-002
06-001
06-003
07-001
08-xxx
Codes
08-001
45
Auto select
1
0
0
3721
5000
67
with faster speeds will undoubtedly have new values for this
memory setting. **Requires Password: 2845490**
09-001
09-002
09-003
Code
09-004
800
430
Default
501
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09-005
09-006
09-007
09-008
09-009
09-010
09-011
09-012
09-013
09-014
09-015
09-016
09-017
09-018
09-019
09-020
09-021
09-069
09-090
09-096
09-097
09-098
09-101
09-110
09-111
09-112
09-115
09-120
09-121
09-123
Code
09-267
501
501
350
350
350
350
350
350
4200
4200
130
160
199
145
165
199
350
800
100
1188
50
0
0
350(k)
25(k)
0
Default
0
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09-268
09-269
09-271
09-273
09-274
09-275
09-276
09-278
09-279
10-028
10-029
10-030
10-063
12-001
Code
12-002
0
30
0
185
0
1
0
177 or
188
172 or
183
135
0
65
Default
2500
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(milliseconds)
Finisher cycle out time (in seconds)
30
Duplexing Auto. Document Handler (DADH)
2376
Continual Velocity Transport (CVT) Center
Registration (pixels)
14-002
Duplexing Auto. Document Handler (DADH) Lead
70
Edge Registration (in scan lines)
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 Feeders Constant Velocity
4988
Transport (CVT) Position (0.1mm Increments)
14-013
Scanner to Document Size Detection Position
700
(0.1mm increments)
14-014
Scanner Lead Edge start (active hotline) in 0.1
350
mm increments **
14-027
Scanner Magnification Adjustment - Adjusts platen
100
scan speed (lead to trail edge to help you
compensate for magnification errors)
15-007
CVT (Constant Velocity Transport) Document
0
Transport roll scanning image gain adjustment
17-001
Disk present or not present (1 = enabled, 0 =
0
disabled)
19-001
Megs of installed Memory (Read Only)
16
20-xxx
Fax related memory settings Too many to list
Codes
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
Read
Fax Not Present 1= Extended Fax Present)
Only
28-002
Embedded Fax Presence (0=No Fax Present, 1=Fax
Read
Present, 2=Fax install in progress)
Only
28-003
Fax modem version (0 = No Fax, 1 = Embedded
Read
Fax, 2 = Server Fax)
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.
12-050
14-001
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One nice thing is that if you dont 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 Components
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 youve
selected. Heres a sample Component Control Screen:
Touch a control code to highlight it and then touch Start to start that
components test. If its 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 codes description (it will say on or off).
Below is a listing of many of the useful codes available to you weve
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 youll find the Output Component Codes list (codes
for motors, lamps, clutches, solenoids, etc.)
Description
Front Door Interlock Switch
Left Door Interlock Switch
DADH Closed Switch (Duplexing
Automatic Document Handler)
DADH Cover Interlock
DADH Document Present Sensor
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05-315
05-320
05-325
05-330
05-335
05-340
05-345
05-350
06-320
06-340
07-301
07-302
07-303
07-304
07-311
07-312
07-313
07-314
07-315
07-321
07-322
07-323
07-324
07-325
07-331
07-332
07-333
07-334
07-335
07-341
High = Document
Present
High = Document
Present
millimeters
High = Document
Present
High = Document
Present
High = Document
Present
High = Document
Present
High = Document
Present
High = ready
Run the ROS motor
(06-020) at the same
time to test sensor.
High = ready
Run the ROS motor
(06-020) to test the
sensor.
High = home
High = home
High = home
High = home
High = switch made
High = switch made
High = switch made
High = switch made
High = switch made
High = switch made
High = switch made
High = switch made
High = switch made
High = switch made
High = out of paper
High = out of paper
High = out of paper
High = out of paper
High = Paper Present
High = >25% paper
stack
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07-342
07-350
07-383
07-384
08-100
10-100
10-120
10-300
10-310
10-315
11-xxx
Codes
08-101
08-102
08-103
08-104
08-150
08-160
09-310
09-350
09-360
09-365
09-370
09-375
09-380
12-300
12-301
14-100
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14-310
14-315
14-320
High / Low
High / Low
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, well 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.
08-045
08-050
Description
Main Motor
DADH Feed Solenoid
DADH Feed Motor
DADH Feed Roll Clutch
DADH CVT (constant velocity transport)
motor
DADH Duplex Solenoid
ROS (Raster Output Scanner / Laser Unit)
ROS (Raster Output Scanner / Laser Unit)
at Standby Speed
Tray 3 elevator motor Up (Warning: Only
energize with Tray OUT)
Tray 4 (HCF) elevator motor Up
(Warning: Only energize with Tray
OUT)
Tray 1 Feed Motor (Warning: Only
energize with Tray OUT)
Tray 2 Feed Motor (Warning: Only
energize with Tray OUT)
Tray 1 & Tray 2 Vertical Transport Motor
Tray 3 Feed Motor (Warning: Only
energize with Tray OUT)
Tray 4 Feed Motor (Warning: Only
energize with Tray OUT)
Tray 3 & Tray 4 Transport Motor
Bypass Feed Solenoid
08-060
08-062
08-070
05-050
06-020
06-025
07-030
07-040
08-010
08-020
08-025
08-030
08-040
On / off
On / off
On / off
On / off
On / off
On / off
Default = not
engaged in standby
On / off
On / off
Default = not
engaged in standby
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09-010
09-022
09-030
10-050
10-065
11-xxx
12-005
14-005
20-xxx
09-035
09-040
09-045
09-060
09-061
09-062
09-063
09-064
09-065
09-066
10-010
10-030
10-035
10-040
10-045
On / off
On / off
On / off
On / off
On / off
On / off
High = fault
On / off
On / off
On / off
On / off
On / off
On / off
On / off
On / off
On / off
On / off
Default is off (sends
sheet to the inverter)
Default is nip open
or solenoid off.
On / off
Drives the tray
between the two offset positions.
On / off
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p.D-1
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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.
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).
(Section D - Part Replacement Procedures)
p.D-2
Service-Excellence
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
youll 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.
p.D-3
Service-Excellence
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.
p.D-4
Service-Excellence
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.
p.D-5
Service-Excellence
spares the entire Feed Assembly and does not spare the Tray 1 & 2
Feed Heads individually.
p.D-6
Service-Excellence
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.
Service-Excellence
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
Photo 8 ROS (Laser Unit)
rear end of the ROS (it
Screw and Serial # Label
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).
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.
(Section D - Part Replacement Procedures)
p.D-8
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p.D-9
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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
Photo 10 Releasing the Transports
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 itll slide out
the front to you. When you are
reinstalling it make sure that the
rail of the Duplex Transport is
Photo 11 Duplex
properly positioned on the metal
Transport (Correct
rail in the machine (see Photo 11)
positioning of rail)
(Section D - Part Replacement Procedures)
p.D-10
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p.D-11
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(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 machines 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.
Youll 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
(Section D - Part Replacement Procedures)
p.D-12
Service-Excellence
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 youre 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 machines
frame.
The Inverter is a relatively complex unit. Inside youll 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)
p.D-13
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p.E-2
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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 youll need to release molex pins from the
fusers Electrical Connector. Itll 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
youve 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
Front Fuser Lamp
want to get hung up on one
Holder Bracket
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
Releasing the tension on
them. Mark how each is
the Pressure Roller.
positioned before you start so
that you can later return them to
(Section E Module Rebuilding / Repairs)
p.E-3
Service-Excellence
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 cant walk off the ends of the roller.
7.) Once youve 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
Fuser Connector
reconnect the Exit Switchs connector
(CRUM)
before you install the top cover (while it is
still accessible).
8.) If you wish to reset the
Fusers 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)
Fuser Electrical Connector
(Pinout)
p.E-4
Service-Excellence
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 /
113R610s drum will
undoubtedly be capable of running a second cycle. Youll 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 wont 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.
(Section E Module Rebuilding / Repairs)
p.E-5
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comes clear of the rear frame and remove the Finger Bracket and
its spring. You will want to take care not to scratch the drums
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.) Heres the tricky
part the Drum Hubs.
Well start with the
Rear Hub. Get a pair
of pliers and get a firm
grip on the rear hub
and rotate the hub
about
counterclockwise it
will resist and then
suddenly pop into a
Drum Hub
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 cartridges 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
(Section E Module Rebuilding / Repairs)
p.E-7
Service-Excellence
works much the same way (except that you rotate the hub
clockwise). When you remove the second hub, make sure the
drum doesnt 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.
Cleaning Blade and Recovery Blade
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 cartridges
frame to release the Corona
Assembly.
Corona Removal
7.) Clean everything up
Release
the metal clip.
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.
p.E-8
Service-Excellence
p.F-1
Service-Excellence
Part Name
604K18591
160K97152
960K11571
160K96540
960K1 3691
101K56940
123K07092
p.F-2
Service-Excellence
007K13495
127K42780
127K42800
127K42870
Laser Modules
604K18500
604K12990
Feed Components
160K92822
050K54361
050K54181
050K54191
604K31370
059K30542
059K30552
059K30381
050K54933
498K06280
059K30390*
059K39200*
059K33951
059K33981
112K00701
6041K 3620
NSX
604K13411
604K18510
008R12896
802E45131
p.F-3
Service-Excellence
Xerographic Components
See p.A-12
Xerographic Modules (Drum Ctgs.) (many versions
+ alternative depending on exact model)
For Drum Cartridge Parts, refer to the alternative list to follow.
list to follow
003K17600
Xerographic Module Latch Kit
122K02300
504K11510
Erase Lamp
Transfer/Detack Corotron (note: one included with each new
Fuser Module)
Fuser Modules
See p.A-11
Fuser Modules (many versions depending on exact model)
+ alternative
For Fuser Parts, refer to the alternative list to follow.
list to follow
Fuser Latch Kit (*Note that there is an aftermarket
604K17672* 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
050K55021
050K54132
110K13980
I20K02590
003K18510
160K92710
105K26331
062K13802
062K21931
062K21941
090K02381
090K02451
122K02290
127K42750
960K20412
160K92770
Scanner Driver PWB (W/O TAG 048, TAG 049, TAG 050)
NSX
130K67500
p.F-4
Service-Excellence
036K01326
036K01336
160K65887
084K08896
084K17497
022 K69682
See p.A-12
960K13691
498K01982
498K04600
498K02030
498K04250
498K02060
498K04270
498K02080
498K04300
498K02170
498K04260
498K02710
498K04290
p.F-5
Service-Excellence
p.F-6
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Description
C35FEIK
604K22070 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
C35XMG
C35DB
113R608
113R610
NSX
C35CN
NSX
C35CNB
NSX
p.F-7
Service-Excellence
C35XLK
C35TLK
C35TCL
C35IJCL
PAPER FEED PARTS:
C35BFRK
059K30381
059K30390 /
059K39200
059K30552
NSX
C35CCDR
604K31360
I20K02590
NSX
for 35ppm Scanners. See p.B-13 for troubleshooting info also read critical information about
how to properly handle the CCD / Lens Assembly.
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).
C35SHS
130K67500
DOCUMENT FEEDER PARTS:
113R497 /
Document Feed Repair Kit (1 Feed Tire, 1
C35DFRK
113R686
Nudger Tire & 1 Retard Roll)
C35DER
Document Exit Roll (or Takeaway Roll)
p.F-8