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702Pxxxxx
WorkCentre 5022/5024
Service Training Student Guide
2014 Xerox Corporation. All rights reserved. XEROX and XEROX and Design are trademarks of Xerox Corporation in the
United States and/or other countries.
2. Product Overview
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Machine Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Technology Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Machine Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Machine Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Connectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Customer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Customer Replaceable Unit (CRU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Documentation Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
3. Service Documentation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
4. Power Control
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Main Printed Wiring Board (PWB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Control Panel PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
WorkCentre 5022/5024 i
Student Guide
5. Paper Supply
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Paper Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Paper Tray 1 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Paper Tray 2 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Bypass Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
7. Scanning
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Scanning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Charge Coupled Device (CCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
8. Xerographics
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Module Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Module Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Xerographic Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Xerographic Process Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Photoreceptor Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Charge Corotron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Raster Output Scanner (ROS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
WorkCentre 5022/5024 ii
Student Guide
Introduction 1
Introduction
Module Overview
Welcome to the Service Training Program.
In this module you will see how to use the materials and resources you need to complete this
course.
Module Objective
When you have completed this module, you will be able to use this Student Guide and Service
Manual to complete the course.
Target Audience
The course is written for Service Providers who have xerographic, copier and printer servicing
skills.
The target audience should be trained on digital products and laser safety. This audience must
be able to use Xerox service documentation, fault analysis procedures and be able to perform
repairs and adjustments a directed in the service documentation.
There is no specific product prerequisite but the target audience should be familiar with the
theory of Xerography.
The course contains all the technical information you will need. The course does not contain the
generic technical information that you may need for Xerographics and laser safety.
Course Objectives
At the completion of the course you should be able to:
Answer questions related to the operation of the machine.
Perform the removal and replacement of major components.
Perform the most critical and frequent adjustments.
Use the service documentation to diagnose and repair electrical and mechanical faults that
could occur in the machine.
Module Structure
The course is structured into eight (8) modules:
1. Introduction
2. Product Overview
3. Service Documentation
4. Power and Control
5. Paper Supply
6. Paper Fed and Registration
7. Scanning
8. Xerographics
Ensure you have the appropriate resources before starting the course.
Course Guidelines
To complete the course as quickly and effectively as possible, please follow these guidelines:
Complete and understand the material in each module as it is presented.
Be sure you understand the material before moving on to the next module.
Refer to the machine throughout the course to confirm the material presented.
Product Certification
This product uses a laser beam to expose the photoreceptor. It is important that all safety
precautions be followed during service procedures.
This product is certified to comply with Laser Product Performance Standards as a Class I
product.
A Class I Product has a laser that does not emit dangerous laser radiation during any mode of
customer operation.
The service representative must observe the established local laser safety precautions while
servicing the product.
Do not place tools on a reflective service in the area of the ROS window.
WARNING: Permanent eye damage can result if the laser is accidentally directed into your
eye. Do not try to bypass laser interlocks for any reason.
WARNING: The use of adjustments or controls other than those specified in the Laser
Safety Training Program may result in an exposure to dangerous laser radiation.
Cautions
CAUTION: All Electro Static Discharge (ESD) precautions must be following when servicing
this product. Failure to do so could result in damage to the equipment.
The electronics in Xerox product have advanced and become very sophisticated to meet the
needs of customers. These advances have increased performance and reduced costs by
allowing more electronic circuits to be contained in smaller areas.
The sophisticated electronics in this product require the use of all standard ESD procedures to
ensure customer satisfaction and reduce service costs.
If you are not trained on ESD or do not have an ESD kit, tell your Training Administrator now.
Module Objectives
At the completion of the module you will be able to:
Know the major features and options of machine.
Explain the physical and functional differences between the machine configurations.
Know which components can be replaced by the customer.
Technical Overview
Technical aspects of the machine include:
Machine Configurations and Options
User Interface (UI)
Paper Feed Path and Capacity
Machine Features
Machine Operations
Scanning
Document Printing
Document Copying
Connectivity
Customer Maintenance
Customer Replaceable Units
Documentation Supplied
Machine Configurations
There a two (2) basic machine configurations:
WorkCentre 5022 which can produce 22 prints per minute.
WorkCentre 5024 which can produce 24 prints per minute.
Both the WorkCentre 5022 and the WorkCentre 5024 come with the following features as the
standard configuration:
a platen scanner/copier
a document feeder
(1) Paper Tray in a Desk Top Model (which holds 250 sheets)
Both the WorkCentre 5022 and the WorkCentre 5024 can be upgraded with the following options:
a second tray for the desk top model (which holds 500 sheets)
a rolling storage stand for the 2 Tray Model
Paper Trays 3 and 4 for the 2 Tray Model in a rolling stand (which holds 500 sheets each)
Figure 2-1. WorkCentre 5022 (Standard Configuration and the 2 Tray Desk Top Models)
Figure 2-2. WorkCentre 5024 with Tray 3 and 4 and the Storage Stand Configurations
Some buttons are not available on some models. If you add certain options, you will be able to
use them. For more information, contact the Customer Support Center.
2. ID Card Copy button 11. Selection Arrows 20. Clear All button
6. Lighten / Darker button 15. Address Book button 24. Clear entry button
7. Original Type button 16. Keypad buttons 25. Data Indicator light
8. 2-Sided button 17. Dial Pause button 26. Error Indicator light
9. Collated/Resolution button 18. Machine Status button 27. Jam Clearance areas
1. Copy button
2. ID Card Copy Press this button to use the ID Card Copy feature. While the ID Card Copy
button feature is selected, the button is lit.
3. Scan button
4. Fax button
5. LCD Display
6. Lighten/Darken Press this button to select a copy density level or toner saver mode. The
button selection moves to the right on the machine status diagram every time the
button is pressed.
When the button is pressed while the right-most icon (toner saver mode) is
lit, the selection moves back to the left-most icon.
7. Original Type Press this button to select a document type of the document.
button The selection moves to the right every time the button is pressed.
9. Collated button Press this button to set collate when copying multiple copies.
The selection switches between sorting and stacking every time the button
is pressed.
When documents are set in the document feeder, this feature is
automatically enabled.
10. Job Status Use to check the progress of active jobs and detailed information about
completed jobs or pending jobs. This area also allows you to delete a job
(cancel printing) and pause jobs.
11. Selection Arrows
12. Log In / Out Press this button to enter or exit System Administration mode. The Log
button In/Out button is lit in System Administration mode.
14. OK button
16. Numeric keypad Press these numeric buttons to enter numbers, such as the total number of
copies.
18. Machine Status Displays error locations, machine status, and other settings.
19. Energy Saver Press this button to enter an energy saver mode when the machine is not in
button use. The button lights up.
Press the Energy Saver button to exit an energy saver mode.
20. Clear All button Press this button to reset the displayed settings of each feature to default
values or to clear the numbers entered. The settings return to the same
condition as when the machine is powered on.
21. Stop button Press this button to cancel a current job or errant job.
22. Start button Press this button to start scanning documents or to confirm the value of
each setting.
24. C (Clear) button Press this button to delete one numeric value that you have entered.
25. Data indicator Blinks while the machine is sending or receiving data.
light
26. Error indicator Blinks when a system error occurs. Lights when an error other than a
light system error (such as paper jam or out of paper) occurs in the machine.
27. Jam Clearance This is a graphic on the control panel to indicate the areas of jam clearance
Areas based on the fault code that is displayed.
Reduce / Enlarge Auto, 50%, 70%, 81%, 94%, 122%, 127%, 141%, 200%, Preset 400%,
100%
Technology Overview
Now that we have seen the basic configuration it is time for a quick overview of the subsystems
that make up the machine.
Both trays can hold papers sizes from A5 (5.5 X 8.5 inches) up to A3 (11 X 17) SEF. The base of
each tray has a motor that raises the tray to the feed position.
The paper feed head contains sets of feed, takeaway and retard rolls.
Note that all paper trays with the exception of the Bypass Tray has an Auto-detect feature.
Bypass Tray
The bypass tray can hold up to 50 sheets from A5 (5.5 X 8.5 inches) up to A3 (11 X 17).
The bypass tray is suitable for heavier paper, envelops, transparencies and labels.
Machine Features
The WorkCentre 5022/5024 is copier, scanner and printer with the following operational features:
Monochrome copying, scanning and printing.
Scanning and printing via a USB port connection to a laptop computer or PC or Network
Scan with the optional Network Kit.
Copy and print percentage reduction or enlargement processed electronically to achieve the
correct percentage size.
Duplex copying, scanning and printing.
Machine Operations
This machine performs three (3) basic tasks:
Document Scanning
Document Printing
Document Copying
Document Scanning
Images can be scanned to a computer through a scanning driver called a TWAIN DRIVER or via
the Network with the Optional Network Kit.
Documents to a maximum size of A3 (11 X 17 inches) can be scanned for copy by placing them
on the document glass or DADF.
The maximum scanning resolution is 600 X 600 dots per inch (dpi).
The scanner contains a single Scan Carriage that houses all the optical components including
the CCD.
Scanning Process
1. Place the document on the document glass or the DADF.
2. Press the scan button on the UI Control Panel.
3. The scanner moves under the document to scan it.
Carriage
Assembly
Document
Glass
Document Printing
The imaging components are contained in four (4) major subassemblies:
Drum Module
Dual Beam ROS - writes the image onto the photoreceptors
Transfer Cortron - transfers the image onto paper
Fuser Module - fixes the toner to the copy paper surface using heat and pressure rollers
Document Copying
The WorkCentre 5022 / 5024 is also equipped with a Document Feeder. Multi-page documents
can be placed in the feeder.
When the Copy button is pushed the Scan Carriage Assembly moves under the platen glass
and scans the image as document pages are feed into the machine.
Connectivity
The USB Port provides laptop or PC connectivity and is used for upgrading firmware and local
printing.
There is an Optional Network Kit which enables scan and print via the network. A Fax Option with
a Keypad Kit will also be available.
Network
Port
USB Port
Customer Maintenance
The user is instructed in the Maintaining the Product Cleaning section of the User Guide to
perform various cleaning activities.
CVT and
Document
Covers
Document
Glass
Constant
Velocity
Glass
Dirt, dust and ink can contaminate these surfaces and will produce image quality defects such as
streaks and spots.
Clean these surfaces using lens and mirror cleaner identified in Section 6, General Procedures
and Information, of the Service Documentation.
Toner
Cartridge
Drum
Documentation Supplied
The customer is supplied with a User Guide and an Installation Guide
User Guide
This guide contains instructions to the customer on printing, scanning and maintenance.
Installation Guide
This guide contains information about how to connect the machine and enable all
connected features.
Module Overview
This module overview of the various sections of the service manual and the information each
section contains will familiarize you with how to use the service documentation to perform your
job.
Objectives
At the completion of the module you will be able to:
Understand the structure and content of the Service Manual.
Introduction
The Introduction consists of these sections:
Getting to Know this Service Manual
Discusses how the content is organized.
How to use the Service Manual
Describes standard procedures for servicing the machine.
Description of Terminology and Symbols
Explains the terms and symbols used throughout this service manual including safety
Danger Warning and Caution.
It is recommended that you print a copy of the Configuration Report at the end of each service
call.
Store the printed report with the machine Service Log book.
Section 2 - Troubleshooting
This section describes the troubleshooting procedures for the WorkCentre 5022/5024, other than
image quality troubleshooting which is covered in Section 3.
This section detail the actions required to remove and replace component in the machine, as well
as any Warnings and Cautions that pertain.
The Adjustment subsection includes mechanical adjustments that may be required to restore
proper operation.
The Adjustment subsection includes mechanical adjustments that may be required to restore
proper operation.
Section 6 - General
This section includes various General Procedures (GP) and service information necessary to
support the WorkCentre 5022/5024. It contains these five (5) subsections:
Specifications
Tools/Service Consumables/Consumables
Service Data
Service Mode
KO PROGRAM# LIST
The location and pin assignments for all Printed Wiring Board (PWB) connectors are shown.
This will cover the location and purpose of the PWBs, the low and high voltage power generation
and distribution components and mechanical drives.
Module Objectives
At the completion of this module you will be able to:
Identify the major electrical components of the machine.
Describe the mechanical drive system for the major components.
Technical Overview
Cover Removal
Most power components are mounted on a panel inside the Rear Cover of the machine.
Access to these components require the removal of the Rear Cover, which is held on by five (5)
screws.
Main Motor
Paper
Feed
Clutches
The Source Power Input Socket and Power ON/OFF Switch are located on the right side of the
machine.
The Power Input Socket accepts 110 or 220 VAC at 50 or 60 Hz.
The Power ON/OFF Switch isolates the machine from the main source power supply.
Power
ON/OFF
Switch
Input
Power
WARNING: AC power is still applied to the input side of the Main Power Switch even when
the switch is turned off.
The high voltage components are described in the Xerographics Module of this course.
The Main PWB memory is used for system data such as configuration data and NVM settings.
The Main PWB is unique due to software upgrades.
The Main PWB monitors the fuser temperature via a thermostat that contacts the heat roll and
sends control signal to the LVPS to regulate power supply to the fuser.
The Main PWB uses 3.3 VDC, 5 VDC and 24 VDC supplied by the LVPS.
There is an Optional Network Kit which enables scan and print via the network. A Fax Option with
a Keypad Kit will also be available.
Network
Port
USB Port
Control
Panel
The Control Panel PWB controls the UI and communicates user input to the Main PWB.
When the left side cover is opened the UI will display a statement Close Cover A.
Electrical
Interlock
When the front cover is opened the UI will display a statement Close Front Door.
Front
Cover
Interlock
Main Motor
Drive Assembly
The Drive Assembly houses the Main Drive Motor and a number of other drive components:
The gear train located on the inside of the Drive Assembly transmits drive to various
components in the machine.
A Toner Dispense Motor mounted on the rear panel is actuated when required to rotate the
shaft in the Toner Cartridge to dispense toner into the developer housing.
Module Objectives
At the completion of this module you will be able to:
Identify the various paper supply areas of the machine.
Technical Overview
Paper Supply
Paper can be supplied from any paper tray or bypass feeder.
The route taken by the paper, after entering the machine, is common to both areas.
Paper Specifications
Both trays can accommodate paper sizes B5 LEF, B5 SEF, A4 LEF, A4 SEF, 8.5 X11 LEF, 8.5 x
11 SEF, 8.5 X 13 SEF, 8.5 X 13.4 SEF, 8.5 X 14 SEF, B4, A3 SEF AND 11 X 17 SEF.
Paper Trays 1 and 2 have different capacities of 70 gsm (20 lb.) paper:
Tray 1 holds up to 250 sheets
Tray 2 holds up to 500 sheets.
Bypass Tray
Suitable paper weight range is 60 to 216 gsm (16 to 80 lb.).
The Bypass Tray is also suitable for heavier paper, envelopes and transparencies.
The Bypass Tray can accommodate paper sizes B5 LEF, B5 SEF, A4 LEF, A4 SEF, 8.5 X11 LEF,
8.5 x 11 SEF, 8.5 X 13 SEF, 8.5 X 13.4 SEF, 8.5 X 14 SEF, B4 SEF, A3 SEF AND 11 X 17 SEF.
Both trays can accommodate paper sizes B5 LEF, B5 SEF, A4 LEF, A4 SEF, 8.5 X11 LEF, 8.5 x
11 SEF, 8.5 X 13 SEF, 8.5 X 13.4 SEF, 8.5 X 14 SEF, B4, A3 SEF AND 11 X 17 SEF.
Tray 3
Tray 4
Operation
1. The paper is stacked on the Bottom Plate of the paper tray.
2. The Bottom Plate is pivoted on one end of the paper stack and raised into the feed position
on the other end.
Tray
Bottom
Plate
Bottom
Plate
Pivots
Paper Stack
The paper stack is raised up by springs as it is used.
Paper
Pad
No Paper
Empty Sensor
No Paper
Empty Sensor
Actuator
When the last sheet of paper leaves the tray, the Tray Empty Sensor Actuator drops into a cutout
in the paper tray Bottom plate, de-actuating the sensor.
A message is sent to the UI informing the user that the paper tray is empty.
Registration
Front to rear registration of the paper is fixed by the position of the Front and Rear Paper Guides.
Adjustment
The Paper Length Guide is adjusted to the length of the paper in the tray.
The Paper Tray 2 Module is optional except that configurations using the stand option must also
have a Paper Tray 2 Module.
Bypass Tray
Description
The Bypass Tray is installed on the left side of the machine.
Paper is fed into the paper path just above the main paper tray feed position.
Components include a Bypass Paper Present Sensor and a Bypass Feed Roller.
Operation
With the Bypass Tray the user aligns the tray front and rear paper guides to match the paper
size.
Front and
Rear Guides
When paper is loaded into the Bypass Tray the paper stack actuates a Bypass Paper Present
Sensor indicating that the paper is in the tray.
The paper tray feeders in the machine and the paper tray modules use the same feed principle
and are almost identical.
Module Objectives
At the completion of this module you will be able to:
Identify paper feed components.
Be aware of the most common repair procedures for the Paper Feed and Registration
subsystem.
Technical Overview
Loading the Paper
Refer to the User Guide for instructions on how to load the paper.
Tray 1
Bottom
Plate
The Tray 1 Bottom Plate is raised by spring action to the feed position.
Paper
Pad
Feed Roll
Retard Pad
Paper Registration
Paper Registration Sensor actuation causes the Main PWB to start the ROS imaging of the
photoreceptor.
Registration
Sensor
Retard
Roll
Lift Shaft
Bottom Plate
Paper Feed
Motor Roll Drive
Gear
Paper Feed
Drive Gears
Clutch
Clutch
Roll Drive
Gear
Paper Feed
Motor
Paper Feed
Drive Gears
Bypass Tray
The Bypass Tray is installed on the left side of the machine.
Bypass
Tray
Paper is fed into the paper path just above the main paper tray feed position.
The bypass tray has an input sensor which is actuated by paper placed in the tray.
Input
Sensor
Bypass Feed
Roller
The Main PWB energizes the bypass feed clutch, connecting drive to the bypass feed roller
shaft.
Bypass Tray
Drive Train
Exit Roll
Main Motor
Tray 1
Drive Train
Bypass Tray
Feed Roll Tray 2
Drive Train
For Tray 2 paper feed roll drive is provided by a separate and dedicated Feed Motor though
gears and clutches on command from the Main PWB.
Invert Motor
Main Motor
Bypass Tray
Tray 1
Paper Paths
Overview
Paper is transported through the machine from the paper trays and bypass feeder.
Regardless of the paper source once the paper reaches the Registration Sensor, the paper exit
route is the same.
2
12
9 11
6
7
10 5
1. Front Cover Switch 5. Tray 2 Paper Size Sensor 6. Tray 1 No Paper Sensor
The collated or non-collated option can be selected from the Control Panel
T/A
Roll
Exit Roll
Registration
Out Roll
Roll
If a document jams in the document feeder, and the machine stops, Open Document Feeder
and remove paper appears on the Control Panel Display.
If a sheet of paper jams somewhere in the paper path one of two faults will be displayed on the
Control Panel Display:
Paper Jam left cover/Tray 2 (open Cover A and remove the paper)
Paper Jam left cover/Bypass (open Cover A and remove the paper)
For complete details on paper jams and clearing paper jams refer to the User Manual.
10 3
7 2
1
9 4, 5, 6
8
1. DADF Document Set SNR 5. DADF Tray Set Guide SNR 2 9. DADF Invert SNR
3. Document Tray Size SNR 2 7. DADF Pre-reg SNR 10. DADF Document Set SNR
Output Tray
Copies and prints are sent to the output area beneath the scanner.
Output
Tray
The most frequent service activities include cleaning and replacing are Feed Rolls, Nudger Rolls,
Retard Rolls, Retard Pads and Bypass Feed Tray Components (In the bypass tray the feed roll
and retard pad may need cleaning or replacing).
Note
The Feed Roll is more easily accessed when the Bypass Assembly is removed from the
machine.
The module describes how documents are fed through the document feeder and scanned.
Module Objectives
At the completion of this module you will be able to:
Identify the scanner components.
Describe the sequence of operation of the scanner.
Understand the most frequently performed maintenance procedures.
Technical Overview
General Description
The machine scans the document once to memory then prints the number of copies or sets
requested.
Process Overview
1. The document is placed on the document glass or in the DADF.
2. The copy button on the Control Panel is pushed.
3. The scan carriage assembly moves under the platen glass to scan the image.
Scan
Carriage
Assembly
Document
Glass
Scanning Overview
Description
The scanner assembly in the machine operates similar to modern scanners that connect to a
personal computer. Light reflected from the document is converted to a digital image by the
Charge Coupled Device (CCD) mounted on the scanner assembly.
Optical Path
The Scan Carriage Assembly houses all the optical components. The document is illuminated by
a Xenon exposure lamp mounted within the Scan Carriage Assembly.
The image is reflected from the document through mirrors focused by the lens and projected onto
the CCD (Charge Coupled Device).
The document width is always scanned at the same size and resolution. Any reduction or
enlargement is processed electronically to achieve the correct percentage size.
The document length (the process direction) is scanned at a speed appropriate to the reduction
or enlargement selected. A fast scan indicates a reduction, a slow scan, a magnification.
Starting Point
Document
Exposure
Lamp
Mirror
Mirror
Scan Carriage
Assembly
Mirror
The scan speed determines the size of the image in the scan direction.
A slow scan speed equals a large image and a fast scan speed a smaller image.
Scan Drive
Motor
The Home Sensor detects when the Scan Carriage is in the home position.
Home Sensor
The document is only scanned once even when multiple copies are required.
Description
The CCD in this machine prints only in monochrome.
Scanned
graphics
and text
Analog Data Digital Data
EIUDFSOIUYKJ
Scanned Analog to
Document CCD Digital
Converter
Each light sensitive device in each array produces one picture element (pixel) of information.
Each pixel represents one spot corresponding to the image on the document.
The analog voltage signals are converted to a digital signal on the CCD PWB before being sent
to the Main PWB for image processing.
Image Processing
The digital image is sent to the Main PWB for processing.
Various image corrections factors are applied to the image to give, for example, sharper outlines.
Digital Data
Infra-red Laser
Data
ROS
Main PWB
The image is also modified according to user selections such as image type, reduction, etc.
Initialization
The CCD must be optimized before scanning starts.
Note: This sets the output of the CCD when no light is present, which is the equivalent of a black
image.
CVT and
Document
Covers
Document
Glass
Constant
Velocity Glass
The underside of the document glass is only accessible after dismantling numerous parts of the
machine.
Only materials listed in the service procedures should be used to clean components.
Refer to Chapter 1, Service Call Procedures, in the Service Manual.
Module Objectives
At the completion of this module you will be able to:
Identify the location and purpose of the components of the Xerographic process.
Be aware of the most common repair procedures in the Xerographic subsystem.
Technical Overview
Xerographic Path
This machine uses conventional Xerographic processes, with some innovative adaptations.
DADF
Exposure Lamp
IIT
CCD
IOT
Duplex
Fuser
Finger
Cleaning Blade USB 2.0
Auger
Magnet
Network
MSI (Option)
STM
Electrical and mechanical power, high voltage and the Main Drive Motor are also required.
Drum Module
Overview
The Toner Cartridge contains enough toner for approximately 9000 prints/copies of 5% area
coverage.
The Toner Empty Sensor monitors the toner level and warns the user when enough toner
remains for approximately 100 prints.
Toner
Cartridge
Components
The Drum Module contains these components:
Charge Device
Photoreceptor Drum
Developer System
Cleaning Components
Drum
Module
Note: the Left Side Cover (A) needs to be open to remove the Drum Module.
The Drum Module no longer has a Crum. After replacement of the module, you will have to
manually enter an NVM value to reset the counter.
Photoreceptor Drum
The photoreceptor consists of an aluminum tube coated with an organic photoconductive layer.
The photoconductive layer retains a static charge in darkness but becomes conductive and loses
its static charge to ground when exposed to light from the laser beam.
The aluminum drum is connected to the machine frame through a contacts at the end of the
Drum Module (CRU).
When the CRU is placed in the machine the contacts connect with a drum contact on the
machine frame.
Contacts
Photoreceptor
Drum
Contacts (2)
Drum Drive
Charge Corotron
Overview
The Charge Corotron, located alongside the Drum Module, charges the surface of the
photoreceptor with high voltage.
The Charge Corotron is an internal Drum Module component and is replaced as part of the Drum
Module.
Charge Corotron
(Internal component)
Operation
The Corotron is connected to the HVPS by contactors on the top of the Drum Module (CRU).
Overview
The ROS is located to the left of the HVPS and under the paper receiving area.
ROS
The HVPS provides power to the ROS on command from the Main PWB.
ROS Components
The ROS contains these components:
Laser Diode
Polygon Mirror
Motor
Mirror to direct the laser beam onto the drum
Glass Window
Note: The laser beam leaves the ROS through a glass window adjacent to the photoreceptor.
Exposure
Exposure is the process of creating a latent image of the document on the drum using a laser
beam from the Raster Output Scanner (ROS).
Polygon Mirror
Motor
Photoreceptor
Laser Diode
SOS Sensor
Note:
Generic ROS Unit The colored laser beams are for illus-
tration purposes only. The machine
only prints in monochrome.
Operation
1. The printer receives a signal to print or copy a document.
2. The Polygon Mirror and Main Motor starts.
3. Paper is fed from the selected paper tray.
4. The beam from the laser diode is reflected from the rotating Polygon Mirror causing the beam
to travel across the surface of the drum.
5. The Start of Scan Sensor (SOS) is triggered as the laser beam starts a new line and triggers
the input of the next line of data to the laser beam. This SOS should not be confused with the
Start of Scan Sensor in the Scanner which monitors the position of the scan carriage.
6. As the drum rolls, the scanner laser beam creates the latent image of the document on the
surface of the drum.
7. The laser beam is switched on and off according to the image data being received from the
Main PWB:
a. When the laser beam is switched on, the charge on the drum will be discharged where
the laser strikes the surface of the drum. This is the image (black printing) area of the
print.
b. When the laser beam is switched off, the charge will remain on the drum. This is the
background (white printing) area of the image.
Development
The latent image is developed by the Magnetic Developer Roller.
Process Overview
the Toner Supply Auger and Developer Mixer Roller rotate in the same direction causing the
toner particles to be agitated.
the agitation creates a negative charge on the tone particles so they are attracted by the
developer. This is called Tribo Electric Charge.
Cleaning
The photoreceptor cleaning function consists of a cleaning blade, an auger and an erase lamp
within the Xerographic CRU.
The final stage of cleaning is the erase lamp which dissipates any remaining charge on the
photoreceptor.
The Erase Lamp is an internal Drum Module component and is replaced as part of the Drum
Module.
Erase Lamp
(Internal component)
Used toner, removed from the photoreceptor, is carried by an auger system back to the waste
container on the CRU.
The Toner is fed from the Toner Cartridge though the Toner Dispense Assembly into a matching
receptacle on the Drum Module.
Drum Module
Toner Receptacle
Figure 8-11.
When the Drum Module is installed into the machine the Toner Cartridge part of the Toner
Dispense Assembly matches up to a Feed Receptacle on the Drum Module.
When the toner has exceeded it useful life the Toner Cartridge (CRU) is replaced.
Fusing
Description
The toner image on the paper is fixed to the surface of the paper by heat and pressure.
The Heat Roll and Pressure Roll are held in constant contact with each other by spring
tension.
The spring tension exerts approximately 4kg of pressure, via the Pressure Roll, onto the
paper that passes between them.
Duplex Clutch
Heat Roller
Pressure Roller
Drum
The Fuser Assembly has a Jam Clearance lever that separates the Fuser rollers when the right
hand cover is opened. This allows paper removal in the event of a paper jam.
Fuser Rollers
Jam Clearance
Lever
Fuser Assembly
LVPS
Control Logic
Control logic is part of the Main PWB.
Main PWB
Data Thermistor
LVPS
Data
Overheat
Thermostat
Fuser Module
Electrical Connection
Operation
the thermistor monitors the temperature of the fuser lamp and sends this information to the
Main PWB.
the Main PWB instructs the LVPS to switch the fuser lamp on or off to maintain the correct
temperature.
if the temperature exceeds the threshold the control logic disconnects the power supply from
the LVPS to the Fuser Lamp and a fuser error is displayed on the Control Panel.
Ventilation
The Fuser and Xerographic components are cooled by the NOHAD Fan located behind the rear
cover of the machine.
NOHAD
Fan