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Color Laser Printer (50/60 Hz) Service Manual DocuPrint

1. 5 1 GENERAL PROCEDURES INFORMATION Contents 6 1 WIRING DATA Contents 7 1 2 99 DocuPrint C55 C55mp NC60 i TABLE OF CONTENTS INTRODUCTION ABOUT THIS MANUAL This manual is part of a multinational documentation system which includes Training This manual contains information that applies to USCO XE XCL ACO This service manual covers both the C55 and NC60 product families Unique NC60 directions will be given Js For example Press the On Line 0 key The On Line key is unique to the C55 family and the 0 key is unique to the NC60 If the entire procedure is unique to a product family it will be noted at the top of the page and in the footer at the bottom of the page USCO references apply to 115 Volt printers XE references apply to 220 240 Volt printers Dry Ink means the same as Toner and Tag means the same as Mod ORGANIZATION This manual is divided into seven sections organized as follows A Publications comment sheet is provided at the end of this manual INTRODUCTION Section 1 SERVICE CALL PROCEDURES This section contains the following Call Flow Instructions Initial Actions System Checks Every Call Activities Scheduled Maintenance Final Action Call Flow The call flow chart shows you how to conduct the service call I
2. 6 29 MENU C55 C55mp 6 30 MENU MAP NC60 6 31 PCL DEMO C55 C55mp 6 32 FAULT HISTORY 60 6 33 POSTSCRIPT DEMO C55 C55mp 6 34 POSTSCRIPT DEMO NC60 6 35 TIPS amp TRICKS NC60 6 36 DENSITY AND COLOR BALANCE TEST PATTERN s 6 38 BOOT SEQUENCE BOOT SEQUENCE 55 55 6 39 BOOT SEQUENCE NC60 6 40 CRU REMOVAL PROCEDURES GP 1 PRINT DRUM REMOVAL 6 41 2 COLOR DEVELOPER REMOVAL 6 41 GP BLACK DEVELOPER REMOVAL 6 42 GP 4 TONER COLLECTOR REMOVAL 6 43 GP 5 FUSER REMOVAL 6 43 2 99 6 1 6 GENERAL PROCEDURES TITLE PAGE NVM SETUPS GP 3 1 FUSER SPEED C55 C55mp V66 FIRMWARE ONLY 6 44 3 2 CONTROL PATCH MD 6 45 3 3 TRANSPARENCY MODE 6 46 GP 3 4 DRUM CLEANING 6 48 GP 3 5 RESET NC60 6 49 DRUM VOLTAGE CHECKS GP 9 1 CHARGE SCOROTRON CURRENT 6 50 GP 9 2 CHARGE GRID VOLTAGE CHECK 6 51 GP 9 3 TRANSFER VOLTAGE CHECK 6 52 GP 9 4 DEVELOPER BIAS VOLTAGE 6 53 INSTALLATION PROCEDURE GP 15 INSTALL u u uuu 6 55 GENERAL INFORMATION UPDATING PRINTER NIC SOFTWARE C55 C55mp 6 62 UPDATING PRINTER NIC SOFTW
3. 1 1 2 POWER GENERATION SWITCH PL 4 5 LOW VOLTAGE 424 VDC POWER SUPPLY PWB 24VDC FT701 INTERLOCKED PL 3 1 E AC1 PCU 2 PWB 4 2 CN307 1 1 AC POWER ON SURREY 7 23 24 24 VD ETT Ep F701 NOISE 24 RET ST701 15 FILTER F703 26 6 3 EM 1404103 1 45 5 I 5 VDC T 1s 15A 5 0 SUPPLY 1 702 13 s Lol 5 5 15 CB 24 V EVES PWE INTERLOCK 1 3 EXHAUST FAN CONTROL SWITCH PCU PWB PL 4 2 EXHAUST FAN ON T L 24 VDC CN1006 Exhaust 2 Control ESS IF PWB PL3 2 EXHAUST FAN 24 VDC INTERLOCKED Qo INPUT POWER SPECIFICATIONS 115 VAC PRINTERS NOMINAL 120 VAC AT 15A AC1 115 VAC AC2 NEUTRAL 220 VAC PRINTERS NOMINAL 220 240 VAC AT 10 15A PCU PWB AC1 110 VAC CONNECTOR AC2 110 VAG PWB Description 7 9 24 VDC Interlock is open STANDBY POWER CHAIN 1 LEVEL 2 SHEET 1 OF 1 BSDs 2 99 Chain 1 Power Generation 7 2 DocuPrint C55 C55mnINC601 2 1 SELECTION AND INDICATION 2 CONN PWB PL 3 CN103 CN315 104 2144 6 1 po 5 27 4 D2 I 4 5 6 7 CONTROL PANEL PWB CONNECTOR PWB CONTROL PANEL PWB PL 1 1 CN310 401 LED ENABLE DATA 0 DATA 1 SWITCH 1 ENABLE READ WRITE REGISTER SELECT DISPLAY ENABLE DC COM 5
4. 190 Process Voltage Magenta Paper 140 Transfer Bias Yellow xxxxx Paper 1400 Volts Consumables Usage These readings track the prints and OHP 2200 Volts Adjustments images used by the various consumables These readings will be Pa Margin reset to zero when new consumable is installed Cyan 364 Volts Cleaning Cycle Never Magenta 421 Volts TC Patch Control Yes Adjustments These readings are stored in the ESS If the ESS Yellow 974 Volts is replaced these values will need to be re entered The DOCUMENT COMPANY Visit our web site at http xerox networkprinters com products c55 2 99 IMAGE QUALITY SPECIFICATIONS DocuPrint C55 C55mp 3 23 TEST PATTERNS Diagnostic Sheet NC60 This test pattern can be used by the Help Center to determine the status of some of the machine parameters General Information Serial Number Printer Serial Number Software Version Current ESS Software version Engine Software Version current IOT Software version Total Memory Installed Total Ram installed in Printer Max used 128 MB Binary Contone Lossy Counters The NC60 printer uses compression and decompression to save memory However if the job is very complex lossy compression may be used The printer will still try to print the job however data may be lost If this occurs the Lossy Counters will increment Add more memory to fix this problem Humi
5. v 5 3 2 99 PARTS LIST SECTION DocuPrint C55 C55mp NC60 5 15 PL 5 1 PL 6 1 DRIVE COVER ASSEMBLY ITEM Sig 9 D es 9 Egli 9 PARTS LIST SECTION 2 99 PL 6 1 5 16 PART NOT SPARED 32 11510 SPARED SPARED 116 7400 116 7390 P O ITEM 1 116E7380 809E1840 11E7380 DESCRIPTION DRIVE COVER ASSEMBLY DRIVE COVER SCREW SCREW BIAS TERMINAL REP 6 1 CHARGE TERMINAL REP 6 1 SCREW TRANS DRUM TERMINAL REP 6 1 SPRING PHOTORECEPTOR LEVER DocuPrint C55 C55mp NC60 PL 6 2 SLIDE ASSEMBLY INNER DRIVE FRAME DocuPrint C55 C55mp NC60 ITEM o O O 13 14 15 16 17 18 19 809 1 670 29 27460 29 27450 15 59930 SPARED SPARED SPARED 12 8 400 SPARED SPARED 8 5730 6 61600 SPARED 6 61610 SPARED 809 1810 29 27500 SPARED 32 11450 DESCRIPTION SLIDE SPRING PIN LINK STUD LINK PLATE RETAINING RING SCREW SCREW LINK RETAINING RING BEARING SLIDE CAM REP 6 2 UPPER SLIDE SHAFT PIN LOWER SLIDE SHAFT RIGHT SIDE FRAME RETURN SPRING LINK SHAFT RETAINING RING GUIDE PARTS LIST SECTION PL 6 2 PL 6 3 INNER DRIVE FRAME COMPONENTS ITEM PART DESCRIPTION 1 5 12200 DRIVE DOG C M Y 2 28 12160 WASHER 3 809E2030 CAM SPRING 4 28 12170 WASHER
6. READJUST ATURE REPEAT STEP 6 WITH MAGENTA SENSOR TEMPERATURE SENSE SIGNAL AND YELLOW 5 6 7 XEROGRAPHICS CHAIN 9 LEVEL 2 SHEET 9 OF 10 2 99 BSDs DocuPrint C55 C55mp NC60 7 17 Chain 9 Xerographics 9 20 ERASE LAMP CONTROL 1 PCU CONN ERASE LAMP PWB PWB ASSEMBLY PL 4 2 PL 10 4 PL 10 2 ERASE LAMP ON L CN103 CN307 24 VDC INTERLOCKED 2 9 21 WASTE TONER FULL CONTROL DRUM CLEANER WASTE TONER 3 SENSOR PL 8 1 4 TONER SENSOR 5 6 CONNECTOR PCU PWB PWB _ 7 XEROGRAPHICS CHAIN 9 LEVEL 2 SHEET 10 OF 10 BSDs 2 99 Chain 9 Xerographics 7 18 DocuPrint C55 C55mp NC60 10 1 FUSER DRIVE FUSER DRIVE MOTOR PL 91 PCU PWB PL 4 2 CN110 FUSER MOTOR CLOCK A CN1003 FUSER MOTOR CLOCK A 1 2 24 VDC INTERLOCKED 5 FUSER MOTOR CLOCK B FUSER MOTOR CLOCK B 10 2 EXIT SENSING 25 T 8 PAPER PRESENT L 5 VDC CN307 103 I STROBE 2 10 1 10 3 FUSER FAN CONTROL PCU PWB ee mete PL 10 4 FUSER FAN ON CN103 CN307 CN305 1 24 VDC CN1013 6 13 2 TT t Fuser Fan Motor Control THE FUSER DRIVE MOTOR IS ROTATES THREE DIFFERENT SPEEDS 1 SLOW SPEED IS USED WHEN A TRANSPARENCY IS MOVING THROUGH THE FUSER 2 MEDIUM SPEED IS USED TO CAM THE CLEANER UP TO THE TRANSFER DRUM AND THEN ROTATE THE CLEANING BRUSH WHILE THE TRANSFER DRUM 1 BEING 7 CLEANED 3 HIGH SPEED IS USED WHEN THE PRINT
7. 4 41 9 8 TRANSFER DRUM 4 43 9 9 TRANSFER ASSEMBLY TRANSFER CLAMSHELL 4 44 TRANSFER DRUM 2 REP 10 1 BYPASS SWITCH 4 47 REP 10 2 TRANSFER DISCHARGE POWER SUPPLY 4 47 REP 10 3 TRANSPARENCY SENSOR 4 48 REP 10 4 FUSER HARNESS 4 49 ROS REP 12 1 ROS ASSEMBLY 4 50 BLACK TONER MOTOR 13 1 BLACK TONER MOTOR 4 51 TRAY 2 MODULE REP 27 1 TRAY 2 MODULE 4 52 REP 27 2 TRAY 2 FEEDER ASSEMBLY 4 52 27 3 TRAY 2 CASSETTE PWB 4 53 REP 27 4 TRAY 2 TRAY EMPTY SENSOR 4 53 REP 27 5 TRAY 2 FEED SOLENOID AND FEED CLUTCH 4 54 REP 27 6 TRAY 2 FEED ROLLERS 4 54 REP 27 7 TRAY 2 DRIVE ROLLER AND DRIVE CLUTCH Z ss 4 55 REPAIRS ADJUSTMENTS SECTION CONTENTS ADJUSTMENTS ADJ 3 1 1 DENSITY AND COLOR BALANCE C55 C55MP 4 56 ADJ 3 1 2 DENSITY AND COLOR BALANCE NC60 4 58 ADJ 3 2 1 MARGINS SIDE TO SIDE AND TOP TO BOTTOM C55 C55MP 4 60 ADJ 3 2 2 MARGINS SIDE TO SIDE AND TOP TO BOTTOM NC60 4 61 ADJ 3 3 NVM INITIALIZE U2 4 62 ADJ 4 1 MAGNETIC ROLLER CLEANER SOLENOID YY 4 65 ADJ6 1 MAGNETIC ROLLER CLEANER CAMS 4 66 ADJ9 1 EA TONE DOWN
8. 7 4 HVPS PWB Connectors 7 25 Chain 6 BSD Laser Scanning 7 5 LVPS PWB Cassette PWB Connectors 7 26 Chain 7 BSD Paper Feed 7 6 C55 C55mp ESS PWB Connectors 7 27 Chain 7 BSD T2 Optional Paper Feed 7 7 NC60 ESS PWB Connectors 7 28 Chain 8 BSD Registration 7 8 Chain 9 BSD Xerographics High Voltage Power Supply 7 9 Connector Drum Detection Main Drive Charge 7 10 Numbers Location Developer Drive Mag Roll Cleaning 7 11 Black Development Black Toner Disp 7 12 CN100s PCUPWB ESS PWB 7 1 Color Development 7 13 CN200 s Cassette PWB 7 4 Color Toner Disp 7 14 Transfer Transfer Drum Positioning CN300 s Connector PWB 7 2 Transfer Cleaning Transfer Discharge 7 15 CN400 s Control Panel PWB 7 2 Stripper Control Transparency Jam CN700 s LVPS PWB 72 Cleaner Jam 7 16 Process Control 7 17 CN800 s HVPS PWB 7 3 Erase Lamp Waste Toner Sump 7 18 Chain 10 BSD Fusing Fuser Drive Exit Sensing Exhaust Fan Oil Sensing 7 19 Fuser Heat 7 20 Chain 13 BSD Accessories Hard Drive Floppy Drive 7 21 2 99 WIRING DATA DocuPrint C55 C55mpINC601 7 1 SECTION CONTENTS 24 INTERLOCK
9. Waste Toner Box D13 Figure 1 Removing the Toner Box REPAIRS ADJUSTMENTS REP 8 12 5 Remove the Solenoids and Keep the parts together Figure 2 Clutches shown Be especially careful with the springs they are different Figure 2 Removing the Clutches and Solenoids Figure 3 Remove the remaining hardware and remove the Right Feeder Frame Right Feeder Frame Figure 3 Removing the Feeder Frame 2 99 4 34 6 Figure 4 Roller Remove the E Ring and Feed Feed Roller 021 Figure 4 Removing the Feed Roller REPLACEMENT NOTE When reassembling the Waste Toner Box make sure it slides back and forth smoothly DocuPrint C55 C55mp NC60 8 13 WASTE TONER SENSOR PARTS LIST ON PL 8 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Remove the Waste Toner Sensor cover and the Waste Toner Sensor Sensor Cover and Arm Waste Toner Sensor 8 Figure 1 Removing the Waste Toner Sensor DocuPrint C55 C55mp NC60 REPLACEMENT NOTE When reassembling the Waste Toner Sensor and Cover make sure the arm slides back and forth smoothly 2 99 4 35 REPAIRS ADJUSTMENTS REP 8 13 REP 9 1 STRIPPER FINGER ASSEMBLY PARTS LIST ON PL 9 3 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Open t
10. 5 33 TONER DISPENSER ASSEMBLY K PL 13 1 BLACK TONER DISPENSER ASSEMBLY K 5 34 PAPER CASSETTE PL 14 1 PAPER CASSETTE COMPONENTS 5 35 TRAY 2 COMPONENTS PL 27 1 TRAY 2 COMPONENTS PART 1 OF 3 5 36 PL 27 2 TRAY 2 COMPONENTS PART 2 OF 3 5 37 PL 27 3 TRAY 2 COMPONENTS PART OF 3 5 38 PART NUMBER INDEX 3 39 PARTS LIST SECTION SECTION CONTENTS OVERVIEW The Parts List section identifies all part numbers and the corresponding location of all spared subsystem components ORGANIZATION PARTS LISTS Each item number in the part number listing corresponds to an item number in the related illustration All the parts in a given subsystem of the machine will be located in the same illustration or in a series of associated illustrations ELECTRICAL CONNECTORS AND FASTENERS This section contains the illustrations and descriptions of the plugs jacks and fasteners used in the machine A part number listing of the connectors is included COMMON HARDWARE The common hardware is listed in alphabetical order by the letter or letters used to identify each item in the part number listing and in the illustrations Dimensions are in millimeters unless otherwise identified PART NUMBER INDEX This index lists all the spared parts in the machine in numerical order Each number is
11. 5 Determine and record the Toner Concentration Setpoints now in NVM a Press Media Server 2 then press Menu 3 until TONER LEVEL YTON is displayed b Press Enter 7 and record the Y Toner Concentration Setpoint c Press Media Server 2 to return to TONER LEVEL d Press Previous 5 to select the next Toner Concentration Setpoint to be checked e Press Enter 7 and record the Toner Concentration setpoint f Repeat steps c through e until all four toner concentration setpoints have been recorded TONER LEVEL Toner Concentration M Toner concentration default 70 C Toner concentration default 70 K Toner concentration default 70 NOTE These readings should normally be between 70 and 140 If they are all 70 or out of the 70 to 140 range they have probably been corrupted If this is the case use the toner concentration values from the diagnostic sheet If a diagnostic sheet is not available and the values are corrupt both the Black and Color CRU s should be replaced after the PCU is initialized pron 6 Compare the values on the Diagnostic sheet with the values stored in NVM Determine which values to re enter after the NVM is initialized As you determine what values are to be used circle them so you can re enter them later a Determining the consumable value to use usage e f the consumable has not been changed sinc
12. 3 12 LIGHT LINES DELETIONS LEAD TO TRAIL EDGE 3 13 DocuPrint C55 C55mp NC60 TITLE PAGE 25 MISREGISTRATION BLACK 3 13 26 MISREGISTRATION YELLOW 3 13 27 MISREGISTRATION SIDE TO 51 3 14 28 MISREGISTRATION LEAD TO TRAIL 3 14 29 MISREGISTRATION HEAVIER STOCK LEAD TO TRAIL 3 14 30 MULTISHEET 3 14 31 OIL SPOTS 3 14 32 REPEATING PRINT DEFECTS EVERY 220 8 66 3 15 33 REPEATING PRINT DEFECTS EVERY 93 MM 3 66 3 15 34 REPEATING PRINT DEFECTS EVERY 63 5 2 5 8 15 35 PRINT DEFECT 63 5 MM 2 5 FROM LEAD EDGE OF PRINT 8 15 36 RESIDUAL 1 3 16 37 SMEARS 3 16 38 SMEARS 3 16 39 SMEARS SIDE TO SIDE ON PORTRAIT 3 16 40 SMEARS RANDOM BLACK PRINTS 3 16 41 TRANSPARENCY PROBLEMS 8 17 42 WRINKLED 8 17 43 WRONG COLORS ON ESS TEST PATTERNS 3 18 2 99 3 1 3 IMAGE QUALITY TITLE PAGE ESS GENERATED TEST PATTERNS 3 19 POSET ee eee Es
13. DocuPrint C55 C55mp NC60 5 29 PART REF PL10 1 ITEM 1 809E1830 55E37720 P O ITEM 1 162K29290 P O ITEM 1 49E71990 809E1850 31 8350 P O ITEM 1 600K65270 162K29310 48E43590 122E2170 14E34360 P O ITEM 1 55E38920 P O ITEM 1 P O ITEM 1 P O ITEM 1 130 7970 162 35650 49 84400 15E59950 DESCRIPTION PART OF TRANSFER FRAME ASSEMBLY SHUTTER SPRING A CONNECTOR SHUTTER SCREW M3X10 FUSER HARNESS SCREW M3X4 CONNECTOR BRACKET SHUTTER SPRING B FUSER ARM SCREW 6 GAMMA SENSOR KIT INCLUDES PL 10 4 ITEM 8 ERASE HARNESS ERASE LAMP COVER ERASE LAMP LAMP SPACER SCREW 6 OIL PROTECT SHEET SCREW M3X8 TRANSPORT FRAME SCREW 6 OIL SENSOR TRANSPARENCY JAM SENSOR JAM SENSOR HARNESS DETECT LEVER PLATE GAMMA SENSOR PLATE PARTS LIST SECTION PL 10 2 PL 10 3 TRANSFER FRAME RIGHT SIDE COMPONENTS 112 20 ITEM 12 13 14 15 16 17 18 19 20 21 22 PARTS LIST SECTION 2 99 PL 10 3 5 30 PART REF PL10 1 ITEM 1 0 ITEM 1 0 1 0 1 12 8160 0 1 7 48440 7 63600 115 5410 0 1 809 2060 13E12580 ITEM 1 P O ITEM 1 P O ITEM 1 P O ITEM 1 809 2010 29 27480 13 13420 809 5780 110 9930 I 2 a 115 6900 115 6900 DESCRIPTION PART OF TRANSFER FRAME ASSEMBLY RIGHT FRAME RETAINING RING 7MM SCREW 6 RIGHT RELEASE LINK LOCK
14. 3 Press the Menu 3 key to step through the diagnostic routines 2 99 6 3 EXITING FROM THE NORMAL DIAGNOSTIC MODE 1 When the PCU DIAG MODE is displayed on the Message Display press the Form Feed 1 key to exit from diagnostics or switch the printer off wait 10 seconds and then switch the printer on GENERAL PROCEDURES NORMAL DIAGNOSTICS NORMAL DIAGNOSTICS SWITCH SCAN This diagnostic routine is used to check the operation of the input sensors and switches 1 Enter Normal diagnostics and press the Menu 3 key until SWITCH SCAN 00 is displayed on the Message Display 2 Press the Next 6 Previous 5 keys until the Message Display steps to the SWITCH SCAN which lists the component to be tested 3 Press the Form Feed 1 key to start the test The SWITCH SCAN number will flash 4 Operate the component Figure 6 1 The appropriate LED K C M Y should Switch on and off 5 Press Media Server 2 to stop the test Repeat steps 2 through 4 to test additional inputs NOTE When Scan row 04 is selected the display will also indicate G XX This is the Gamma sensor reading and varies from 40 to 100 depending on the condition of the transfer drum When the white patch is under the sensor it will read in the 370 range GENERAL PROCEDURES NORMAL DIAGNOSTICS OIL SENSOR EXIT SENSOR GAMMA SENSOR TRANSPARENCY JAM SENSOR CLEANER JAM SWITCH TRANSPARENCY SENSOR TRANSFER DRUM H
15. 4 67 ADJ 11 1 TRANSFER DRUM 4 68 ADJ 12 1 ROS POSITIONING 4 70 REPAIRS ADJUSTMENTS SECTION CONTENTS 2 99 4 2 DocuPrint C55 C55mp NC60 1 1 REAR COVER PARTS LIST ON PL 1 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Figure 1 Open the Printer 2 Open the Upper Rear Cover 3 Remove four screws and remove the Top Rear Cover Top Rear Cover D29 Figure 1 Removing the Top Rear Cover 2 99 DocuPrint C55 C55mp NC60 4 3 REP 1 2 REAR COVER PARTS LIST ON PL 1 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Figure 1 Remove two screws 2 Remove two screws lift up then out and remove the Rear Cover Screws D1 Figure 1 Removing the Rear Cover REPAIRS ADJUSTMENTS REP 1 1 1 2 1 3 SIDE COVER PARTS LIST ON PL 1 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Raise the Upper Rear Cover 2 Figure 1 Remove the screws and remove the Side Cover Upper Rear Cover Screws D3 Figure 1 Removing the Side Covers REPAIRS ADJUSTMENTS 2 99 REP 1 3 1 4 4 4 REP 1 4 FRONT COVER PARTS LIST ON PL 1 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Release and open the Fuser Cover 2 Figure 1 Remove the
16. 8 CN3 8Cassette Harness 9 CN3 9Cassette Harness CN110 Pin Destination 1 CN1003 1 Fusing Motor 2 CN1003 3 Fusing Motor 3 CN1003 4 Fusing Motor 4 CN1003 6 Fusing Motor 5 CN1003 5 Fusing Motor CN111 Pin Destination 1 Paper Feed Motor 2 PaperFeedMotor 3 PaperFeedMotor 4 Paper Feed Motor 5 Paper Feed Motor CN112 Pin Destination Main Motor Main Motor Main Motor Main Motor Main Motor CN113 7 CN114 115 7 116 2 Color Toner Motor 2 99 7 23 117 CN118 CN119 CONNECTOR WIRING PCU Connectors Os eso oo CN308 309 CN301 CN304 CN306 CN307 j 8 gr CN302 CN303 CN305 CN317 102 102 982 16 CN301 Pin Destination 1 401 1 Gamma PWB 2 CN310 3 CN314 CN315 BE CN311 CN312 CN313 1 102 Figure 7 2 Connector PWB Connectors CN307 Pin Destination 1 CN103 28 PCU PWB 4 401 4 Control Panel 5 401 5 Control Panel 6 401 6 Control Panel Transparency Jam Sensor CN1011 1 CN315 2 enaoi 2 Gamma PWB Pin Panel 1 _ 1 9 2 11 Control Pane 3
17. Xerox DocuPrint NC60 PostScript Font Listing Available Fonts AvantGarde Book AvantGarde BookOblique AvantGarde Demi AvantGarde DemiOblique Bookman Demi Bookman Demiltalic Bookman Light Bookman Lightitalic Courier Courier Bold Courier BoldOblique Courier Oblique Helvetica Helvetica Bold Helvetica BoldOblique Helvetica Narrow Helvetica Narrow Bold Helvetica Narrow BoldOblique Helvetica Narrow Oblique Helvetica Oblique NewCenturySchlbk Bold NewCenturySchibk Bolditalic NewCenturySchlbk Italic NewCenturySchlbk Roman Palatino Bold Palatino Boldltalic Palatino italic Palatino Roman Symbol Times Bold Times Boldltalic Times ttalic Times Roman ZapfChancery Mediumitalic ZapfDingbats Bytes of VM available 5091552 v 951117 ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp 7 ABCDEFG abcdefg 0123456789 8215 ABCDEFG abcdefg 0123456789 amp A ABCDEFG abcdefg 0123456789 amp S ABCDEFG abcdefg 0123456789 amp S ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG a cdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 8 15
18. Toner on the backside of the print Uneven density Undesirable density differences or variations from one area of the print to another Wavy lines Solid straight lines typically in the lead to trail edge direction that are wavy or curvy Washed out image an image that is too light or lacks density It can be the entire image or a part of the image Wrinkles or creases Creasing or folds on the print in the lead to trail edge direction DocuPrint C55 C55mp NC60 COVERS REP 1 1 TOP REAR COVER 4 3 1 2 REAR COVER 4 3 REP 1 3 SIDE COVER 4 4 REP 1 4 FRONT COVER 4 4 2 1 TOP FRONT COVER 4 5 LOW VOLTAGE POWER SUPPLY REP 3 1 LOW VOLTAGE POWER SUPPLY ASSEMBLY 4 6 3 2 CASSETTE PWB 4 7 REP 3 3 PCU PWB 4 7 REP 3 4 ESS PWB 4 7 DRIVES OUTER 1 REP 4 1 MAIN DRIVE 4 8 4 2 MAIN DRIVE MOTOR BELTS 4 9 REP 4 3 DEVELOPER DRIVE MOTOR BELTS 4 10 4 4 INTERLOCK SWITCHES 4 11 4 5 COLOR TONER MOTOR 4 12 REP 4 6 DEVELOPER MOTOR 4 13 4 7 TONER SOLENOIDS 4 14 REP 4 8 MAGNETIC ROLLER CLEANING SOLENOID 4 16 DRIVES OUTER 2 5 1
19. ITEM 112 33 29 22 25 Q 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 REF PL8 1 ITEM 1 P O ITEM 1 P O ITEM 1 7E48530 P O ITEM 1 P O ITEM 1 P O ITEM 1 P O ITEM 1 P O ITEM 1 NA 8E5740 6E61530 13E12570 809E2140 130E8000 22E21000 11E7390 809E1860 22E21010 P O ITEM 1 809E2050 7E48510 809E2080 16E12470 8E5720 22E21020 5E12180 7E48500 REF ONLY P O ITEM 1 P O ITEM 1 121E13450 P O ITEM 1 DESCRIPTION PART OF PAPER FEED ASSEMBLY LOWER GUIDE UPPER REGISTRATION ROLLER GEAR RETAINING RING 7 BUSHING RETAINING RING 4MM WASHER RETAINING RING 5MM CAM CAM SHAFT BUSHING CAM SPRING REGISTRATION PAPER TRAY OUT SENSOR REP 8 3 8 4 LOWER REGISTRATION ROLLER REP 8 11 REGISTRATION LEVER REGISTRATION SPRING FEED ROLLER REP 8 12 WASHER SPRING GEAR SPRING SLEEVE CLUTCH BOSS P O ITEM 1 PAPER DRIVE ROLLER REP 8 8 ONE WAY CLUTCH GEAR FEED CLUTCH ASSEMBLY REP 8 5 SCREW 6 SCREW 4 8 FEED SOLENOID REP 8 5 SOLENOID BRACKET PARTS LIST SECTION 2 99 PL 8 2 5 22 DocuPrint C55 C55mp NC60 PL 8 3 PAPER FEED ASSEMBLY PART 3 OF 3 ITEM 1 2 6 8 27 27 14 17 O Im 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 2 99 DocuPrint C55 C55mp NC60 5 23
20. cM4p toConmoPane 4 7 12 Control Panel 5 CN303 B Pin Destination peni Transparency Sen 2 _ 01 2 Sen Destination 73 EN6013 Transparency Sen Transfer Drum Clean Sol CN312 Transfer Drum Clean Sol Pin Destination I CNSIT L1 Bypass swith CN308 2 Bypass Switch CN313 CNIGHOPCUPWB f Pin Destination L6 CNI037PCU Pwe SHOUT CN318 1 Transfer Drum Home aes Pin Destination CN309 CN1001 2 Transfer Drum Home Cleaner Jam Switch CN1013 4 Fan Motor Destination Position Sensor me 2 CN10132 Fan Motor i Oil Sensor CNS06 OiSemserCNibQ2 Posion Sensor o Pin Destination 3 LOilSensorCNi0i03 CNSA 1 1009 4 Fuser Assy CN310 Pin Destination L2 1009 9 Fuser Assy Pin Destination Trai EAS 01009 10 Assy 1009 5 Fuser Assy 72 cNaoi 2 Control Panel a controtPanet CONNECTOR WIRING 2 99 Connector PWB Connectors 7 24 DocuPrint C55 C55mp NC60 Transfer Figure7 3 High Voltage Power Supply PWB Connectors CN801 CN802 CN803 Pin Destination Pin Destination CN1009 24 Color Dev Assy 1 CNI0 1PCUPWB
21. plor From a different line of thinking the new pace of printing ax Friendly Zip Color Vivid Color Visit our web site at Http xerox networkprinters com products NC60 THE DOCUMENT COMPANY 7 Xerox The Document Company the stylized X DocuPrint and all Xerox product names trademarks of XEROX CORPORATION Adobe Postscript and the Postscript logo are trademarks of Adobe Systems Incorporated which may be registered in certain jurisdictions Adobe PostScript 3 2 99 GENERAL PROCEDURES DocuPrint NC60 6 35 POSTSCRIPT DEMO TIPS amp TRICKS NC60 Menu Up until Item Down until Menus Print Print Tips amp Tricks This page lists some common tips and tricks which will make printing easier Practical Tips for the Xerox DocuPrint NC60 Color Laser Printer PostScript Printer Driver Features Using your PostScript Driver enables many of the features listed below Intelligent Color Intelligent Color applies the optimum imaging method for documents containing a mix of photos bitmaps charts graphics and text This setting will produce the best combination of print quality and speed for a full range of documents Vivid Color When printing charts and graphs Vivid Color will enhance your document with bright solid colors This setting is recommended for full color business documents Enhanced 1200 Image Quality For the best print quality choose 1200 Image Quality in yo
22. 2 99 2 33 OF2 5 Message display works OK Switches do not work correctly PROCEDURE When the switches do not work properly refer to BSD 2 1 and check the following e CN103 20 Switch Enable for an open or a short If OK replace the Control Panel PWB If the problem still exists replace the PCU PWB OTHER FAULTS RAPs OF2 OF2 6 Circles Continuously PROCEDURE When the is circling continuously it is not receiving messages from the ESS PWB Perform the following checks Retry between each check 1 Remove and reseat the ESS PWB you may want to remove the left side cover and the EME shield to ensure that the PWB is seated Disconnect the NIC if one is present Remove and reseat the DRAM SIMM s on the ESS C55 C55mp If there are more than two SIMM s check to ensure that the larger value SIMM s are installed in J8 and J9 4 C55 C55mp Check the version of the ESS PWB The number is written in yellow ink parallel to the ESS face plate near the bottom of the ESS The bottom of the ESS is the point FURTHEST away from the DRAM SIMM s If the ESS PWB number is 160K43690 or 160K49680 Replace the ESS PWB 5 C55 C55mp Reconfigure the ESS PWB to the original RAM configuration 2 8 MB SIMM s this will verify if this is a DRAM problem If the printer works in the original configuration but not with customers memory replace the ESS PWB OTHER FAULTS RAPs OF2 C55 C55mp If the ESS IF PWB PL
23. DocuPrint C55 C55mp NC60 Color Laser Printer 50 60 Hz Service Manual CAUTION 7 Certain components in the DocuPrint C55 C55mp 4 NC60 Color Laser Printers are susceptible to damage from electrostatic discharge Observe all ESD procedures to avoid component damage 701P14760 February 1999 All Service documentation is supplied to Xerox external customers for informational purposes only Xerox Service Documentation is intended for use by certified product trained personnel only Xerox does not warrant or represent that such documentation is complete nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation Customer performed service of equipment or modules may affect the warranty offered by Xerox with respect to such equipment You should consult the applicable warranty for its terms regarding customer or third party provided service If the customer services such equipment modules components parts thereof the customer releases Xerox from any and all liability for the customer actions and the customer agrees to indemnify defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service Prepared by Xerox Corporation Multinational Customer and Service Education 780 Salt Road Webster New York 14580 01999 by Xerox Corporation All rights reserved Xerox and all
24. Figure 4 Entire Drawing Without Tag Symbol PARTS LIST SECTION INTRODUCTION PL 1 1 COVERS 12 13 22 25 ITEM 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 PART NOT SPARED 38E17370 48E43540 NOT SPARED 48E43550 NOT SPARED 48E43560 NOT SPARED 48E43580 NOT SPARED NOT SPARED 48K56920 802 6940 12 12 162 29280 101E13090 24E2480 3E42110 802E6950 P O ITEM 12 P O ITEM 12 48E53740 48E53730 NA NOT SPARED P O ITEM 16 DESCRIPTION SPACER OUTPUT GUIDE TOP REAR COVER REP 1 1 SCREW M3X8 REAR COVER REP 1 2 SCREW M3X6 RIGHT COVER REP 1 3 SCREW 8 LEFT COVER REP 1 3 SCREW BLIND COVER FRONT COVER ASSEMBLY C55 REP 1 4 FRONT COVER ASSEMBLY NC60 REP 1 4 FRONT COVER DISPLAY PANEL HARNESS CONTROL PANEL ROD BUTTON UNIT C55 BUTTON UNIT NC60 PANEL A PANEL B LEFT COVER RIGHT COVER SCREW M3X6 SUPPRESSION PWB PARTS LIST SECTION 2 99 PL 1 1 5 4 DocuPrint C55 C55mp NC60 PL 2 1 PRINT EXIT ASSEMBLY 1 2 26 MEM O 24 _ E E N O dq o 23 24 25 26 2 99 DocuPrint C55 C55mp NC60 5 5 PART 48K56910 130E7980 22K53910 P O ITEM 3 38E18360 P O ITEM 1 P O ITEM 1 7E51210 7E51200 15E64370 809E5670 13E12520 23E14890 809E1780 NOT SPA
25. NG Tray Lower Feeder Require MENU Cyan Count lt gt CUSTOM DEMOS Magenta Count PCL Yellow Count Postscript This is the Menu page It shows a overall view of the ENGLISH ITALIANO ESPANOL erm MULTINATIONAL FRANCAIS DEUTSCH PORTUGUTS Menu structure on the C55 oi PARALLEL NETWORK SETUP The Service Menu is not shown since it is not used by COMMUNICATIONS Enable Appropriate Network Card Required Mode ETHERNET NOVELL IPX TCP IP NETBEUT the custom er Handshake Enable Print Server Print Host Enable Connector Enable IP Addressing Group SERIAL TOKEN RING Mode Set IP Address Name Enable Enable IPX Encapsule TFTP Enable Remark Mode Connector Scan Rate Gateway Service Serial Setup Speed Pserver Name Net Mask BAUD Rate Source Routing Primary Server LPR Enable SNMP Data Bits Tree LPR Banner System Contact Stop Bits ETHER TALK Context Appsocket System Name Parity TOKEN TALK Enable System Location GENERAL PROCEDURES MENU Flow Control LOCAL TALK Enable Enable Phase Zone Mode COLOR ADJUST CONFIGURATION Startup Page Med Srv Enable TIMING Wait Timeout Manual Timeout Hold Timeout PowerSaver SERVICE EDGE SMOOTHING COLOR MODE Vivid Photo Unadjusted OVERPRINT MEDIA SERVER Media Server Required THE DOCUMENT COMPANY SUPPORT INFO Printer Name Serial Number Xerox Service Xerox Supply Dealer Service Dealer Supply MEMORY Input Buffer Font Cache HALFTONE TYP
26. PART REF PL8 1 ITEM 1 P O ITEM 1 P O ITEM 1 P O ITEM 1 P O ITEM 1 162K35660 55E37750 121E13470 P O ITEM 1 P O ITEM 1 P O ITEM 1 P O ITEM 1 809E2120 13E12570 P O ITEM 1 16E12490 809E2150 7E48570 P O ITEM 1 P O ITEM 1 162K35640 P O ITEM 1 121E13460 7E48520 7E48490 P O ITEM 1 NA P O ITEM 1 o lt DESCRIPTION PART OF PAPER FEED ASSEMBLY LOWER GUIDE PIVOT STUD SCREW M3X8 TEMP HUMIDITY SENSOR SENSOR HARNESS CLUTCH COVER REGISTRATION CLUTCH 8 6 RETAINING RING 4MM RETAINING RING 5 WASHER CLUTCH SPRING BUSHING CLUTCH BOSS SLEEVE SPRING GEAR CABLE TIE CONNECTOR VIDEO HARNESS SCREW M3X8 GROUNDING ROLL SOLENOID GEAR GEAR SIDE PLATE GRND ROLL CLUTCH REF ONLY REP 8 7 PARTS LIST SECTION PL 8 3 PL 9 1 FUSER TD CLEANER DRIVES 112 33 PL 9 2 ITEM 1 ITEM PART DESCRIPTION PL 9 3 ITEM 1 PL 9 4 ITEM 1 1 22K53890 TRANSFER FRAME ASSEMBLY 2 1E43740 RIGHT TRANSFER FRAME 8 P O ITEM 1 RETAINING RING 2MM 4 13E13360 BEARING 5 P O ITEM 1 SCREW M3X6 6 7E48280 GEAR 7 23E14880 TRANSFER BELT 8 28E12140 WASHER 9 P O ITEM 1 RETAINING RING 5MM 10 121E13400 TR DRUM CLEANING SOLENOID REP 9 2 11 23E14910 BELT B 12 23E14900 BELT A 13 7E48380 FUSER IDLER GEAR 14 15E64300 FUSER MOTOR PLATE 15 P O ITEM 1 SCREW 8 16 7E48340 IDLER GEAR 17 162K35580 HARNESS 18 130E797
27. Xerox DocuPrint NC60 More to work with esc L lt gt 0 nosob4096T Xerox DocuPrint NC60 More to work with lt gt lt gt 0 050040967 Xerox DocuPrint 60 More to work with esc L lt gt 50 MEE 5054096 Xerox DocuPrint NC60 More to work with esc L esc sop WEE nosob4096T 10 567 MEE Point Size 25 999 75 PCL is a registered trademark of Hewlett Packard Company Times CG Omega are registered trademarks of Miles Inc is trademark of Ludlow Industries UK Ltd Univers is a registered trademark of Linotype Hell AG and or its subsidiaries Antique Olive is a trademark of Fonderie Olive Times New Roman is a registered Trademark and Albertus And Arial are trademarks of the Monotype Corporation plc are all Agfa fonts and resident fonts of this model Agfa is a registered trademark of Agfa Inc DocuPrint NC60 2 99 6 27 GENERAL PROCEDURES PCL FONT PS FONT C55 C55mp Press DispayRexs men _ Xerox DocuPrint C55 mp Color Laser Printer PostScript Resident Fonts Internal Fonts Times Roman Times Bold Times Italic Times Boldltalic ITC Avant Garde GothictBook ITC Avant Garde Gothic Demi ITC Avant Garde Gothic BookOblique ITC Avant Garde Gothic DomiOblique This page lists the PostScript Fonts which are resident on the
28. 2 Press Form Feed 1 again to exit from Normal diagnostics 3 Or switch the printer off wait 10 seconds and then switch the printer on GENERAL PROCEDURES SPECIAL DIAGNOSTICS COUNTER SET2 This Diagnostic routine is used to preset the Set2 counters to a desired value 1 Enter Special diagnostics and press the Menu 3 key until COUNTER SET2 TTL is displayed on the Message Display 2 Press the Next 6 Previous 5 keys until the Message Display steps to the counter to be changed Table 3 3 Press the Enter 7 key the display will indicate XXXX XXXX is the counter name THHHHHHHE is the current counter value 4 Press the Menu 3 key to select the digit to be changed 5 Press the Next 6 Previous 5 keys to change the counter value 6 To store the counter change insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored 7 Press the Media Server 2 key to return the COUNTER SET2 list Repeat steps 2 through 6 to change additional counters 2 99 6 8 TONER LEVEL This Diagnostic routine is used to set the toner concentration setpoints in the developer assembly 1 Enter Special diagnostics and press the Menu 3 key until TONER LEVEL YTON is displayed on the Message Display 2 Press the Next 6 Previous 5 keys until the Message Display steps to the color to
29. ABCDEFG abcdelg 0 123456789 amp ABCDEFG abcdefg 0123456789 amp 7 ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abedefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp 01234567894 714 ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp ABCDEFG abcdefg 0123456789 amp _ ABCDEFG abcdefg 0123456789 amp Chere Cel X UIS 2 99 GENERAL PROCEDURES DocuPrint NC60 6 29 PS FONTS MENU C55 C55mp Xerox TO ENTER MENU DocuPrint C55 mp TOENTER M Color Laser Printer Press MENU TO NAVIGATE THROUGH MENUS Press ENTER to select an item or to enter a submenu Press NEXT to go to next selection within a menu Press PREVIOUS to go to the previous menu selection Press MEDIA SERVER to go to the MEDIA SERVER menu TO ENTER MEDIA SERVER FROM ON LINE lt OFF LINE gt lt CONTROL gt On Line TOP MENU Next until lt PRINT gt Press MEDIA SERVER CONTROL CANCEL JOB lt STARTUP gt RESET PRINTER BLK DEV CART COLOR DEV CART Next until lt MENU gt RETURN ENCE PRINT DRUM C raemor RISER MODULE 4 PG COUNT lt s gt YES gt TRANSPARENCY ELLOS Rd Cenk Mode PSFONTS Black Count PROCESS
30. AppSocket Enabl AppSocket PDL AppSocket Bin PS Etalk Enable HTTP Enable IP Address Res IP Address Subnet Mask Default Gateway Port Timeout Novell Menu Novell Enable Notify Novell PDL Novell Binary PS Novell Mode Frame Type Pollinglnterval PServer Name Primary Server NDS Tree NDS Context 2 99 6 23 System Menu On Language On Paper Size Auto Paper Type Off Page Policy On Policy Timeout Auto Hold Timeout Off Manual Timeout On Print Quantity Auto Startup Page Off Print PS Errors On Defaults Auto Power Saver Off On Tray Menu On Tray Cust Size DHCP Tray 0 0 0 0 Tray Sequence 0 0 0 0 0 0 0 0 Imaging 60 Edge Smoothing Color Mode OverPrint On Halftone Type On Ehn Alignment Auto Fast Black Off Process Black NDS BEM Auto 2 XRX 0000AA79007B THE DOCUMENT COMPANY English Letter 8 5x11 Plain Off 30 Seconds 1 Minutes 2 Minutes 1 No Off Inches 15 Minutes SPFolio 216x315 Plain Off Off Vivid Off Smooth Screen Off Yes Off XEROX PCL Menu Font Number Symbol Set Orientation Form Length Line Terminat Parallel Menu Port Enable Port Timeout Parallel PDL Binary PS Bidirectional Serial Menu Port Enable Port Timeout Serial PDL Binary PS Baud Rate Flow Control Service Menu Print Quantity OHP Mode Select Tray Margin Left Margin Top Cleaning Cycle Patch Control GENERAL PROCEDURES CONFIGURATION 0 PC 8 Portrait
31. E7 PRINT DRUM JAM OPEN PRINTER JAM OPEN PRINTER 5 FUSER JAM OPEN PRINTER JAM OPEN PRINTER El TRAY 1 JAM OPEN PRINTER El TRAY 1 JAM OPEN PRINTER JAM OPEN PRINTER E7 PRINT DRUM JAM OPEN PRINTER E4 INPUT OPEN PRINTER 5 FUSER JAM OPEN PRINTER E4 INPUT OPEN PRINTER U 2NVRAM ERROR POWER OFF ON THE DOCUMENT COMPANY 2 99 GENERAL PROCEDURES DocuPrint NC60 6 33 FAULT HISTORY POSTSCRIPT DEMO 55 55 Press DispayReais Eme STATU me gt Eme QUANTYs me i Eme _ Eme XS _ fener PROCESSNG This is a demo of some of the PostScript features GENERAL PROCEDURES POSTSCRIPT DEMO Doc Print 55 Color Laser Printer Now you can do so much more THE DOCUMENT COMPANY Visit our web site at Http xerox networkprinters comy products c55 Xerox The Document Company the stylized X DocuPrint and all Xerox product names are trademarks of XEROX CORPORATION Adobe Postscript and the Postscript logo are trademarks of Adobe Systems Incorporated which may be registered in certain jurisdictions 2 99 6 34 DocuPrint C55 C55mp POSTSCRIPT DEMO NC60 DocuPrint NC60 Network Color Laser Printer Menu Down until Print Postscript Demo Processing Postscript Demo This is a demo of some of the PostScript features m m
32. K C M Y If a defect only shows on one of the basic colors suspect a developer related problem Locate The Defect in Table 1 and perform the corresponding corrective action 2 99 3 2 DocuPrint C55 C55mp NC60 Defect Name Description Possible Causes Corrective Action 1 BACKGROUND OVERALL 1 Density out of adjustment 1 Perform the Density and Color Balance Adjustment ADJ 3 1 2 Color balance out of adjustment 2 Perform the Density and Color Balance Adjustment ADJ 3 1 3 Print Drum Module failure 3 Replace the Print Drum Module 4 Developer failure or near end of life 4 Replace the developer module s 5 Print Drum Arcing 5 Refer to OF8 Arcing RAP in Section 2 6 New developer assembly did not initialize 6 Run a Diagnostic Sheet and check the Toner Concentration Setpoints for newly installed developer assembly If the Setpoints are at 70 default replace the developer assembly 7 Dirty Printer Sump Full Refer to BSD 9 21 and check the Waste Toner Full signal CN102 3 for a short to ground 8 Extraneous light leak 8 Ensure the printer is not in direct sunlight 9 Temperature RH Sensor failure 9 If the readings on the diagnostic sheet are out of range RH 0 or RH gt 100 or Temp 0 refer to the chart below Diag Refer to BSD 9 19 and check Sheet CN105 1 Humidity Sense for a short to ground RH gt 100 105 1 Humidity Sense for an open CN105 2 Humidity
33. Poor Transfer 1 Check the following LEAD EDGE OF PRINT Check contact between right transfer drum bearing and Transfer contact on frame Check Transfer Drum Nip ADJ 11 1 in Section 2 Paper out of specification Use 20 to 24 lb paper 2 99 IMAGE QUALITY RAPs DocuPrint C55 C55mp NC60 3 15 IMAGE QUALITY DEFECTS Defect Name Description Possible Causes Corrective Action 36 RESIDUAL IMAGE 1 Failed Print Drum Cleaning Blade 1 Remove the Cleaning Blade 3 screws and clean the blade Reinstall and make several prints to verify cleaning If problem still exists replace the Print Drum Module 2 Low 2 If Oil is low refer to the W5 RAP and check the operation of the Fuser Oil Sensor Add Oil Run 20 blank prints to clean the fuser roll 37 SMEARS BLACK 1 Fuser Speed incorrect V66 IOT Firmware 1 Perform Fuser Speed check GP 3 1 38 SMEARS YELLOW 1 Fuser Speed incorrect V66 IOT Firmware 1 Perform Fuser Speed check GP 3 1 39 SMEARS SIDE TO SIDE 1 Light shocked Print Drum 1 Dark rest the Print Drum ON PORTRAIT PRINT Replace the Print Drum 2 Main drive belt slipping 2 Replace the main drive belt 40 SMEARS RANDOM BLACK PRINTS Image being disturbed during transfer 1 Foreign material in Transfer Drum Cleaning Brush or in Transfer Drum Lower Frame IMAGE QUALITY RAPs 2 99 IMAGE QUALITY DEFECTS 3 16 DocuPrint C55 C55mp NC60 Defect Name Description Po
34. Process Voltage Magenta xxxxx A Yellow Transfer Bias ere Paper 1400 Volts k OHP 2200 Volts Adjustments Developer Bias Black 357 Volts Cyan 364 Volts Top Margin Omm Left Margin Omm Cleaning Cycle Never Magenta 421 Volts TC Patch Control Yes Yellow 374 Volts The DOCUMENT COMPANY Visit our web site at http xerox networkprinters com products c55 GENERAL PROCEDURES 2 99 DIAGNOSTICS 6 24 DocuPrint C55 C55mp DIAGNOSTIC SHEET NC60 Xerox DocuPrint NC60 Color Laser Printer Menu Up until Menus Service Menu Diagnostic Sheet General Information Density Rate Set Points 3 i i Serial Number XXX XXXXXX Black 90 Down until Print Software Version 1 80 39 INL ROM Cyan 90 Diag Summary Engine Software Version Magenta 90 Total System Memory Yellow 90 Processing 5134 Color Balance Default Diag Summary Gamma Set Points Black 41 Cyan 61 Binary Lossy Counter Magenta 64 Contone Lossy Counter Yellow 62 This page lists the many of the NVM values for the Toner Concentration printer For a detailed explanation of this page refer to Fuser Temperature Set Point Section 3 ESS GENERATED TEST PATTERNS Print Counts oan ae otal Magenta 110 Finit Yellow 102 Control Point ack 103 an 112 genta 103 ow 102 Cyan Magenta Yellow Consumable Usage Status Fuser Fuser Oil Okay Black Developer Color Developers Cyan xx Magenta x
35. Product Specifications ESS IOT test patterns and other General Procedures Section 7 WIRING DATA This section contains Block Schematic Diagrams BSDs Plug Jack PWB Location Diagrams and wiring diagrams DocuPrint C55 C55mp NC60 HOW TO USE THIS MANUAL Section 1 Service Call Procedures will direct you to each section of the manual necessary to perform a service call You will begin with Initial Actions which suggest how to collect problem symptoms and evidence to be used in the next section the System Checks Section Details in the System Checks are designed to assist you in classifying repairing and verifying the repair of the problem From here you may be directed to any of the other six sections of the service manual depending the symptoms observed and the results of suggested tests After a repair has been verified or during a repair activity instructions are included to direct you into Every Call Activities REFERENCE SYMBOLOGY Reference Symbology provides supportive data for Repairs Adjustments and the RAPs The symbols that refer to this supportive data are shown in the paragraphs that follow Note This symbol is used to refer to notes usually found on the same page Parts Lists PL 2 4 example In the example above the parts list reference and the exploded view drawing would be found in Section 5 on sub section 2 4 Descriptions of commonly used graphic symbols are included in or
36. Refer to Section 6 if detailed Diagnostic procedures are required a Enter Normal diagnostics Menu 3 Enter 7 Power On b Use Menu 3 to scroll to COUNTER SET DRUM c Press Enter 7 and record the Drum usage value d Press Media Server 2 to return to COUNTER SET e Press Previous 5 to select the next Consumable to be checked f Press Enter 7 and record the next Consumable Usage g Repeat steps d through f until at least the first seven consumables have been recorded The last five are not critical REPAIRS ADJUSTMENTS ADJ 3 3 2 99 4 62 DocuPrint C55 C55mp NC60 4 Determine and record the Print Counts a Press Media Server 2 then press Menu 3 until PCU DIAG MODE is displayed b Enter Special Diagnostics PCU DIAG MODE displayed press On Line 0 then press Enter 7 release both at same time c Use Menu 3 to scroll to COUNTER SET2 TTL d Press Enter 7 and record the TTL Count e Press Media Server 2 to return to COUNTER SET2 f Press Previous 5 to select the next page count to be checked 0 Press Enter 7 and record the page count h Repeat steps e through g until the five page counts have been recorded The last eight are not critical COUNTER SET2 Print Counts mj MPR pem orc Scan Eror Counter Mam pum mj B NEN Developer Motor Error Counter
37. SP Folio 216x315 mm Recommended 8x10 85 13 ED at 20 to 85 relative humidity 16 5 inches 419 MM 16 5 inches 419 MM Appx 89 lbs Appx 40 KG Paper Exit System Maximum Altitude CAPABILITIES NC60 Face down on the top cover 6560 feet 2000M Printing Speed letter size Capacity 150 sheets Sound Level Black 16 ppm Print Materials Information 32 dbA Standby Max Color 3 ppm For complete details see the User s Guide 52 dbA Running Max Warm Up Time Part Number er Comments 180 seconds Description Resolution Paper 20 to 24 Ib Best 80 to 90 gsm 600 x 600 x 1 with 64 MB of RAM Paper 16 to 24 Ib Good 60 to 90 gsm With PostScript Contone 600 x 600 x 4 DUCES i ess than with 64 MB of Paper 80 gsm or greater Not MP than 24 Ib 90 gsm 3R4446 Transparence 3796002 Best A4 clear 2 99 GENERAL PROCEDURES DocuPrint NC60 6 69 Product Specifications CONTROLLER SPECIFICATIONS C55 C55mp AMD 29040 RISC processor operating at 50 25 Mhz Memory 24 MB DRAM 6 MB FLASH ROM Standard on C55 C55mp Upgradable to a maximum of 64 MB Printer Description Languages PDL Standard on C55 PCL 5C Optional Adobe PS II Upgrade Standard on C55mp PCL 5C and Adobe PS II Coresident Resident Fonts 35 Type 1 PostScript printers only 35 Intellifonts PCL 5C 10 TrueType PCL 5C Interfaces Standard IEEE 1284 pa
38. Sixchoices are available they are we Cm DEFAULT This is the best setting for Xerox This setting is used if you have configured the using Hidden diagnostics This setting is best for minimizing E4 E6 Jams with maximum transparency brightness This setting is best for minimizing transfer breakdown with maximum transparency brightness This setting is best for minimizing E4 E6 Jams with minimum finger offsetting defects This setting is best for minimizing transfer breakdown with minimum oil finger offsetting defects 5 Select the choice which best represents your situation and press Enter 2 99 6 47 GENERAL PROCEDURES GP 3 3 GP 3 4 DRUM CLEANING PURPOSE The purpose of this procedure is force the transfer drum to run cleaning cycles This helps prevent deletions in high volume applications Refer to GP 3 4A for the C55 C55mp Refer to GP 3 4B for the NC60 GENERAL PROCEDURES GP 3 4 GP 3 4A DRUM CLEANING C55 C55mp ADJUSTMENT 1 Press On Line to enter the Off Line mode then press Menu 2 Press Next until SERVICE is displayed then press Enter 3 Press Next until ADJUSTMENTS is displayed then press Enter 4 Press Next until CLEANING CYCLES is displayed then press Enter 5 The following choices are available Never e 10 through 100 6 For high volume customers the recommended setting is 30 transfer drum is cleaned every 30 Images 2 99
39. Switch the power on to recheck for the fault PROCEDURE Refer to OF5 1 for Tray 1 Load Paper problems Refer to OF5 2 for Tray 2 Load Paper problems DocuPrint C55 C55mp NC60 OF5 1 Constant Tray 1 Load Paper message Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 01 Press Form Feed 1 Remove Cassette 1 Observe the Black LED while actuating and deactuating the Tray 1 Empty Sensor The Black LED switches off and on Y N Refer to BSD 7 1 and check the Tray Empty Sensor circuit CN102 6 4 5 for an open If OK replace the Tray Empty Sensor If the problem still exists replace the PCU PWB Replace the PCU PWB If the problem still exists replace the ESS PWB 2 99 2 37 OF5 2 Constant Tray 2 Load Paper message Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 03 Press Form Feed 1 Remove Cassette 2 Observe the Black LED while actuating and deactuating the Tray 2 Empty Sensor The Black LED switches off and on Y N Refer to BSD T2 7 1 and check the T2 Tray Empty Sensor circuit CN109 4 5 6 for an open If OK replace the T2 Tray Empty Sensor If the problem still exists replace the PCU PWB Replace the PCU PWB If the problem still exists replace the ESS PWB OTHER FAULTS RAPs OF5 OF6A ESS RAP 55 55 This RAP is used when you suspect a problem with the C55 C55mp ESS PROCEDURE Switch the Printer o
40. TD CLEANER CLUTCH ASSY REP 9 3 TD CLEANER ASSY C55 REP 9 4 TD CLEANER ASSY NC60 REP 9 4 TD CLEANER BRUSH CLUTCH RETAINING RING 2MM CLUTCH BOSS CLUTCH SLEEVE CLUTCH SPRING GEAR WASHER GEAR BEARING CAM CAMSHAFT PARTS LIST SECTION PL 9 4 PL 10 1 TRANSFER FRAME LEFT SIDE COMPONENTS 1 2 25 PL 10 2 ITEM 1 PL 10 3 ITEM 1 PL 10 4 ITEM 1 PARTS LIST SECTION 2 99 PL 10 1 5 28 ITEM PART 1 22K53890 2 1 43760 3 1 4 1 5 1 6 53 5390 7 127 10930 8 1 9 1 10 P OITEM 1 11 14 32670 12 1 13 101 13680 14 P O ITEM 1 15 1 16 P O ITEM 1 17 1 18 15E64450 19 P O ITEM 1 20 120 15820 21 P O ITEM 1 22 49 84420 23 62 8750 24 15 64440 25 P O ITEM 1 26 13 12570 DESCRIPTION TRANSFER FRAME ASSEMBLY SAME AS PL9 1 ITEM 1 LEFT FRAME SCREW M3X10 SCREW M3X6 SCREW M3X8 OZONE FILTER FUSER FAN SCREW M3X8 RETAINING RING 7MM SCREW M3X6 LOCK BLOCK RETAINING RING 6MM HARNESS COVER INTERLOCK ACTUATOR RETAINING RING 5MM RIGHT UPPER LINK LEFT UPPER LINK SCREW FAN HOUSING BRACKET BRACKET SCREW TRANSPORT LINK STAY SEAL SEAL RETAINING RING BEARING DocuPrint C55 C55mp NC60 PL 10 2 TRANSFER FRAME UPPER COMPONENTS ITEM _ ot 12 13 14 15 16 17 18 19 20 21 22 23 24
41. The Gamma Sensor did not see the expected difference between the 3 patches during setup Possible causes for Under Limit Irregular errors tend to be the same Transfer Nip too small or poor transfer in general Toner concentration in the developer assembly is too low Arcing may be causing excessive toner consumption e Very low Relative Humidity Magenta is especially sensitive to this problem The error occurs if Relative Humidity is less than 10 counts General information on Diagnostic sheet Developer assembly problem High Voltage Power supply problem Possible causes for Over Limit errors e Very high Relative Humidity The error occurs if Relative Humidity is greater than 35 counts General information Diagnostic sheet e Dirty white patch on transfer drum The toner concentration in the developer assembly is too high IMAGE QUALITY SPECIFICATIONS TEST PATTERNS Calibration Errors occur when reading the white patch and the difference between full Gamma voltage and half Gamma voltage is not what was expected Suspect a dirty white patch or bad Gamma Sensor Density Rate Setpoints The default is 90 If the Density and Color Balance has been adjusted these setpoints will change The range is between 80 and 100 If the Density and Color Balance tries to exceed a limit the process control will indicate an over or under error count is approximately 10 Volts of developer bia
42. and run the Motor Test again Note any changes in the sounds If there is noticeable change in the sound examine the Print Drum by opening the Waste Toner trap door and probing with a small screwdriver If this area is clogged you can remove the left side cover by removing the trap door and removing 4 screws This area can then be vacuumed out before reassembly All Printers if a thumping noise is heard check to see if the Main Drive Motor Belt is slipping INITIAL ACTION Remove and inspect the Print Drum Module Check to ensure that no foreign material is wedged in the Print Drum Module drive gears Rotate the Transfer Drum by hand to ensure that it moves Check for any binding caused by a tucked over Transfer Drum Cleaner Brush Blade Reinstall the Print Drum Module Switch the power off wait 10 seconds and Switch the power on Recheck for the fault DocuPrint C55 C55mp NC60 PROCEDURE Enter IOT normal diagnostics Scroll to the MOTOR TEST program and press Form Feed 1 to switch on the motors while observing the Main Drive Motor The Main Drive Motor is rotating Y N The Main Motor is noisy Y N Go to BSD 9 3 in Section 7 and troubleshoot the 24 VDC Interlocked CN112 5 If OK replace the PCU PWB If the problem still exists replace the Main Drive Motor Go to BSD 9 3 in Section 7 and check CN112 to ensure it is plugged in If the problem still exists replace the PCU PWB f the proble
43. be changed Table 4 3 Press the Enter 7 key the display will indicate XXXX XXXX is the color is the current toner concentration setpoint 4 Press the Next 6 Previous 5 keys to change the setpoint 5 To store the change insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored 6 Press the Media Server 2 key to return the TONER LEVEL list Repeat steps 2 through 5 to change other setpoints DocuPrint C55 C55mp NC60 ID LEVEL This Diagnostic routine is used to set the image density 1 Enter Special diagnostics and press the Menu 3 key until ID LEVEL YELLOW is displayed on the Message Display 2 Press the Next 6 Previous 5 keys until the Message Display steps to the color density to be changed Table 5 3 Press the Enter 7 key the display will indicate XXXX XXXX is the color name THER is the current density value 4 Press the Next 6 Previous 5 keys to change the density value 5 To store the density change insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored 6 stored 7 Press the Media Server 2 key to return the ID LEVEL list Repeat steps 2 through 5 to change additional densities NOTE This value i
44. followed by a reference to the parts list on which the part may be found PARTS LIST SECTION INTRODUCTION OTHER INFORMATION ABBREVIATIONS Abbreviations are used in the parts lists and the exploded view illustrations to provide information in a limited amount of space The following abbreviations are used in this manual Ess Subsystem 2 Hee SYMBOLOGY Symbology used in the Parts List section is identified in the Symbology section 2 99 5 2 SUBSYSTEM INFORMATION USE OF THE TERM ASSEMBLY The term assembly will be used for items in the part number listing that include other itemized parts in the part number listing When the word assembly is found in the part number listing there will be a corresponding item number on the illustrations followed by a bracket and a listing of the contents of the assembly BRACKETS A bracket is used when an assembly or kit is spared but is not shown in the illustration The item number of the assembly or kit precedes the bracket the item numbers of the piece parts follow the bracket Tag The notation W Tag in the parts description indicates that the part configuration has been updated Check the Change Tag Index in the General Information section of the Service Data for the name and purpose of the modification In some cases part or assembly be spared in two versions with the Tag and without the Tag In those cases use whiche
45. for an open If no open exists replace the PCU PWB If the problem still exists replace the T2 Feed Solenoid Measure between CN109 9 and ground Make one print while monitoring the meter The meter swings from 24 VDC to 0 and back to 24 Y N Go to BSD T2 7 4 in Section 7 and troubleshoot the T2 Drive Clutch signal CN109 9 for an open If no open exists replace the PCU PWB If the problem still exists replace the T2 Drive Clutch Check for a mechanical problem with the Feed Clutch and Drive Clutch 2 99 2 5 E3 BYPASS JAM RAP Paper fed from the Bypass Tray did not reach the Registration Sensor INITIAL ACTION Carefully inspect the bypass opening for paper Switch the power off wait 10 seconds and switch the power on Run another print and recheck for the fault PROCEDURE If paper does not feed from the Bypass but does feed from Tray 1 check for an obstruction in the bypass slot Check to ensure that the switch is installed correctly and has not fallen out If no paper is loaded in the Bypass when the E3 occurs refer to BSD 7 5 in Section 7 and check the Bypass Switch signal CN312 2 for a short to ground If no short exists replace the PCU PWB If the problem still exists replace the Bypass Switch STATUS INDICATOR RAPs 2 4 INPUT JAM RAP Paper was on the Registration Sensor too long INITIAL ACTION Open the printer and check for any obstruction in the register
46. key NOTE 1 Remove the Rear Cover to view the Black Toner Motor gears Enter the MOTOR TEST program then press the On Line 0 key to run the motor Release the On Line 0 key to stop the motor Do not run the Black Toner motor for more than 2 seconds or overtoning will occur GENERAL PROCEDURES NORMAL DIAGNOSTICS CLUTCH TEST This Diagnostic routine is used to test the operation of the clutches and solenoids 1 Enter Normal diagnostics and press the Menu 3 key until CLUTCH TEST is displayed on the Message Display 2 Press the Form Feed 1 key to start the test TEST PRINT This Diagnostic routine is used to print the IOT internal test pattern Other test patterns which can be printed are stored in the ESS 1 Enter Normal diagnostics and press the Menu 3 key until TEST PRINT is displayed on the Message Display 2 Press the Form Feed 1 key to start the 5 Use the Menu 3 key to select the value to be changed Table 1 Use the Next 6 Previous 5 keys to change the setting 6 Press the Media Server 2 key to return to the TEST PRINT display Press Form Feed 1 to make the test print Table 1 3 The following clutches and solenoids will test using ie defaut Values operate 3 During Warm up and printing the Message Display will indicate P H T H is the print coefficient normally 0 or 1 is the temperature normally 164 170 C is the toner concentration
47. 1 Remove the Outer Drive Frame Remove the Pulley Remove the 4 Clutch Covers Remove the E Rings and Screws and then remove the Outer Drive Frame REPAIRS ADJUSTMENTS REP 4 3 4 Figure 2 Remove Developer Drive Belt C Outer Drive Frame Clutch Covers Figure 2 Removing Developer Drive Belt C 5 Figure 3 Remove Developer Drive Belt D Pulley E10 Figure 1 Removing the Outer Drive Frame Figure 3 Removing Developer Drive Belt D 2 99 4 10 DocuPrint C55 C55mp NC60 4 4 INTERLOCK SWITCHES PARTS LIST ON PL 4 5 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following Print Drum Module Color Developer Module Black Developer Module Right Side Cover REP 1 3 Top Cover REP 1 1 f Rear Cover REP 1 2 2 Remove the Drive Motor REP 4 2 D o 3 Remove the Pulley Remove the 4 Clutch Covers o o m then remove the Outer Drive Frame DocuPrint C55 C55mp NC60 Figure 1 Remove the Outer Drive Frame Remove the E Rings and Screws and 4 Figure 2 Remove the Interlock Return Outer Drive Spring Frame 5 Remove the Interlock Switches Clutch Covers Spring Laser Interlock Switch 24 V Interlock Switch E11 Pull ree Figure 2 Removing the Interlock Switches E10 Figure 1 Removing the Outer Drive Frame 2 99 REPAIRS ADJUSTMENTS 4
48. 1 CNI0 6PCUPWB CN1009 13 Color Dev Assy 2 CNI0 2PCUPWB 2 CNi06 10PCUPWB CN100922 Color Dev Assy 3 CNI0 3PCUPWB 3 lt 106 11 Black Developer Bias 4 CNI0 SPCUPWB 4 CNI0e12PCUPWB Destination 5 cNi 0 sPCUPWB 5 CNI0e13PCUPWB CN1001 8 Black Dev Assy 6 CNI0 9PCUPWB 8 CNI0 4PCUPWB 2 99 DocuPrint C55 C55mp NC60 7 25 Black Bias Lead Color Bias Leads Charge Connector Destination Charge Spring Plate Grid Connector Destination Grid Spring Plate Transfer Connector CONNECTOR WIRING HVPS PWB Connectors 1 703 cn7oa Cassette PWB NT Me Power Supply PWB Figure 7 4 Low VoltagePower Supply PWB Cassette PWB Connectors Power Supply PWB Cassette PWB FT701 CN703 Destination Pin Destination interlock switch t 107 15 CN702 2 CNI07H6PCUPWB 3 CNIUTI7PCUPWB 704 201 Pin Destination 7 Destination 1 Photoreceptor Module CN107 13 PCU PWB 2 Photoreceptor Module CN107 14 PCU PWB L3 Photoreceptor Module CN107 5 PCU PWB 707 CN107 6 PWB Pin Destination CN107 7 PCU PWB 1 CN108 1PCUPWB CN107 8 PCU PWB 2 CN108 2 PCU PWB CN107 9 PCU PWB CN107 10 PCU PWB CN107 11 PCU PWB CN107 12 PCU PWB CN202 Destination FT1003 1 Black Toner Mot FT1003 2 Black To
49. 11 Decrease Increase 3 Adjust Color Balance Choose The circle Which Best Matches The Gray Reference abcdef abedef abcdef abedef abcdef abcdef abedef Gray Reference Current Xerox Corporation 1996 ver 1 2 Figure 1 Density and Color Balance Test Pattern 2 99 4 56 ADJ 3 1 1A Color Density C55 C55mp CHECKING THE COLOR DENSITY 1 Press On Line to put the printer in the Off Line mode Press Menu Press Next until SETUP gt is displayed Press Enter 4 When COLOR ADJUST gt is displayed press Enter 5 Analyze the test page and choose the number which represents the Color Density the customer desires Keep mind that this is a 3096 gray Darker is not always better ADJUSTING THE COLOR DENSITY 1 Perform the Color Density Check 2 Press Next until COLOR DENSITY is displayed Press Enter 3 When CHOOSE NUMBER is displayed press Enter 4 Use Next Previous to change the numerical setting 5 Press Enter 6 Confirm the change 7 Analyze the test page and determine if additional adjustment is required 8 Press Next until OK ALL CHANGES is displayed then press Enter 9 Press On Line to return the printer to the On Line mode DocuPrint C55 C55mp ADJ 3 1 1B Black Density C55 C55mp CHECKING THE BLACK DENSITY 1 Press On Line to put the printer in the Off Line mode Press Menu Press Next until SETUP gt is displayed Press E
50. 3 1 6 160K32850 has been replaced check to see that it has a plastic insulating washer at each mounting hole Some of the spare 160K32850 were manufactured without these washers A purge is under way to fix this problem In the meantime contact your Technical Support Organization Check CN104 harness between PCU PWB and IF PWB Replace PCU PWB Replace ESS IF PWB 160K32850 2 99 2 34 OF2 7 Rebooting message never clears When the Rebooting message is displayed the ESS is booting and waiting for a ready message from the IOT rebooting message usually lasts for approximately 1minute and is followed by the Initializing message PROCEDURE Switch the power off wait 10 seconds and Switch the power on and recheck for the fault 1 Switch the power off and unplug the ESS by sliding it out about 6 inches 2 Run the IOT Test Print a Hold Menu 3 and Enter 7 and switch the power on b User Menu 3 to scroll to Test Print Press Form Feed 1 4 f you cannot enter diagnostics or the test print does not run replace the PCU PWB 5 f the Test Print is produced replace the ESS PWB DocuPrint C55 C55mp NC60 TRAY 1 PAPER SIZE SENSING RAP This RAP is used to troubleshoot the paper size sensing for Tray 1 Use this RAP when the paper size that is loaded is not the same size that is being sensed INITIAL ACTION Remove Tray 1 and check the movable length stop Make sure the
51. 3 19 Test Pattern 3 19 Density and Color Balance Test Pattern 3 21 Diagnostic Test Pattern C55 C55mp 3 22 Diagnostic Sheet NC60 3 24 100 Stripe Test Pattern 3 26 Step Test Pattern 3 27 35 3 28 Blank Print uie 3 29 IOT GENERATED TEST PATTERNS 3 30 6 220 3 31 IMAGE QUALITY SECTION CONTENTS IQ1 IMAGE QUALITY DEFECT ENTRY RAP PROCEDURE CAUTION The drum can become lightshocked if exposed to external light sources for three minutes or longer The result is poor print quality performance usually appearing as dark streaks This can be corrected in most cases by dark resting the drum with the machine in Standby and all covers properly installed Do not allow the drum to be exposed to external light sources 1 Select the SERVICE Menu and print the PQ Set test patterns These test patterns are generated in the ESS Print the IOT Test Pattern Inspect the test prints for image quality defects IMAGE QUALITY RAPs IQ1 NOTE f a defect is present both prints the defect is probably IOT related If the defect is not present on both prints the defect is probably ESS related careful with this assumption however since the IOT test pattern may mask some defects NOTE Look carefully at the basic colors
52. 4 47 REP 10 2 TRANSFER DISCHARGE POWER SUPPLY PARTS LIST ON PL 10 4 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Figure 1 Disconnect the connector remove the screws and remove the Transfer Discharge Power Supply Transfer Discharge Power Supply A39 Figure 1 Removing the Transfer Discharge Power Supply REPAIRS ADJUSTMENTS REP 10 1 10 2 REP 10 3 TRANSPARENCY SENSOR PARTS LIST ON PL 10 4 HARNESS REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Figure 1 Remove six screws 3 Carefully pry the Transfer Drum Frame away the lower frame and remove the Transfer Drum Lower Frame Transfer Drum Transfer Drum Lower Frame A33 Figure 1 Removing the Transfer Drum Lower Frame REPAIRS ADJUSTMENTS REP 10 3 4 Figure 2 Disconnect the connector and remove the Transparency Sensor Transparency Sensor D24 Figure 2 Removing the Transparency Sensor 2 99 4 48 REPLACEMENT NOTE Figure 3 When Reinstalling the Transfer Drum Lower Frame rotate the Transfer Drum Flange until the V Shaped cutouts on the Transfer Drum Flanges are inserted in the V of the Lower Transfer Frame The Transfer Drum Flanges do NOT rotate When the Lower Frame is installed properly the drum gear can be rotated in either direction and the nip adjustment
53. 4 7E48500 8 2 809E2080 8 2 6 61530 8 2 7 48510 8 2 809 2090 4 5 6 61550 9 3 7 48520 8 3 809 2100 9 3 6 61560 5 1 7 48530 8 2 809 2110 45 6 61570 5 1 7 48540 4 6 809 2120 8 3 6 61580 5 1 7 48570 8 3 809 2140 8 2 6 61590 5 1 7 48580 9 4 809 2150 8 3 6 61600 6 2 7 48590 9 4 809 2170 4 1 6E61610 6 2 7E48600 9 4 809E2180 9 4 6E61620 12 1 7E51200 2 1 809E2190 9 4 6E61630 10 4 7E51210 2 1 809E2200 9 4 6E61640 5 1 7E51250 27 1 809E2210 9 4 6E61650 5 1 7E51260 27 2 809E2240 12 1 6E61680 27 1 7E63600 9 2 809E5600 6 3 733W3642 3 2 7E63600 10 3 809E5610 6 3 733W3647 3 2 802E6940 1 1 809E5620 7 1 733W3660 3 2A 802E6950 1 1 809E5640 8 1 733W3675 32A 80935800 27 1 809E5660 2 1 733W6865 3 2 809E1670 6 2 809E5670 2 1 PARTS LIST SECTION 2 99 PART NUMBER INDEX 5 40 DocuPrint C55 C55mp NC60 TITLE PAGE IOT DIAGNOSTICS ENTERING THE NORMAL DIAGNOSTIC MODE 6 3 EXITING FROM THE DIAGNOSTIC MODE 6 3 NORMAL DIAGNOSTICS 6 4 SWITCH SCAN 6 4 OPTICAL SYS TEST 6 5 VOL TEST MAIN 6 5 MOTOR TEST 6 5 CLUTCH TEST 6 6 TEST PRINT 6 6 NV RAM INITIAL 6 7 COUNTER SET 6 7 SPECIAL DIAGNOSTICS ENTERING THE
54. 5 809E5600 SPRING 6 8 5750 CAM 7 5E12210 DRIVE DOG K 8 809 5610 SPRING 9 13 13380 BEARING 10 SPARED RETAINING RING 11 SPARED RETAINING RING 12 15 64310 FRAME SIDE PLATE PARTS LIST SECTION 2 99 PL 6 3 5 18 DocuPrint C55 C55mp NC60 PL 7 1 DEVELOPER CONNECTORS BRACKET ITEM Q GQ NN N DD NN ISIS Q N D gt 2 O O O QI GO N O PART NOT SPARED NOT SPARED NOT SPARED NOT SPARED 3E42100 NOT SPARED NOT SPARED 162K29330 116E7360 32E11460 162K35590 17E8360 NOT SPARED 118E13770 NOT SPARED 809E1970 NOT SPARED NOT SPARED NOT SPARED NOT SPARED 162K29300 809E5620 NOT SPARED NOT SPARED 32E11470 116E7350 15E64350 NOT SPARED DESCRIPTION FAN SCREW M3X30 SCREW M3X6 PLATE TONER HINGE K SCREW M3X8 SCREW M3X10 HARNESS GROUND CLIP CONNECTOR BRACKET HARNESS STOPPER NYLON RIVET PROTECTOR SHEET SCREW M3X8 SPRING K RIVET SUPPORT PLATE HARNESS GUIDE SCREW HARNESS SLIDE SPRING SCREW M3X6 SCREW M3X10 HARNESS PLATE GROUND CLIP SUPPORT PLATE SCREW M4X6 2 99 PARTS LIST SECTION DocuPrint C55 C55mp NC60 5 19 PL 7 1 PL 7 2 PRINT DRUM CONNECTORS BRACKETS PARTS LIST SECTION PL 7 2 ITEM O Q GQ N N oL n 2 2 o O O Q Q N O m mI On PART 12E8410 NOT SPARED NOT SPAR
55. Allow the Printer to try to tone up to recheck for the fault PROCEDURE Enter IOT normal diagnostics Scroll to the MOTOR TEST program and Press Form Feed 1 to switch on the motors while observing the Color Toner Motor The Color Toner Motor is rotating normally A STATUS INDICATOR RAPs J2 A Y N Refer to BSD 9 11 in Section 7 and troubleshoot the Color Toner Motor lines CN116 1 2 for an open or a short to ground If no wiring problem exists replace the PCU PWB f the problem still exists replace the Color Toner Motor Exit from diagnostics Set up the meter to read 24 VDC Measure between CN115 14 and ground Switch the power off wait 10 seconds and switch the power on while monitoring the meter The meter swings from 24 VDC to 0 Y N Go to BSD 9 10 in Section 7 and trouble shoot the Magenta Toner Solenoid signal and 24 VDC Interlocked 115 14 13 for an open If no open exists replace the PCU PWB If the problem still exists replace the Magenta Toner Solenoid Check the Magenta Dispense Shaft to see if it rotates when the Solenoid energizes If not look for a mechanical problem gears etc Check the ground to the Magenta Toner Concentration Sensor CN118 5 to CN1009 21 BSD 9 10 If the ground is OK replace the PCU PWB 2 99 2 16 DocuPrint C55 C55mp NC60 J3 ADD TONER RAP The cyan toner concentration sensor has detected low cyan toner in the cyan develo
56. C55 C55mp ADJ 3 1 1C Color Balance C55 C55mp CHECK NOTE Do Not make changes in the Density or the Color Balance without first consulting the customer The customer may have altered the balance in the print drivers to achieve specific results with their documents NOTE It is often difficult to detect changes when performing this procedure You may find it helpful to first run the Printer Diagnostic test pattern SERVICE TEST PATTERNS DIAGNOSTICS Once the adjustments have been made run another diagnostics pattern and compare it to the first Expect to see the following Color Density adjustment changes the Cyan Magenta and Yellow Density Rate Setpoints and Developer Bias equally Black Density adjustment changes the Black Density Rate Setpoint and Developer Bias Color Balance adjustment changes the Cyan Magenta and Yellow Density Rate Setpoints and Developer Bias depending on the amount and direction of change REPAIRS ADJUSTMENTS ADJ 3 1 1 Run a print of the Color Balance Test Pattern SERVICE TEST PATTERNS PATTERN TYPE PCL COLOR BALANCE 1 Figure 1 Examine the existing density and color balance with the customer 2 f adjustment is required refer to the appropriate procedure Density And Color Balance Adjusment Test Page 1 Adjust Color Density 30 Halftone CYAN MAGENTA YELLOW i c 2 Adjust Color Density 30 Halftone BLACK GRAYSCALE 7 8 9 Current 10
57. Developer Module Right Side Cover REP 1 3 Top Cover REP 1 1 Rear Cover REP 1 2 the Main Drive Motor Belts REP 4 2 REPAIRS ADJUSTMENTS REP 5 2 3 Figure 1 Remove the Drive Cover Cover Figure 1 Removing the Drive Cover 2 99 4 18 E2 4 Figure 2 Remove the Tension springs Tension Springs 4 Figure 2 Removing Springs DocuPrint C55 C55mp NC60 5 Figure 3 Remove the 3 pins and the Block Figure 3 Removing the Pins and Block DocuPrint C55 C55mp NC60 6 Figure 4 Remove the Inner Drive Frame Inner Drive Frame E5 Figure 4 Removing the Inner Drive Frame 2 99 4 19 Figure 5 Remove the Outer Drive Frame a Remove the Pulley b Remove the Clutch Covers c Remove the Outer Drive Frame Outer Drive Frame Clutch Covers oA a 2 Ec 4 yj uma Pulley E Figure 5 Removing the Outer Drive Frame REPAIRS ADJUSTMENTS REP 5 2 8 Figure 6 Remove the Magnetic Roller Clutch Roller BN E13 Figure 6 Removing the Magnetic Roller Clutch REPAIRS ADJUSTMENTS 2 99 REP 5 2 4 20 DocuPrint C55 C55mp NC60 REP 6 1 DRUM TERMINALS PARTS LIST ON PL 6 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Figure 1 Remove the following a b Print Drum Module Color Developer Module Black Develop
58. F1 DISK ERROR FLOPPY RAP The Floppy Disk cannot be read INITIAL ACTION Note The Floppy Disk must be a DOS format Load a different floppy and try to read it If the floppy still cannot be read check the following for a good connection CN102 between the Floppy drive and the ESS BSD 13 in Section 7 e CN103 the flat cable between the Floppy drive and the ESS BSD 13 in Section 7 If the problem still exists replace the Floppy Drive before replacing the ESS PWB STATUS INDICATOR RAPs F1 F2 F3 F2 DISK I O ERROR FLOPPY RAP The Floppy Disk cannot be read INITIAL ACTION Note The Floppy Disk must be a DOS format Load a different floppy and try to read it If the floppy still cannot be read check the following for a good connection e CN102 between the Floppy drive and the ESS BSD 13 in Section 7 e CN103 the flat cable between the Floppy drive and the ESS BSD 13 in Section 7 If the problem still exists replace the Floppy Drive before replacing the ESS PWB 2 99 2 12 F3 ACTION FAILED FLOPPY RAP The Floppy Disk cannot be accessed INITIAL ACTION Note The Floppy Disk must be a DOS format Load a different floppy and try to read it If the floppy still cannot be read check the following for a good connection CN102 between the Floppy drive and the ESS BSD 13 in Section 7 e CN103 the flat cable between the Floppy drive and the ESS BSD 13 in Section 7 If the proble
59. GP 3 2B CONTROL PATCH C55 C55mp ADJUSTMENT USING SERVICE MENU ESS FIRMWARE V3 5 2 AND UP 1 Press On Line to enter the Off Line mode then press Menu 2 Press Next until SERVICE is displayed then press Enter 3 Press Next until ADJUSTMENTS is displayed then press Enter 4 Press Next until PATCH CONTROL is displayed then press Enter 5 Switch the PATCH CONTROL ON or OFF GP 3 2C CONTROL PATCH NC60 ADJUSTMENT USING SERVICE MENU 1 Press Menu Up until Service is displayed 2 Press Down until patch Control is displayed 3 Press Value Up until the Patch control is ON or OFF then press Enter REPAIRS ADJUSTMENTS GP 3 2 GP 3 3 TRANSPARENCY MODE PURPOSE The purpose of this procedure is to optimize the Transfer Bias for transparencies This procedure has been designed to address the following problems e Mistacking on the Transfer Drum E6 E4 Jams e Transfer Breakdown very high frequency small diameter deletions e Fuser oil fingers offset 2 5 mm wide x 5 50 mm long brighter areas on the transparency that resemble human fingers when projected Refer to GP 3 3A for the C55 C55mp Adjustment Refer to GP 3 3B for the NC60 Adjustment REPAIRS ADJUSTMENTS GP 3 3 3 3A TRANSPARENCY MODE C55 C55mp ADJUSTMENT 1 Press On Line to enter the Off Line mode then press Menu 2 Press Next until MEDIA is displayed then press Enter 3 Press Next until TRANSPARENC
60. If the display indicates any version other than 66 exit from diagnostics do not perform the adjustment 3 With PCU DIAG MODE 66 displayed press On Line then Enter Release both keys at the same time 4 The message display will indicate PCU DIAG SPECIAL 5 With PCU DIAG SPECIAL displayed press Medial Server then Previous Release both keys at the same time 6 The message display will indicate DIAG BACK GROUND REPAIRS ADJUSTMENTS GP 3 1 10 11 12 Press Menu to scroll to CONTROL K DVBIAS Use Next Previous to scroll to CONTROL FS MOTOR Press Enter The display will indicate FS MOTOR 3729 Use Next Previous to change the Fuser Motor speed to 3729 To store the change actuate and hold the Bypass switch insert a piece of paper in the bypass slot then press the Form Feed key The ON Line LED will switch on and then off when the change is stored Exit from diagnostics by switching the printer off Wait 10 seconds then switch the printer on 2 99 6 44 DocuPrint C55 C55mp GP 3 2 CONTROL PATCH MD PURPOSE NOTE This adjustment only applies to IOT Firmware version 75 and above C55 C55mp ESS Firmware version 3 5 2 and up and NC60 firmware includes this adjustment in the Service menu Refer to GP 3 2A for firmware version 75 Refer to GP 3 2B for the C55 C55mp ESS version 3 5 2 and above adjustment Refer to GP 3 2C for the NC60 adjustment The purpose of this adjustme
61. NOTES 6 74 DocuPrint 55 55 CHANGE TAG INDEX NC60 INTRODUCTION Modifications to the printer are identified by a tag number which is recorded on a tag matrix card There are two tag matrix cards One is inside the ESS PWB cover and indicates the Systems Configuration The second card the TAG Matrix is attached to the printer frame on the inside of the left rear side viewed from the printer front CLASSIFICATION CODES A tag number may be required to identify differences between parts that cannot be interchanged differences in diagnostic repair installation or adjustment procedures A tag number may also re required to identify the presence of optional hardware special non volatile memory programming or whether mandatory modifications have been installed Each tag number is given a classification code to identify the type of change that the tag has made The classification codes and their descriptions are listed in the table below Classification Description Code N Tag not installed in the field Repair Tag DocuPrint NC60 2 99 6 75 GENERAL PROCEDURES Tags NOTES GENERAL PROCEDURES 2 99 NOTES 6 76 DocuPrint NC60 7 WIRING DATA TITLE PAGE TITLE PAGE Chain 1 BSD Standby Power 7 2 PCU PWB Connectors 7 22 Chain 2 BSD Mode Selection 7 3 Connector PWB Connectors 7 24 Chain 3 BSD Run Control
62. PROCEDURES GP 3 5 GP 9 1 CHARGE SCOROTRON CURRENT CHECK PURPOSE The purpose of this check is to ensure that the Charge Scorotron current is within specifications WARNING Switch the Main Power off PROCEDURE 1 Figure 1 Disconnect the charge wire center large red from the right side of the printer Set up the multimeter to read 700 pA Figure 1 Connect the meter between the wire removed in step 1 and the charge terminal on the right frame 4 Enter Normal Diagnostics Menu 3 Enter 7 Power ON 5 Use Menu 3 to scroll to VOL TEST MAIN CH Caution Check to ensure that the red meter lead is not contacting the frame 6 Press Form Feed 1 to switch on the High Voltage Power Supply 7 The current should be 700 50 20 UA 8 Press Media Server 2 to switch the Power Supply off NOTE Do not keep the power supply on any longer than necessary The constant charge can fatigue the print drum GENERAL PROCEDURES GP 9 1 Connecting The Meter K3 Charge Lead 2 99 6 50 Figure 1 Checking the Charge Current DocuPrint C55 C55mp NC60 GP 9 2 CHARGE GRID VOLTAGE CHECK PURPOSE The purpose of this check is to ensure that the Grid Voltage is within specifications Note During normal operation the Grid voltage will be one of three voltages 500 600 700 PROCEDURE 1 Setupthe multimeter to read 700 VDC 2 Figure 1 Connect the meter to the Gr
63. Press Next until OK ALL CHANGES is displayed then press Enter Press On Line to return the printer to the On Line mode 2 99 4 57 REPAIRS ADJUSTMENTS ADJ 3 1 1 ADJ 3 1 2 DENSITY AND COLOR BALANCE NC60 PURPOSE To adjust the Density and Color Balance of the print generated by the ESS This procedure actually consists of three adjustments ADJ 3 1 2A Color Density NC60 ADJ 3 1 2B Black Density NC60 ADJ 3 1 2C Color Balance NC60 CHECK NOTE On the NC60 you must disconnect all input ports from the ESS before performing this adjustment NOTE Do Not make changes in the Density or the Color Balance without first consulting the customer The customer may have altered the balance in the print drivers to achieve specific results with their documents NOTE It is often difficult to see changes in the color balance Changes will show in the values under Density Rate Setpoints and Developer Bias Color Density adjustment changes the Cyan Magenta and Yellow Density Rate Setpoints and Developer Bias equally Black Density adjustment changes the Black Density Rate Setpoint and Developer Bias Color Balance adjustment changes the Cyan Magenta and Yellow Density Rate Setpoints and Developer Bias depending on the amount and direction of change Run a print of the Color Balance Test Pattern Menu Down until Color Adjust then press Item Down 1 Figure 1 Examine the existing density and color bal
64. Processing PCL Fonts This is page one of a two page menu and lists the 45 PCL Fonts which are resident on the ESS This may vary somewhat from printer to printer XEROX Internal Fonts Font Font ID 0 1 2 3 4 5 6 7 8 9 22 DocuPrint NC60 PCL Compatible Resident Font List Font Name Courier Courier CG Times CG times CG Times Bd CG times Bd Times It CG times Bd CG Times Bdlt CG times CG Omega CG Omega It CG Omega It CG Omega Balt CG Omega _ Balt Cornet Cornet Clarendon DcBd Courier Univers Medium Univers Md Univers Univers Univers Univers Univers Univers Univers CdMd Univers Univers CdBd Univers Univers Univers Univers CdBalt Univers AntiqOlive AntiqOlive AntiqOlive Bd AntiqOlive AntiqOlive lt AntiqOlive It Garamond Antiqua Garamond Antiqua Symbol set Print Sample Xerox DocuPrint NC60 to work with lt I lt gt 50 h0s0b4096T Xerox DocuPrint NC60 More to work with esc L lt 5 gt 50 10 064096 Xerox DocuPrint NC60 More to work with lt esc gt ___l lt esc gt sOp hOsOb4096T Xerox DocuPrint NC60 More to w
65. RED 4 9 8 BLACK TONER CONTROL PCU CASSETTE BLACK TONER PWB PWB MOTOR PL42 PL 13 1 5 07 CN201 CN202 FT1003 TONER MOTOR CLOCK A DES PCU PWB d TONERMOTORCLOCKB 1 gt BLACK 6 MAGNETIC lt gt THE BLACK TONER SENSE SIGNAL MEASURES THE TONER CONCENTRATION THE BLACK DEVELOPER CLUTCH HOUSING THE BLACK DEVELOPER LINK IS USED TO DETECT WHEN A NEW BLACK DEVELOPER MODULE IS INSTALLED IT MELTS OPEN AND STARTS THE BLACK DEVELOPER COUNT gt THE PCU PWB CHANGES THE DEVELOPER BIAS IN ORDER TO CHANGE THE IMAGE DENSITY IT USES INPUT FROM THE GAMMA SENSOR TO DETERMINE THE CHANGE REQUIRED J4 THE BLACK TONER MOTOR IS CONTROLLED BY THE BLACK SENSE SIGNAL IT DETERMINES J6 7 WHEN TO RUN THE TONER MOTOR THE CLOCK A AND CLOCK B SIGNALS ARE APPROXIMATELY 12 VDC WHEN MEASURED TO GROUND XEROGRAPHICS THE CLOCK A AND CLOCK B SIGNALS ARE APPROXIMATELY 22 VAC WHEN MEASURED ACROSS A amp B CHAIN 9 LEVEL 2 SHEET 4 10 BSDs 2 99 Chain 9 Xerographics 7 12 DocuPrint C55 C55mp NC60 CYAN MAGNETIC COLOR DEVELOPER CLUTCH ASSEMBLY RED MAGENTA MAGNETIC CLUTCH PL 5 1 4 VDC INTER MAGENTA MAG YELLOW MAG CLUTCH RED MAGENTA MAG CLUTCH CYAN MAG YELLOW MAGNETIC CLUTCH CLUTCH Yellow Magnetic 2 Roller RED WHEN ONE OF THE COLOR MAGNETIC CLUTCHES IS ENERGIZED THE APPROPRIATE MAGNETIC ROLL ROTATES AND DEVELOPS THE SELECTED COLOR 7 THE BIAS VOLTAGE SUPPLIED TO THE CYAN MAGENTA AND YELLOW MAGNETIC RO
66. Row 01 Press Form Feed 1 Remove the cassette and actuate and deactuate the Tray Empty Sensor while observing the Black LED A STATUS INDICATOR RAPs E1 A The Black LED switches on and off Y Go to BSD 7 1 in Section 7 and trouble shoot the Tray Empty Sensor signal CN102 6 for a short to ground If no short exists replace the PCU PWB If the problem still exists replace the Tray Empty Sensor Exit from the SWITCH SCAN program Close the Printer Remove the paper cassette Scroll to the MOTOR TEST program Press Form Feed 1 to switch on the motors while observing the Paper Feed Motor The Paper Feed Motor is rotating normally Y N Go to BSD 7 3 in Section 7 and trouble shoot the 24 VDC Interlocked 111 5 and Paper Feed Motor for an open If the motor was noisy check the clock lines If the lines are OK replace the PCU PWB If the problem still exists replace the Paper Feed Motor Exit from diagnostics Set up the meter to read 24 VDC Measure between CN101 5 and ground Make one print while monitoring the meter The meter swings from 24 VDC to 0 Y N Go to BSD 7 4 in Section 7 and trouble shoot the Feed Solenoid signal and 24 VDC _ Interlocked CN101 5 3 for an open 2 99 2 4 If no open exists replace the PCU PWB If the problem still exists replace the Paper Feed Solenoid Check for a mechanical problem with the feed clutch DocuPrin
67. SCREW M3X6 SCREW TENSION ARM TENSION PULLEY RETAINING RING 4MM SPRING SPRING TENSION ARM TENSION PULLEY PARTS LIST SECTION PL 4 1 PL 4 2 PCU HVPS Q o0 i i PARTS LIST SECTION PART NOT SPARED NOT SPARED NOT SPARED NOT SPARED 160K50080 180K60120 NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED 105K16410 DESCRIPTION CABLE CLAMP RIGHT SIDE FRAME CABLE CLAMP CABLE CLAMP PCU BOARD C55 PCU BOARD NC60 SCREW SCREW M3X8 STANDOFF PLATE STANDOFF HVPS DocuPrint C55 C55mp NC60 PL 4 3 COLOR MOTOR DEVELOPER MOTOR DocuPrint C55 C55mp NC60 2 99 5 11 ITEM Q ON 11 12 13 PART NOT SPARED NOT SPARED NOT SPARED NOT SPARED 127E10890 NOT SPARED 20E28760 162K35600 127E10900 7 48420 SPARED SPARED SPARED DESCRIPTION DRIVES FRAME SCREW 6 SCREW 4 8 SCREW 4 6 DEVELOPER MOTOR REP 4 6 RETAINING RING DEVELOPER PULLEY HARNESS COLOR TONER MOTOR REP 4 5 GEAR RETAINING RING CABLE TIE RIGHT SIDE FRAME PARTS LIST SECTION PL 4 3 PL 4 4 MAIN DRIVE COMPONENTS PARTS LIST SECTION PL 4 4 2 99 5 12 ITEM Q O 11 12 13 14 15 16 PART NOT SPARED NOT SPARED 20E28780 23E14940 29E25280 6E61520 NOT SPARED 13E13390 13E13350 15
68. SETPOINTSs BLACK TC KKK 10 IMAGES SHOW SETPOINTS CYAN TC 220 IMAGES TO 30 IMAGES 2 lt 40 IMAGES gt SHOW SETPOINTS MAGENTA lt 50 IMAGES gt lt MAGENTA TC gt MMM lt 60 IMAGES SHOW SETPOINTS YELLOW TC 70 IMAGES YELLOW TC YYY 80 IMAGES 2 90 IMAGES gt SHOW SETPOINTS 100 IMAGES EXIT THIS MENU gt ADJUSTMENTS PATCH CONTROL SERVICE DISK SERVICES FORMAT DISK PATCH CONTROL ON lt DISK SERVICES gt FORMAT DISK ARE YOU SURE lt OFF gt YES lt EXIT THIS MENU gt DISK SERVICES SERVICE RESET CRU RESET K DEV lt EXIT THIS MENU gt lt RESET CRU gt lt RESET K DEV gt pis SERVICE EXIT THIS MENU RESET CRU RESET CMY DEV RESET CMY DEV gt lt YES gt lt NO gt RESET CRU RESET PRINTDRU lt RESET PRINTDRU gt lt YES gt lt NO gt RESET CRU RESET FUSER lt RESET FUSER gt lt YES gt lt NO gt RESET CRU EXIT THIS MENU gt 2 99 GENERAL PROCEDURES DocuPrint 55 55 6 17 SERVICE Notes GENERAL PROCEDURES 2 99 NOTES 6 18 DocuPrint C55 C55mp NC60 MENUS NC60 ONLY PROCEDURE NOTE Before entering the NC60 Menus ensure that the printer has completed the initialization cycle and the On Line LED is on Press the MENU UP or MENU DOWN key You are now in the menus Navigating through the Menus Menu up or Menu Down Scrolls through the Menus Item Up or Item Down Enters the Menu display and scrolls through the sub
69. SIMM 160K40560 PCL PS FONT SIMM 4 733W3660 4MB MEMORY SIMM 733W3647 8MB MEMORY SIMM 733W3642 16 MEMORY SIMM 733W3675 32MB MEMORY SIMM 5 146 560 HARD DISK DRIVE 6 121 15660 MEDIA SERVER 7 162028010 DATA HARNESS 8 162027990 DC POWER HARNESS 9 162028000 DATA HARNESS 10 117 18150 PARALLEL CABLE 2 99 PARTS LIST SECTION DocuPrint C55 C55mp 5 7 PL 3 2 PL 3 2 NC60 ESS COMPONENTS ITEM PART DESCRIPTION 1 160K44790 TOKEN RING CARD OPTIONAL 160K54960 ETHERNET CARD 100 MB OPTIONAL 2 733W6865 8MB MEMORY SIMM 733W6866 16MB MEMORY SIMM 733W6867 32MB MEMORY SIMM 3 121K25380 HARD DISK DRIVE 4 121K15660 MEDIA SERVER 5 162K28010 DATA HARNESS 6 162K27990 DC POWER HARNESS 7 162K28000 DATA HARNESS PARTS LIST SECTION 2 99 PL 3 2B 5 8 DocuPrint NC60 PL 4 1 MAIN DRIVES DocuPrint C55 C55mp NC60 ITEM O O ae 11 12 13 14 15 16 17 18 19 20 21 22 23 2 99 5 9 12 8440 809 1700 SPARED 12 8430 SPARED SPARED 127 10950 NOT SPARED 127E10940 NA 49E84410 NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED 22 21890 SPARED 809 2170 SPARED 31 8800 22 21880 DESCRIPTION LOWER LINK LOWER LINK SPRING RETAINING RING 7MM UPPER LINK BRACKET RIGHT SIDE FRAME PAPER FEED MOTOR SCREW M3X8 MAIN DRIVE MOTOR REP 4 1 MAIN DRIVE BRACKET CABLE CLAMP SCREW M3X6
70. SPECIAL DIAGNOSTIC 6 8 EXITING FROM THE SPECIAL DIAGNOSTIC 6 8 COUNTER 6 8 TONER LEVEL 6 8 ID LEVEL 6 9 TIMEOUT SET 6 9 PANEL KEY TEST 6 9 COUNTER LIMIT 6 10 BACKGROUND DIAGNOSTICS ENTERING THE BACKGROUND DIAGNOSTIC 6 11 EXITING FROM THE BACKGROUND DIAGNOSTIC 6 11 6 11 CONTROL 6 12 HEATER TEST 6 13 TC BIAS 6 14 TS LIFE Se eee ees 6 14 DocuPrint C55 C55mp NC60 TITLE PAGE OFF LINE MENUS C55 C55mp 6 15 MENUS 601 6 19 ESS TEST PATTERNS AND INFORMATION PAGES STARTUP 55 55 6 20 STARTUP NC60 6 21 SETTINGS 55 55 6 22 CONFIGURATION NC60 6 23 DIAGNOSTIC SHEET C55 C55mp 6 24 DIAGNOSTIC SHEET NC60 6 25 PCL FONT 55 55 6 26 PCL FONT NC60 Y 6 27 PS FONT 55 55 6 28 PS FONT NC60
71. SRDY Status Ready for open If all appear OK replace the Control Panel PWB If the problem still exists replace the PCU PWB DocuPrint C55 C55mp NC60 OF2 3 The message display is flickering off and on or displaying random characters PROCEDURE Refer to BSD 2 1 and check the following signals e f the Message is flickering off and on check CN103 27 DATA 1 for an open e f the Message is illegible and the LED is on all the time check CN103 25 DATA 3 for a short to ground e f the Message is illegible and the M LED is on all the time check CN103 27 DATA 1 for a short to ground e f the Message is illegible and the Y LED is on all the time check CN103 28 DATA 0 for a short to ground If all appear OK replace the Control Panel PWB If the problem still exists replace the PCU PWB DocuPrint C55 C55mp NC60 OF2 4 Message display works OK LEDs do not work correctly PROCEDURE If the On Line LED never comes on refer to BSD 6 and check the following CN104 6 CRDY Command Ready for an open e 104 2 CMD Command for an open or a short If the LEDs are flickering off and on refer to BSD 2 1 and check the following e CN103 21 LED Enable for a short to ground If the LEDs are off refer to BSD 2 1 and check the following e CN103 21 LED Enable for an open If all appear OK replace the Control Panel PWB If the problem still exists replace the PCU PWB
72. STATUS MAE place dis ARE CONDUCTED PROCESS CONTROL SETUP MESSAGE DISPLAY SIMM 1 THROUGH SIMM 4 TEST IF THE ESS FAILS TO COMMUNICATE XIE RAM TEST WITH THE MESSAGE DISPLAY A U3 OPTIONAL NIC CARD SLOT TEST STATUS CODE IS DISPLAYED 10MB ETHERNET TEST INTERNAL NIC OPTION FLASH ROM TEST FLOPPY TEST DP TEK TEST MEMORY TEST ESS READY 5 ESS PWB AD C55 C55mp LITES WHEN THERE IS 5 VDC AVAILABLE ON THE ESS LITES WHEN THE ESS PASSES SELF TEST VPS ALL LEDS LIGHT WHEN THE ESS FAILS SELF TEST Status amm 6 Codes P lt 00 PCU ROM check sum failure NC60 01 fail THE POWER LED LITES WHEN THERE IS 5 VDC AVAILABLE ON THE ESS HEC Sum THE FAIL LED LITES IF THE ESS FAILS SELF TEST 2 NVM RAM check sum failure U3 Communication failure 7 PCU PWB RUN CONTROL CHAIN 3 LEVEL 2 SHEET 1 OF 1 BSDs 2 99 Chain 3 Run Control 7 4 DocuPrint 55 55 601 55 CONNECTOR PWB PL 3 2 ESS PWB PL 3 2 TIF TIF Daughter Daughter PWB PWB C55 C55mp C55 C55mp Compression ane Raster Processing P R L L E L P R T NC60 C55 C55mp Options Serial Local Talk PWB Ethernet PWB Token Ring PWB NC60 Options Serial included 10 MB Ethernet included Token Ring PWB 100 MB Ethernet PWB optional OPTIONAL PWB PCU PWB PL 4 2 LASER INTERLOC
73. TIPS The following are some general trouble shooting tips and hints which will help you locate components and test points 1 The procedures for entering exiting and using the C55 C55mp NC60 diagnostic programs can be found in Section 6 General Procedures Refer to the Table of Contents found on page 6 1 for the specific program 2 Figure 2 1 on the right is also located in Section 6 and shows the location of the input electrical components in the printer It is especially helpful when using the Switch Scan program Refer to this figure if you are unsure of input component location The BSDs in Section 7 may also prove helpful when locating the various electrical components 3 The Connectors can be located Section 7 Refer to Section 7 Table of contents on page 7 1 The table below shows the location of the most common connectors Numbers STATUS INDICATOR RAPs TROUBLESHOOTING TIPS OIL SENSOR EXIT SENSOR GAMMA SENSOR TRANSPARENCY JAM SENSOR 424 V CLEANER JAM cH SWITCH TRANSPARENCY SENSOR TRANSFER DRUM HOME SENSOR REGISTRATION SENSOR BYPASS SWITCH WASTE TONER BOTTLE SENSOR PS0 PS1 PS2 PS3 PS4 TR Y EMPTY TEMPERATURE SENSOR HUMIDITY SENSOR T2TRAYEMPTY 12 12 2 SENSOR S0 81 52 53 54 Figure 2 1 Input Component Location 2 99 2 2 DocuPrint C55 C55mp NC60 1 1 Cassette 1 is not in the
74. The Yellow toner is low The Magenta toner is low XEHGGHAPHIES EA The color developer is misinstalled or is overtoned CHAIN 9 LEVEL 2 SHEET 6 OF 10 BSDs Chain 9 Xerographics DocuPrint C55 C55mp NC60 9 12 TRANSFER TRANSFER DRUM PLETRI TRANSFER DC POWER TRANSFER DISCHARGE CONNECTOR NEUTRALIZATION PWB POWER SUPPLY TRANSFER DISCHARGE NEUTRALIZATION COROTRON 9 13 TRANSFER DRUM POSITIONING TRANSFER DRUM CONN HOME POSITION PWB SENSOR PL 10 4 PL94 CN1001 CN313 AM TR 4 45 VDC TRANSFER DRUM HOME CN315 H 5VDC CN103 TRANSFER DRUM CLEANING CLEANING BRUSH PCU PWB TRANSFER DRUM HOME POSITION TRANSFER DRUM SENSOR CLEANING SOLENOID 9 14 TRANSFER CLEANING CONTROL TRANSFER PCU CONN DRUM CLEANING PWB PWB SOLENOID PL 4 2 PL 10 4 PL 9 1 THE TRANSFER DRUM IS GEAR DRIVEN BY THE PRINT TRANSFER CLEANIN CN103 CN315 CN316 SFER DRUM VIA THE MAIN DRIVE MOTOR BSD 9 3 ON L 24 a n i 2 DRIVE FOR THE TRANSFER DRUM CLEANING SYSTEM 1 5 IS PROVIDED BY THE FUSER MOTOR BSD 10 1 24 VDC INTERLOCKED DISCHARGE TRANSFER PCU CONN POWER DISCHARGE Transfer Drum Main Drive Motor did not rotate PWB TD POWER Supp SUPPLY NEUTRALIZATION PL 4 2 CN103 gaor PL104 CN317 ON 1 5 VDC PL 10 4 E 1 24 INTERLOCKED 1 COROTRON XEROGRAPHICS CHAIN 9 LEVEL 2 SHEET 7 OF 10 2 99 BSDs DocuPrint C55 C55mp NC60 7 15 Chain
75. Version 66 replace the PCU PWB All Printers switch the power off wait 10 seconds and switch the power on Recheck for the fault PROCEDURE Remove the Printer Rear Cover There is a hole located at the left rear of the printer This hole is used to view the gears for the Toner motor NOTE the following steps we will be operating the Black Toner Motor Do not allow the motor to run for over 2 seconds or overtoning can result A STATUS INDICATOR RAPs J4 A Enter normal diagnostics Scroll to the MOTOR TEST program and press Form Feed 1 to switch on the motors Look through the hole and switch on the Black Toner Motor by pressing On Line 0 Release On Line 0 to stop the motor Press Media Server 2 to stop the test The Motor Runs Y N Set up the meter to read 24 VDC Measure between CN107 13 and ground Press Form Feed 1 to switch on the motors Press On Line 0 to switch on the Black Toner Motor Release On Line 0 to stop the motor Press Media Server 2 to stop the test The meter reads approximately 12 VDC when On Line 0 was pressed Y N Go to BSD 9 8 in Section 7 and troubleshoot the Black Toner Motor lines CN107 13 14 for an open If the lines are OK replace the Black Toner Motor Check the Black toner box for auger binding Check the ground to the Black Toner Concentration Sensor CN107 2 to CN1001 4 BSD 9 7 If the ground is OK replace the PCU PWB To
76. Xerox products mentioned in this publication are registered trademarks of the Xerox Corporation CLASS 1 LASER PRODUCTS This product is certified as a Class 1 Laser product and complies with DHHS Laser Radiation Standards 21 CFR Chapter 1 Sub chapter J WARNING Use of controls adjustments or perform ances of procedures other than those specified in this manual may result in hazardous radiation exposures The C55 C55mp NC60 each contain invisible laser There is no visual indication that the laser beam is present During servicing the C55 C55mp NC60 remain a Class 1 product because of the interlock system Do not attempt to cheat the interlock switches on this printer Product DocuPrint C55 C55mp NC60 Title Part Number Date Service Manual 701P14760 February 1999 5 TABLE CONTENTS TITLE PAGE INTRODUCTION About This Manual i Organization i How to use This Manual iii Reference Symbology iii SERVICE CALL PROCEDURES Contents 1 1 STATUS INDICATOR RAPS Contents 2 1 IMAGE QUALITY RAPS Contents 3 1 REPAIR ADJUSTMENT PROCEDURES Contents 4 1 PARTS LIST SECTION Contents
77. a short to ground CN1 18 9 e Magenta Toner 5 VDC for an open CN118 2 DocuPrint C55 C55mp NC60 A Yellow Toner Sense signal for an open or a short to ground CN118 8 e Yellow Toner 5 VDC for an open CN118 1 If all of the above check OK replace the Color Developer Cartridge If the problem still exists replace the PCU PWB 2 99 2 19 J6 REPLACE BLACK DEVELOPER CARTRIDGE RAP NOTE This code is normally preceded by a W2 code The Black Developer Cartridge is at end of life INITIAL ACTION Check the Black Developer Cartridge life C55 C55mp Press On Line then press Menu use Next to scroll to the MAINTENANCE menu press Enter Use Next to scroll to BLACK DEV CART press Enter NC60 Press Menu Up until Service Down until CRU Usage Press Value Up to scroll to the Black Dev Cart Check the remaining on the Black Developer Cartridge If the cartridge is at end of life notify the customer and have them install a new Black Developer Cartridge PROCEDURE If the J6 code does not clear when a new Black Developer Cartridge is install go to BSD 9 7 and check the New Developer Sense signal CN107 3 for an open or short If the J6 code exists even though the Black Cartridge has not reached end of life refer to BSD 9 7 and check the following e Black Toner Sense signal for an open or a short to ground 107 4 e Black Toner 5 VDC for open CN107 1 If all of th
78. any questions please call us Toll Free USA 1 800 TeamXRX Canada 1 800 93XEROX or Visit our Web site at http xerox networkprinters com GENERAL PROCEDURES 2 99 TIPS amp TRICKS 6 36 DocuPrint NC60 Practical Tips for the Xerox DocuPrint NC60 Color Laser Printer Shared Printing Hold Job Hold Job is a wait for me feature that delays printing for a specified period of time so you can load special media or be present when printing starts Press the machine s enter button when the LED is flashing to print your job The amount of delay is set through the machine control panel or client services tools Secure Print Your NC60 printer allows you to defer printing of a job until a matching Password is entered from the Control Panel The user assigns the Password in the Password edit box after selecting Secure Print This feature requires the Hard Disk option be installed on your printer Proof Print When printing multiple sets Proof Printing saves steps You send your document once and the printer processes and prints the first set After you review the document simply release the rest at the printer This feature requires the Hard Disk option be installed on your printer Recommended Media Your DocuPrint NC60 will produce brilliant color images on a wide variety of print media Carefully choosing media for your printer is important in achieving the best images and ensuring trouble free operation Pape Use
79. change the numerical setting 4 Press Enter 5 Analyze the test page and determine if additional adjustment is required 6 Press OnLine REPAIRS ADJUSTMENTS ADJ 3 1 2 2 99 4 58 DocuPrint NC60 ADJ 3 1 2B Black Density NC60 CHECKING THE BLACK DENSITY 1 Run a print of the Color Balance Test Pattern Menu Down until Color Adjust then press Item Down Analyze the test page and choose the number which represents the Black Density the customer desires Keep mind that this is a 3096 gray Darker is not always better ADJUSTING THE BLACK DENSITY 1 2 Perform the Black Density Check Press Item Up until Black Density is displayed Press Value Up or Value Down to change the numerical setting Press Enter Analyze the test page and determine if additional adjustment is required Press On Line DocuPrint NC60 ADJ 3 1 2C Color Balance NC60 CHECKING THE COLOR BALANCE 1 Run print of the Color Balance Pattern Menu Down until Color Adjust then press Item Down Analyze the test page and choose the number which represents the Color Balance the customer desires ADJUSTING THE COLOR BALANCE 1 2 Perform the Color Balance Check Press Item Up until Color Balance is displayed Press Value Up or Value Down to change the numerical setting Press Enter Analyze the test page and determine if additional adjustment is required Press On Line 2 99
80. concentration values stored in NVM These values are needed before initializing the Non Volatile Memory or installing a new PCU PWB NOTE Before initializing the NVM or replacing the PCU PWB you must obtain the consumable usage and toner concentration setpoints usage and setpoints must be reentered after initializing the NVM or replacing the PWB This procedure adjustments ADJ 3 3A actually consists of two Determining Consumable Usage And Toner Concentration Values ADJ 3 3B Initializing the NVM ADJ 3 3A DETERMINING THE CONSUM ABLE USAGE AND TONER CONCENTRATION VALUES 1 Locate the Service Log and obtain the copy of the Printer Diagnostic Test Pattern Note the location of the Toner Concentration setpoints the Consumable Usage Status and the Print Counts These are the most critical NVM values 2 Ask the customer if they have replaced any of the CRUs since the last service call NOTE 1 If the CRUs have not been replaced since the last service call the Toner Concentration Setpoints on the Diagnostic sheet are probably correct for the CRUS now in use NOTE 2 Make a copy of this page and the next page and fill in the NVM values on the copy NOTE 3 If a Diagnostic Sheet is not available continue with this procedure If the toner concentration values are corrupted you will have to replace both developer modules 3 Determine and record the Consumable Usage COUNTER SET values now in NVM
81. diagnostic mode is used during manufacturing to set the basic printer parameters should rarely require adjustment in the field The Background Diagnostic Mode is used to Initialize the following Gamma Sensor A adjust Gamma Sensor calibration Gamma Sensor C correction Black Developer Detect K TC Color Developer Detect C M Y TC Both Developers Detect K C M Y TC Drum Fuser Set the Control Values for the following Plain Paper Transfer Current Transparency Transfer Current Gamma Transfer Current K Developer Bias C Developer Bias M Developer Bias Y Developer Bias Process Control Off On Fuser Motor Speed GP 3 4 Paper Feed Motor Speed Check and set the fuser temperature DocuPrint C55 C55mp NC60 ENTERING THE BACKGROUND DIAGNOS TIC MODE 1 Enter Normal Diagnostics Menu 3 Enter 7 Power 2 Enter Special Diagnostics while PCU DIAG MODE XX is displayed press On Line 0 then press Enter 7 Release both keys at the same time 3 Enter Background Diagnostics while PCU DIAG MODE SPECIAL is displayed press Media Server 2 then press Previous 5 Release both keys at the same time 4 The Message Display will indicate DIAG BACK GROUND 5 Press the Menu 3 key to step through the diagnostic routines EXITING FROM THE BACKGROUND DIAG NOSTIC MODE 1 When DIAG BACK GROUND is displayed on the Message Display press the Form Feed 1 key to exit f
82. is inserted Y N Refer To BSD 7 2 and check Paper Size 4 CN107 12 for a short to ground If wiring is OK replace the PCU PWB If the problem stil exists replace the Cassette PWB Remove the cassette and move the length stop to the A4 11 7 position Insert the cassette Observe the LED s The Black LED goes on when the cassette is inserted Y N Refer To BSD 7 2 and check Paper Size 3 CN107 11 for a short to ground B 2 99 2 35 If wiring is OK replace the PCU PWB If the problem stil exists replace the Cassette PWB Press Media Server 2 select Scan Row 01 Press Form Feed 1 Remove the cassette and move the length stop to the Letter 11 position Insert the cassette Observe the LED s The Yellow LED goes on when the cassette is inserted Y N Refer To BSD 7 2 and check Paper Size 2 CN107 10 for a short to ground If wiring is OK replace the PCU PWB If the problem stil exists replace the Cassette PWB Remove the cassette and move the length stop to the Executive 10 5 position Insert the cassette Observe the LED s The Magenta LED goes on when the cassette is inserted Y N Refer To BSD 7 2 and check Paper Size 1 CN107 9 for a short to ground If wiring is OK replace the PCU PWB If the problem stil exists replace the Cassette PWB Replace the PCU PWB If the problem still exists replace the ESS PWB 10 5 11 A4 14 Figure
83. menus Value Up or Value Down Selects values within the submenu Enter Stores selected values or performs the selected function DocuPrint NC60 The printer menus are in layers The TOP MENU layer consists of the following Parallel Menu Job Menu Password Serial Menu Ethernet Menu Novell Menu Media Server Print Menu PCL Menu System Menu Color Adjust Service Menu Reset Menu NOTE The Password option is used to send a print and hold it until you are at the printer to receive it This option is only available if the printer has a hard drive Imaging Menu NOTE The Media Server option is only available if the printer has the Media Server Option and a floppy disk is inserted NOTE The Reset Menu is only visible if the On Line and Enter keys are pressed and held at power on The keys must be held until the display indicates Power On Version X XX then release the keys 2 99 6 19 To see how the Menus are layered refer to the NC60 Menu page To run the NC60 MENU page Menu Up until Menus Print Item Down until Print Menu Map Processing Menu Map GENERAL PROCEDURES MENUS ESS TEST PATTERNS AND X INFORMATION PAGES erox STARTUP C55 C55mp DocuP rint C55mp Color Laser Printer Press Display Reads wm Now you can do so much more STARTUP PROCESSING This is the startup page It can be set to print automati cally on
84. of the print to ensure that they are square If the lines are not square perform the adjustment REPAIRS ADJUSTMENTS ADJ 12 1 Registration Abc Defg Hijk Abe Defg Hijk Lmnop Orstuvw XYZ gogo gogo c Test Pattern A 600 x 600 Test Pattern A 600 x 600 Figure 1 Test Pattern A Registration Lines 2 99 4 70 ADJUSTMENT 1 Loosen the screws and move the ROS assembly as shown 2 Tighten the screws and repeat the Check Figure 2 Moving the ROS K9 DocuPrint C55 C55mp NC60 TITLE PAGE INTRODUCTION OVERVIEW 5 2 ORGANIZATION 5 2 SUBSYSTEM INFORMATION 5 2 SYMBOLOGY 5 3 PARTS LIST COVERS PL 1 1 COVERS 5 4 PRINT EXIT PL 2 1 PRINT EXIT ASSEMBLY 5 5 LVPS ESS PL 3 1 LVPS ESS 5 6 PL 3 2A C55 C55MP ESS COMPONENTS 5 7 PL 3 2B NC60 ESS COMPONENTS 5 8 RIGHT SIDE COMPONENTS 1 PL 4 1 MAIN DRIVES 5 9 PL 4 2 PCU HVPS 5 10 PL 4 3 COLOR TONER MOTOR DEVELOPER MOTOR 5 11 PL 4 4 MAIN DRIVE COMPONENTS 5 12 PL 4 5 INTERLOCK SWITCHES DEVEL OPER DRIVE COMPONENTS 5 13 PL 4 6 TONER SOLENOID MAGNETIC ROLL CLE
85. other defects for additional information Ghosting Drum related Offsetting Fuser related Residual Image Cleaner related Resolution See the resolution specification Skewed image See the Image Skew Specification Skips An area on the print where the developed image is disturbed before or during fusing Depending on the type of smear it may look like a band or streak Smear An area on the print were the developed image is disturbed before or during fusing Depending on the type of smear it may look like a band or streak 2 99 3 32 Solid Area Deletions Deletions which occur in a solid area Spot An undesirable circular mark on the print that differs in color or density from the surrounding area Spot deletion A circular shaped deletion The edges can be fuzzy or sharply defined Spot white light colored A spot that is noticeable an image area See spot deletions Spot dark colored A spot that is noticeable in a non image area Streak An undesirable strip on the print that differs in color or density from the surrounding area The strip looks like it is comprised of many small lines of varying length and width giving the appearance of a brush stroke See lines bands streaks Trail Edge Defects Darkened trail edges of solid areas about the last 4MM of the solid area Trail edge deletions TED s The last few MM s of solid areas are lighter in density See Deletions
86. paper etc in the paper path e Mechanical drive problem DocuPrint C55 C55mp NC60 E5 FUSER JAM RAP Paper did not reach the Exit Sensor INITIAL ACTION Open the Printer and remove the Fuser Assembly Check for any obstructions in the fuser paper path Switch the power off wait 10 seconds and switch the power on another print to recheck for the fault PROCEDURE Check the following e Obstructions in the paper path e Defective stripper fingers e Mechanical drive problem Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 00 Press Form Feed 1 Open the Printer then open the Fuser cover Actuate and deactuate the Exit Sensor while observing the Yellow LED The Yellow LED switches on and off Y N With SCAN ROW 00 still selected actuate and deactuate the Bypass Switch while observing the Cyan LED The Cyan LED switches on and off Y N Go to BSD 10 2 and troubleshoot the Strobe 2 signal CN103 18 for an open If no open exists replace the PCU PWB DocuPrint C55 C55mp NC60 A B Go to BSD 10 2 in Section 7 and trouble shoot the Exit Sensor signal 5 VDC and GND 308 1 3 2 for an open If no open exists replace the PCU PWB If the problem still exists replace the Exit Sensor Exit from the SWITCH SCAN program Remove the Front Cover and then close the Printer Scroll to the MOTOR TEST program and press Form Feed 1 to switch on the motor
87. pressed the will change to a lt Form Feed 1 Previous 5 26 Media Server 3 Next 6 7 2 s 4 f all keys check OK the display will indicate 1 2 3 4 5 6 7 8 5 Once all keys are checked the display will show the DATE and then return to PANEL KEY TEST GENERAL PROCEDURES SPECIAL DIAGNOSTICS COUNTER LIMIT This Diagnostic routine is used to change the limits for the consumables 1 Enter Special diagnostics and press the Menu 3 key until COUNTER LIM DRUM is displayed on the Message Display Press the Next 6 Previous 5 keys until the Message Display steps to the consumable limit to be changed Table 8 Press the Enter 7 key the display will indicate XXXX XXXX is the consumable name THHHHHHHE is the current limit Press the Menu 3 key to select the digit to be changed Press the Next 6 Previous 5 keys to change the limit To store the counter change insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored Press the Media Server 2 key to return the COUNTER LIMIT list Repeat steps 2 through 6 to change additional counters GENERAL PROCEDURES SPECIAL DIAGNOSTICS Table 8 Consumable Defaults KDVN K Developer Notify 2 99 6 10 DocuPrint C55 C55mp NC60 BACKGROUND DIAGNOSTICS The Background
88. roller area Switch the power off wait 10 seconds and switch the power on another print to recheck for the fault Make sure the Grounding Roller is rotating freely Perform the Transfer Drum Nip Adjustment ADJ 11 1 PROCEDURE Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 00 Press Form Feed 1 Open the Printer Actuate and deactuate the Registration Sensor while observing the Magenta LED The Magenta LED switches on and off Y N Go to BSD 8 1 in Section 7 and trouble shoot the Registration Sensor signal CN102 9 for a short to ground If no short exists replace the PCU PWB If the problem still exists replace the Registration Sensor Press Media Server 2 Select Scan Row 04 Press Form Feed 1 Actuate and deactuate the Transparency Sensor while observing the Cyan LED A STATUS INDICATOR RAPs E4 A The Cyan LED switches on and off Y N Go to BSD 8 4 in Section 7 and trouble shoot the Transparency Sensor signal CN311 1 for a short to ground If no short exists replace the PCU PWB If the problem still exists replace the Transparency Sensor Exit from the SWITCH SCAN program Close the Printer Remove the paper cassette Scroll to the MOTOR TEST program and press Form Feed 1 to switch on the motors while observing the Paper Feed Motor The Paper Feed Motor is rotating normally Y Go to BSD 7 3 Section 7 and trouble shoo
89. standard office plain paper with weights from 16 24 Ibs Best results will be achieved with laser class papers such as Xerox Color Xpressions Paper Avoid rough graphic arts papers card stock heavy papers vellum linen papers T shirt transfer material pre printed forms and letterhead with raised printing Envelopes and labels designed for laser printers must be run through the manual feeder and will print in black and whit only Transparencies The NC60 automatically detects transparencies and adjusts the printer to optimize print quality To save money and produce the brightest transparencies we recommend using clear laser printer or copier transparencies that do not have a removable stripe or paper backing Best results will be obtained by using the low cost transparencies specifically designed for the DocuPrint NC60 Xerox 3R6256 We do not recommend transparencies designed for other types of color copiers or color printers laser or inkjet For reliable feeding load a maximum of 75 transparencies in the paper tray When printing transparencies continuously print 5 10 sheets of blank pages after each set of 75 transparencies This will improve overall reliability and print quality when printing large volumes of transparencies Separator Sheets This convenient feature inserts a paper separator between each transparency sheet This feature requires the Second tray feeder option be installed on your printer Moving Your Prin
90. this is a premature failure follow the applicable warranty replacement procedures If the problem still exists continue with this RAP DocuPrint C55 C55mp NC60 PROCEDURE Enter normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 05 Press Form Feed 1 Open the Printer and remove the Fuser Assembly Actuate and deactuate the Oil Sensor while observing the Cyan LED The Cyan LED switches off and on Y N With Scan Row 05 still selected actuate and deactuate the Cleaner Jam Switch while observing the Magenta LED The Magenta LED switches off and on Y Refer to BSD 10 4 and check the Strobe 1 signal CN103 19 for an open If no open exists replace the PCU PWB Refer to BSD 10 4 and check the Oil Low signal 5 VDC and GND CN309 2 1 3 for an open If no open exists replace the PCU PWB If the problem still exists replace the Oil Sensor Check the ball that actuates the Oil Sensor to ensure that it is moving freely Reinstall the Fuser Assembly and close the printer to see if the fault clears If the problem still exists replace the Wiper Roll and Oil Bottle If the problem still exists replace the PCU PWB 2 99 2 21 TO THERMISTOR ERROR RAP The Fuser Thermistor readings are out of range the Fuser is missing or the Fuser is not seated correctly INITIAL ACTION NOTE During the following check be careful not to tip the Fuser Remove the Fuser Module and check the
91. wheels will not rotate Transfer Drum Flange V Shaped Cutout Transfer Drum Lower Frame A43A Figure 3 Reinstalling the Transfer Drum Lower Frame DocuPrint C55 C55mp NC60 REP 10 4 FUSER HARNESS PARTS LIST ON PL 10 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Remove the Right Side Cover REP 1 3 3 Figure 1 Remove the Fuser Assembly Figure 1 Removing the Fuser Assembly DocuPrint C55 C55mp NC60 4 5 Figure 2 Remove the Harness Cover Disconnect the connectors and remove the Fuser Harness Harness ver N 4 Cove Harness A38 Figure 2 Removing the Fuser Harness 2 99 4 49 REPAIRS ADJUSTMENTS REP 10 4 12 1 ROS ASSEMBLY PARTS LIST ON PL 12 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Top Rear Cover REP 1 1 2 Figure 1 Disconnect the connectors remove the screws and remove the ROS Assembly Ros 4 Assembly D47 Figure 1 Removing the ROS REPAIRS ADJUSTMENTS 2 99 REP 12 1 4 50 DocuPrint C55 C55mp NC60 REP 13 1 BLACK TONER MOTOR 2 Figure 2 Remove connectors lift and 3 Figure 3 Remove the screws and remove the Black Toner H PARTS LIST ON PL 13 1 remove the Black oner Hopper the Toner Motor REMOVAL Toner WARNING Hopper Switch the Main Power off and disconnect the Power Cord 1 Fi
92. 0 SPARED SPARED 162 35700 DESCRIPTION RIGHT SIDE FRAME SCREW TONER SOLENOID Y REP 4 7 SCREW MAG ROLL CLEANER SOLENOID REP 4 7 TONER SOLENOID M REP 4 7 TONER SOLENOID C REP 4 7 RETAINING RING IDLER GEAR IDLER GEAR CABLE CLAMP HARNESS DocuPrint C55 C55mp NC60 PL 5 1 CLUTCHES MAG ROLL ROLL CLEANER 27 6 9 ITEM PART DESCRIPTION 28 9 12 1 RIGHT SIDE FRAME 2 NOT SPARED DRIVES FRAME 3 NOT SPARED RETAINING RING 4 13E12550 CLUTCH BEARING 5 SPARED RETAINING RING 6 7 48310 CLUTCH GEAR 7 809 1740 CLUTCH SPRING 8 16 12450 CLUTCH SLEEVE 9 8 5720 CLUTCH BOSS 10 7 48330 GEAR 11 809E1770 SPRING 12 16 12460 SLEEVE 13 7 48320 GEAR 14 SPARED SCREW 15 6E61580 SHAFT 16 121E13390 MAGNETIC CLUTCH Y REP 5 2 17 6E61650 SHAFT 18 121E13410 MAGNETIC CLUTCH REP 5 2 19 121E13420 MAGNETIC CLUTCH C REP 5 2 20 6E61570 SHAFT 21 121 13430 MAGNETIC CLUTCH K REP 5 2 22 6 61640 SHAFT 23 6E61590 SHAFT lt 24 13 12510 BEARING gt lt n 25 6 61560 SHUTTER SHAFT m lt 26 NOT SPARED SCREW 26 D 3 4 Ces 27 REFERENCE ONLY TONER CLUTCH ASSY 3 2 gt 5 1 e SR 3 28 REFERENCE ONLY MAG ROLL CLEANER 3 19 7 CLUTCH REP 5 1 IS e 4 9 46 SS I 18 38 74 AS e exa 2 VR 3 22 b 4 s de ec EUM eta
93. 0 ontrol PF Motor 3221 Paper Feed Mot Speed ontrol FS Motor 3527 Fuser Motor Speed P ontrol Patch MD atch Control On Off ontrol BLKHI MD On Fast Black On Off Control SLPGM MD Process Control after Power Save On Off ontrol Toner MD On ContinousToner On Off 2 99 6 12 DocuPrint C55 C55mp NC60 5 4 Changing the temperature values Table 10 Fuser Defaults This Diagnostic routine is used to check and a With HEATER TEST displayed press Defaut Description change the fuser temperature control points the Enter 7 Key C55 C55mp During the heater test the following data is b Use the Menu 3 key to select the 102 6 value to be changed user On TU coke c Use the Next SJ Previous 5 keys to oa ben change the value emperature level being monitored Plain 140 The fuser has five different paper setpoints d To E dd 5 NC60 i i ive di aper into the bypass slot to actuate RO D the Bypass Switch then press the transparency setpoints OHP CO through OHP lt C4 setpoint selected depends on the Form Feed 1 key The On Line LED mode of operation will switch on and then off when the C2 124 Paper intermediate setpoint 1 Enter Background diagnostics and press change is stored the Menu 3 key until HEATER TEST is e Press Media Server 2 to exit from Plain C4 145 Paper control setpoint displayed on the Messag
94. 0 TR DRUM HOME POSITION SENSOR 19 P O ITEM 1 SCREW M3X14 20 7E48360 IDLER GEAR 21 7E48370 CLEANER GEAR 22 7E48350 FUSER GEAR 23 P O ITEM 1 SCREW M4X6 24 127E10910 FUSER MOTOR 25 162K29320 FUSER HARNESS 26 162K35630 HARNESS 27 P O ITEM 1 CABLE CLAMP 28 49E84450 BRACKET 29 115E5840 CONTACT 30 162K35710 HARNESS 81 P O ITEM 1 SCREW M3X6 32 115E5850 CONTACT 809E5770 SPRING PARTS LIST SECTION 2 99 PL 9 1 5 24 DocuPrint C55 C55mp NC60 PL 9 2 TRANSFER FRAME LEFT ITEM PART 1 REF PL9 1 ITEM 1 2 1E43760 3 P O ITEM 1 4 12E8150 5A 7E48440 5B 7E63600 6 X P OITEM 1 7 P O ITEM 1 8 809 5680 9 P OITEM 1 10 P OITEM 1 11 1 12 13 12520 13 809 2020 14 55 37740 15 P OITEM 1 16 121 13440 17 29 27470 18 31 8360 19 809 2040 20 31 8370 21 13 12590 22 809 2060 23 24 120 15810 2 99 DocuPrint C55 C55mp NC60 5 25 DESCRIPTION PART OF TRANSFER FRAME ASSEMBLY LEFT TRANSFER FRAME SCREW 6 LEFT RELEASE LINK LOCK PAWL UPPER LOCK PAWL LOWER SCREW 6 RETAINING RING 7MM TRANSPORT LOCK SPRING RETAINING RING 2MM BUSHING RETAINING RING 4MM BEARING WASTE SPRING WASTE SHUTTER RETAINING RING STRIPPER SOLENOID PIN STRIPPER LINK STRIPPER SOL SPRING STRIPPER ARM LEFT DRUM BEARING TR DRUM SPRING ACTUATOR PARTS LIST SECTION PL 9 2 PL 9 3 STRIPPER FINGERS ITEM PA
95. 104 Pin Destination 1 CN702 1LVPS 2 CN702 2LVPS amp 3 CN104 8 PCU PWB 4 CN104 10 PCU PWB CN101 Hard Drive CN102 Floppy Optional NIC Connector CN103 Floppy Figure 7 6 NC60 ESS PWB Connectors 18 CN702 8LVPS 19 CN7O2901VPS 20 CN702 10LVPS 7 CONNECTOR WIRING ESS PWB Connectors 5 CN104 2 PCU PWB 11 CN104 5 PCU PWB 6 CN104 9 PCU PWB 12 CN104 7 PCU PWB CN104 6 PCU PWB 13 CN702 3 LVPS 8 CN104 11 PCU PWB 14 CN702 4 LVPS 9 CN104 1 PCU PWB 15 CN702 5 LVPS 10 CN104 12 PCU PWB 16 CN702 6 LVPS 2 99 7 28 DocuPrint NC60
96. 11 REP 4 4 4 5 COLOR TONER MOTOR 4 Figure 2 Remove the Color Toner Motor PARTS LIST ON PL 4 3 Outer Drive Frame REMOVAL Color Toner Clutch Covers WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following Print Drum Module Color Developer Module Black Developer Module Right Side Cover REP 1 3 Top Cover REP 1 1 f Rear Cover REP 1 2 2 Remove the Main Drive Motor Belts REP 4 2 Figure 1 Remove the Outer Drive Frame D o 3 Remove the Pulley E18 Remove the 4 Clutch Covers Remove the E Rings and Screws and Figure 2 Removing the Color Toner Motor then remove the Outer Drive Frame o o m Pulley E10 Figure 1 Removing the Outer Drive Frame REPAIRS ADJUSTMENTS 2 99 REP 4 5 4 12 DocuPrint C55 C55mp NC60 4 6 DEVELOPER MOTOR PARTS LIST ON PL 4 3 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following Print Drum Module Color Developer Module Black Developer Module Right Side Cover REP 1 3 Top Cover REP 1 1 f Rear Cover REP 1 2 Remove the Main Drive Motor Belts REP 4 2 Remove the Developer Drive Motor Belts REP 4 3 Figure 1 Disconnect the connector and remove the Developer Motor D o DocuPrint C55 C55mp NC60 Developer Motor E17 Figure 1 Removing the
97. 13380 4 6 13 12560 13 1 162 29310 102 20 28760 4 3 31 8370 9 2 49 84430 10 4 121E13390 5 1 13 12570 8 2 162 27990 3 2A 20 28770 4 5 1 8800 4 1 49E84450 9 1 2 99 PARTS LIST SECTION DocuPrint C55 C55mp NC60 5 39 PART NUMBER INDEX PL PART PL PART PL PART PL NUMBER LOC NUMBER LOC NUMBER LOC NUMBER LOC 49E84460 27 3 733W6866 3 2 809E1700 4 1 809E5680 9 2 50K35390 13 1 733W6867 3 2 809E1720 8 1 809E5770 9 1 50K40300 14 1 7 48280 9 809 1740 5 1 809E5780 10 3 53E5390 10 1 7 48300 12 1 809 1750 12 1 809 5790 27 3 55E37720 10 2 7 48310 5 1 809E1760 8 1 809E5810 27 1 55E37730 13 1 7 48320 5 1 809E1770 5 1 8E5720 5 1 55E37740 9 2 7 48330 5 1 809E1780 2 1 8E5720 8 2 55E37750 8 3 7E48340 9 1 809E1790 12 1 8E5730 6 2 55E38910 2 1 7 48350 9 809 1810 6 2 8 5740 8 2 55E38920 10 2 7 48360 9 1 809 1830 10 2 8E5750 6 3 55E38931 8 1 7E48370 9 1 809E1840 6 1 8E5780 9 4 5E12180 8 2 7 48380 9 809 1850 10 2 8R7748 8 1 5E12200 6 3 7 48390 13 1 809 1860 8 2 908 1730 7 2 5E12210 6 3 7E48400 13 1 809E1970 7 1 5K4960 9 4 7E48410 13 1 809E1990 13 1 600K65260 8 1 7E48420 4 3 809E2000 8 1 600K65270 10 2 7E48430 13 1 809E2000 10 4 600K65270 10 4 7E48440 9 2 809E2010 10 3 600K71720 9 4 7 48440 10 3 809 2020 9 2 600 75290 9 4 7 48450 4 5 809 2030 6 3 600K75290 11 1 7 48460 4 5 809 2040 9 2 62 8750 10 1 7 48470 10 4 809 2050 8 2 6 58160 2 1 7 48480 44 809 2060 9 2 6 61510 8 1 7E48490 8 3 809E2060 10 3 6E61520 4
98. 2 Humidity Sense GND for an open 0 CN105 5 Temp Sense for an open or short to ground If the wiring checks OK replace the Tem perature Humidity Sensor IMAGE QUALITY RAPs 2 99 IMAGE QUALITY DEFECTS 3 4 DocuPrint C55 C55mp NC60 Defect Name Description Possible Causes Corrective Action 4 BACKGROUND CYAN 1 Overtoning 1 Refer to ADJ 9 1 step 11 and complete the procedure if required 2 No Cyan Bias or constant Cyan Toner 2 Refer to BSD 9 1 and check the Cyan Dispensing Developer Bias voltage If no voltage is present replace the High Voltage Power Supply If the voltage is OK check the Cyan Developer Bias lead CN803 1 for an open If the wiring is OK refer to BSD 9 10 and check the Cyan Toner Solenoid CN115 12 for a short to ground If no short is present replace the color developer module 5 BACKGROUND MAGENTA 1 Overtoning 1 Refer to ADJ 9 1 step 11 and complete the procedure if required 2 No Magenta bias or constant Magenta Toner 2 Refer to BSD 9 1 and check the Magenta Dispensing Developer Bias voltage If no voltage is present replace the High Voltage Power Supply If the voltage is OK check the Magenta Developer Bias lead CN803 3 for an open If the wiring is OK refer to BSD 9 10 and check the Magenta Toner Solenoid CN115 14 for a short to ground If no short is present replace the color developer module 6 BACKGROUND YELLOW 1 Overtoning 1 Refer to ADJ 9 1 step 11 and compl
99. 2 3 Length Stop Location OTHER FAULTS RAPs OF3 OF4 TRAY 2 PAPER SIZE SENSING RAP This RAP is used to troubleshoot the paper size sensing for Tray 2 Use this RAP when the paper size that is loaded is not the same size that is being sensed INITIAL ACTION Remove Tray 2 and check the movable length stop Make sure the tab which actuates the sensors is not broken Carefully load the paper size which is not being detected correctly Switch the power off wait 10 seconds and switch the power on Make a print of the paper size which is loaded to recheck for the fault PROCEDURE Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 03 Press Form Feed 1 Remove Cassette 2 Remove the Length Stop and re insert Cassette 2 without the stop Observe the LEDs Cyan Magenta and Yellow are all On Y N Refer to BSD T2 7 2 and check the following e Cyan is Off Check the T2 Paper Size 0 signal CN109 1 for a short to ground Magenta is Off Check the T2 Paper Size 1 signal CN109 2 for a short to ground e Yellow is Off Check the T2 Paper Size 2 signal CN109 3 for a short to ground OTHER FAULTS RAPs 4 B If OK replace the T2 Cassette PWB If problem still exists replace the PCU PWB With Scan Row 03 still selected remove the cassette and put the Length Stop in the Executive 10 5 position Figure 2 4 Insert the cassette and observe the LEDs Cyan is On Magenta is O
100. 2 99 NOTES 6 54 DocuPrint C55 C55mp NC60 GP 15 1 INSTALL b Remove the packaging materials printer e Release the latches and open the front PROCEDURE and consumables from the carton Make panel sure that you have all the components 1 General Notes shown in the illustration below i DO NOT connect the power cord to the printer until you are instructed to do so The Printer weighs approximately 89 AN pounds 40 Kg without consumables To avoid accidents two people should lift the printer into place before installing If you need assistance with your installation call your Dealer or contact e Team XRX US 1 800 TeamXRX 1 800 832 6979 Xerox National Call Center Canada 1 800 939 3769 For all other countries please call your local Xerox Support f Release the latch and open the rear panel Remove the foam sheet 2 Prepare for installation a Be sure to remove the outer box by removing the four clips as shown c Place the printer where it will be used TWO people should lift the printer d Remove the tape from the printer exterior 2 99 GENERAL PROCEDURES DocuPrint C55 C55mp NC60 6 55 GP 15 1 INSTALL Remove interior packaging d Remove the roller and the foam cylinder f Remove the two clips from the transfer a Remove the tape by pulling straight up being sure to remove all FIVE seals drum by pulling on the strings taped to attached to back of the foam cylinder the front of yo
101. 20 VDC EC The Drum Module is not installed correctly XEROGRAPHICS CHAIN 9 LEVEL 2 SHEET 2 OF 10 BSDs 2 99 Chain 9 Xeroaraphics 7 10 DocuPrint C55 C55mnINC601 DEVELOPER E DRIVE MOTOR 2 DEVELOPER PL 4 3 gt lt DRIVE a i MOTOR DEVELOPER MOTOR LOCK L 5 VDC 1005 y 7 DEVELOPER MOTOR ON L 5 E 3 2 22 MAGNETIC ROLL lt LLY 42 7 CLEANER SOLENOID 24 VDC INTERLOCKED GND PCU PWB 9 6 MAGNETIC ROLL CLEANING MAGNETIC ROLL CLEANER SOLENOID PL 4 6 24 VDC INTERLOCKED MAGNETIC ROLL CLEANER SOLENOID ON L 24 VDC H G THE DEVELOPER DRIVE MOTOR SUPPLIES DRIVE FOR ALL FOUR CLEANER AS COLORS WHEN THE MAGNETIC ROLL CLEANER SOLENOID IS DEENERGIZED ALL FOUR MAGNETIC ROLLS ARE READY TO BE CLEANED WHEN THE SOLENOID IS ENERGIZED ALL CLEANER BLADES ARE MOVED AWAY FROM THE ROLLS THE ROLL WHICH IS ROTATING CREATES A BRUSH AND DEVELOPS AN IMAGE Status Codes Description ue The Developer Drive motor is not rotating XEROGRAPHICS CHAIN 9 LEVEL 2 SHEET 3 OF 10 2 99 BSDs DocuPrint C55 C55mp NC60 7 11 Chain 9 Xerographics BLACK 1 DEVELOPER MAGNETIC CLUTCH PL 5 1 424 VDC INTERLOCKED BLACK MAGNETIC CLUTCH ON L 24 VDC 2 BLACK DEVELOPER ASSEMBLY BLACK TONER SENSE SIGNAL CN1001 3 1 1 4 1 11 7 i BLACK TONER i KDEV LINK MOTOR I I NEW DEVELOPER SENSE SIGNAL 1 I I BLACK DEVELOPER BIAS B
102. 200V Magenta default is 1400 Yellow default is 2600 As the humidity changes the voltage is also changed to compensate Developer Bias The default bias is 400V four developer bias voltages are set during the Process Control cycle at power on The voltage range is from 250 to 550 volts general the higher the bias the darker the print If the values get too high or too low the charge voltage may change to compensate The Magenta voltage tends to be higher These values will also change when the color balance procedure is performed General Information Serial Number XXX XXXXXX Software Version 1 80 39 INL ROM Engine Software Version Total System Memory Base J3 J4 J5 J6 Binary Lossy Counter Contone Lossy Counter Relative Humidity Temperature Fuser Temperature 157 Print Counts Total XXXXX Black XXXXX Cyan XXXXX Magenta XXXXX Yellow XXXXX Consumable Usage Status Fuser Xxx Print Drum Xxx Fuser Oil Okay Black Developer Color Developers Cyan xx Magenta xx Yellow Adjustments Top Margin 0 0 Left Margin 0 0 Cleaning Cycle Never TC Patch Control Off Fast Black On Extra Toner On Cyclic toneup On OHP Mode None Process Control Status Black OK Cyan OK Magenta OK Yellow OK Calibration OK Xerox DocuPrint NC60 Color Laser Printer Diagnostic Sheet Density Rate Set Points Black 90 Cyan 90 Magenta 90 Yellow 90 Color Balance Default Gamma Set Points Black 41 Cyan 61 Mage
103. 3360 9 1 162029320 9 1 22 21010 8 2 32 11490 6 1 105K16410 4 2 121 13460 8 3 13 13370 8 1 162029330 7 1 22 21010 27 3 35 41680 13 1 105 17050 10 4 121 13470 83 13 13380 6 3 162K29340 10 4 22 21020 8 2 35 41690 9 4 110 7550 4 5 121E14310 272 13E13390 4 4 162K29350 10 4 22E21030 8 1 35E41700 9 4 110E7560 4 5 121 14320 272 13E13420 10 3 162K35580 9 1 22E21880 4 1 35E41710 9 4 110E7570 10 4 121K15660 3 2A 13E13430 27 3 162K35590 7 1 22 21890 4 1 35E41720 9 4 110E9930 10 3 122 2170 10 2 146 560 3 2A 162K35600 43 22 21900 27 3 35 43370 9 4 115 5410 10 3 122 1760 12 1 14 2670 10 1 162K35610 4 5 22 53880 8 1 8 17370 1 1 115 5830 2 1 127 10890 4 3 14 4360 10 2 162K35620 7 2 22 53890 9 1 8 17380 81 115 5840 91 127 10900 43 15 59930 6 2 162 35630 9 1 22 53890 10 1 8 18350 10 4 115 5850 91 127E10910 9 1 15 59940 7 2 162K35640 8 3 22K53910 2 1 38E18360 2 1 115E5860 10 4 127E10920 13 1 15E59950 10 2 162K35650 102 23E14880 9 1 38E18371 10 4 115E6900 10 3 127 10930 10 1 15E59960 9 4 162K35660 8 3 23E14890 2 1 3E42100 7 1 116E7350 7 1 127E10940 4 1 15E59970 9 4 162K35700 4 6 23E14900 9 1 3E42110 1 1 116E7360 7 1 127E10950 4 1 15E64300 9 1 162K35710 9 1 23E14910 9 1 42 1390 9 4 116 7370 7 2 12 8150 9 2 15 64310 6 3 162K35720 27 1 23 14920 4 5 48 43530 2 1 116 7380 6 1 12 8160 10 3 15 64320 44 16 12450 5 1 23 14930 4 5 48 43540 14 116 7390 6 1 12E8400 6 2 15E64340 12 1 16E12460 5 1 23E14940 4 4 48E43550 1 1 116E7400
104. 4 59 REPAIRS ADJUSTMENTS ADJ 3 1 2 ADJ 3 2 1 MARGINS SIDE TO SIDE and TOP TO BOTTOM C55 C55mp PURPOSE To adjust the top and left margins with respect to a portrait page using the Control Panel CHECK 1 Run a print of Test Pattern A a Put the printer in the Off Line mode by pressing the On Line button b Press Menu and then use the Previous Next buttons to scroll to SERVICE Press Enter c When TEST PATTERNS is displayed press Enter d Use Previous Next to scroll to PATTERN TYPE Press Enter e When PCL is displayed press Enter f When TEST PATTERN A is displayed press Enter g Use Previous Next to scroll to RUN TEST JOB Press Enter h When YES is displayed press Enter to print Test Pattern A 2 Figure 1 Measure the Margins a The distance from the Lead Edge of the copy paper to the 8 mm line should be 8 mm b The distance from the Side Edge of the copy paper to the 8 mm line should be 8 mm REPAIRS ADJUSTMENTS ADJ 3 2 1 Lead Edge 8mm Side Edge E E e Figure 1 Margins Measurement 2 99 4 60 ADJUSTMENT 1 Access the adjustment menu a Put the printer in the Off Line mode by pressing the On Line button Press Menu and then use the Previous Next buttons to scroll to SERVICE Press Enter Use Previous Next to scroll to ADJUSTMENTS Press Enter Use Previous Next to scroll to LEFT MARGIN OR TOP MARGIN Press Enter Us
105. 55 C55mp NC60 E Set up the meter to read 24 VDC Measure between 103 4 and ground Make one print while monitoring the meter The meter swings from 24 VDC to 0 and back to 24 Y N Go to BSD 9 16 in Section 7 and trouble shoot the Stripper Solenoid signal and 24 VDC Interlocked CN103 4 CN303 2 1 for an open or a short If no short or open can be found replace the PCU PWB If the problem still exists replace the Stripper Solenoid Set up the meter to read 5 VDC Measure between CN103 11 and ground Switch the power off wait 10 seconds and switch the power on The meter swings from 3 8 VDC to 5 when the white patch passes in front of the Gamma Sensor Y N Go to BSD 8 5 in Section 7 and troubleshoot the Gamma Sensor all lines for an open If the lines are OK replace the PCU PWB If the problem still exists replace the Gamma Sensor Refer to Section 6 GP 9 3 and perform the Transfer Voltage Check The Transfer voltage is within specifi cation F 2 99 2 9 F Y N Go to BSD 9 1 in Section 7 and trouble shoot the following for an open or short e Black Transfer Lead from the Power Supply Transfer On Signal 106 3 Transfer Control Signal CN106 5 Bias Control Signal CN106 6 24 VDC to Power Supply CN106 1 If no wiring problem can be found replace the PCU PWB If the problem still exists replace the High voltage Power Supply Refer to BSD 9 1 in
106. 5mp NC60 REP 9 2 TRANSFER DRUM CLEAN ING SOLENOID PARTS LIST ON PL 9 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Figure 1 Remove the large E Ring securing the Transfer Drum Assembly latch and slide the latch off the pin This will allow access to the screw securing the Transfer Drum Cleaning Solenoid Figure 1 Removing the E Ring DocuPrint C55 C55mp NC60 3 Figure 2 Remove the screw and remove the Transfer Drum Cleaning Solenoid Cutout A31 Figure 2 Removing the Transfer Drum Cleaning Solenoid 2 99 4 37 REPLACEMENT NOTE When reinstalling the Transfer Drum Cleaning Solenoid make sure the tab on the solenoid is located in the cutout in the frame NOTE Observe the Cleaner Assembly during the copy quality setup When the Cleaning Solenoid is energized the Cleaning Assembly should be cammed forward When the Solenoid is deenergized the Cleaning Assembly should be cammed away REPAIRS ADJUSTMENTS REP 9 2 REP 9 3 TRANSFER DRUM CLEANER CLUTCH PARTS LIST ON PL 9 4 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Remove the Transfer Drum Cleaning Solenoid REP 9 2 3 Figure 1 Remove the Spring Clip and E Rings The right E Ring is very small 4 Remove the right and left bearings 5 Remove the E Ring and large washer f
107. 6 1 12E8410 7 2 15 64350 7 1 16 12470 8 2 23 14950 44 48 43560 1 1 117 18520 27 1 12 8420 7 2 15 64370 2 1 16 12490 8 3 24 2480 14 48 43570 12 1 118 13750 72 12 8430 4 1 15E64440 10 1 16E12500 9 4 26E60290 9 4 48E43580 1 1 118E13760 8 1 12E8440 4 1 15E64450 10 1 16E13280 27 3 28 12140 9 48 43590 10 2 118 13770 7 1 12 8450 27 2 15 64460 10 4 17 7740 12 1 28 12150 13 1 48 53670 27 3 118 13780 8 1 130 7970 9 160 27110 3 2A 17 8350 7 2 28 12160 6 3 48E53730 1 1 11E7360 7 2 130E7970 10 2 160K32790 3 1 17E8360 7 1 28E12170 6 3 48E53740 1 1 11E7370 12 1 130 7980 2 1 160K32850 3 1 17E8370 12 1 29E25280 4 4 48E53750 9 4 11E7380 6 1 130 8000 8 2 160K40220 3 2A 180K60120 42 29E25290 9 4 48E53770 27 1 11E7390 8 2 130 8010 10 4 160 40550 3 2 19E36010 9 3 29E27440 9 3 48E53780 27 1 11E7400 13 1 130 8490 27 3 160K40560 3 2A 19E37480 7 2 29E27450 6 2 48E53790 27 1 11E7610 27 1 13E12510 5 1 160040980 3 2A 19K4100 9 3 29E27460 6 2 48K56910 2 1 120E15800 21 13E12520 2 1 160 41070 27 1 1 43740 9 1 29 27470 9 2 48 56920 1 1 120 15810 92 13 12520 9 2 160044790 3 2 1 43750 13 1 29 27480 10 3 49 71990 10 2 120E15820 10 1 13E12520 9 3 160K49683 3 1 1E43760 9 2 29E27490 10 4 49E72000 4 5 121E13350 46 13 12520 9 4 160K50080 4 2 1 43760 10 1 29 27500 6 2 49 84400 10 2 121 13360 46 13 12540 13 1 160K54960 3 2B 1 46930 2 1 31 8350 10 2 49E84410 4 1 121E13370 46 13 12550 5 1 160K63720 3 1 1E46940 8 1 31E8360 9 2 49E84420 10 1 121E
108. 6 48 GP 3 4A DRUM CLEANING NC60 ADJUSTMENT 1 2 Press Menu Up until Service is displayed Press Item Down until Cleaning Cycle is displayed Press Value Up to display the current setting The following choices are available e Never e 10 through 100 For high volume customers the recommended setting is 30 transfer drum is cleaned every 30 Images Select the choice which best represents your situation and press Enter DocuPrint C55 C55mp NC60 3 5 RESET NC60 PURPOSE NOTE Before performing a reset print a Configuration Sheet Up to Service Down Config Sheet then press Enter The purpose of this procedure is enable the Reset Menu When this menu is available you can perform the following e Reset the ESS to Factory Defaults e Reset the Network to Defaults e Reset the CRUs e Restart the Printer e Delete All pending jobs e Initialize the Hard Disk e Format the Hard Disk PROCEDURE 1 Enable the Reset Menu a Switch the Power Off b Press and hold On Line and Enter then switch the power on c Continue to hold On Line and Enter until POWER ON VERSION is displayed then release the keys 2 Reset the Printer a Press Menu Up until the item to be reset is displayed b Press Value Up until Yes is displayed Press Form Feed 3 Have the customer use the Configuration Sheet to reset any lost values 2 99 NC60 6 49 GENERAL
109. 60 Off On 30 Auto On On On 30 Auto Off 9600 Hardware I None Tray 1 0 0 Never not set DIAGNOSTIC SHEET C55 C55mp Press Display Reads PRINT SET Next until DIAGNOSTICS PROCESSING gt This page lists the many of the NVM values for the printer For a detailed explanation of this page refer to Section 3 ESS GENERATED TEST PATTERNS Xerox DocuPrint C55mp Color Laser Printer Printer Diagnostics Process Control Status General Information Black Okay Software Version x x x Cyan Okay Software Part Number xxxxxxxx Magenta Okay Engine software Version xx Yellow Okay Serial Number xxx xxx xxx Calibration Okay Total Ram Installed 24 Base 8 Mb Density Rate Setpoints MB Black 90 J10 J11 0 Mb Cyan 90 Total Pages Magenta 90 Binary Lossy Counter 0 Prints genta 4 Yellow 90 Contone Lossy Counter 0 Prints Relative Humidity 20 Counts Temperature 107 Counts Toner Concentration Fuser Temperature 157 Counts Setpoint Black 91 Cyan 94 Magenta 102 Consumable Usage Status Fuser xxx Prints Print Drum 939 Images Yellow 96 Control Point Fuser Oil Okay Black Developer xxx Images Black 89 Color Developers Cyan 94 socii 100 i i Yellow 88 E dtd Value ellow ages Black 92 E Cyan 94 Print Counts Magenta 102 Total Pages xxxxx Yellow 84 Black xxxxx Cyan XXxxx
110. 9 Xerographics 9 16 STRIPPER CONTROL 1 PCU STRIPPER PWB SOLENOID PL 4 2 PL9 2 STRIPPER ON CN307 CN303 L 24 VDC 24 VDC INTERLOCKED 2 STRIPPER SOLENOID 9 17 TRANSPARENCY JAM SENSING TRANSPARENCY JAM SENSOR 3 TRANSPARENCY JAM SENSOR PL 10 2 4 iji STROBE2 CONNECTOR PWB CLEANER JAM SWITCH BEHIND CONNECTOR PWB i 9 18 CLEANER JAM DETECTION CLEANER PAPER SENSED SWITCH L 5 VDC CN307 p CN103 PL 10 d ES 1 19 6 7 XEROGRAPHICS CHAIN 9 LEVEL 2 SHEET 8 OF 10 BSDs 2 99 Chain 9 Xerographics 7 16 DocuPrint C55 C55mp NC60 1 GAMMA PWB PL 10 2 CN30 PROCESS CONTROL SEQUENCE 1 SENSE SIGNAL 1 IF TONER CONCENTRATION WAS LOW DURING PREVIOUS RUN 2 ADJUST THE TONER CONCENTRATION GND A READ THE TEMPERATURE AN RELATIVE HUMIDITY 1 SENSOR GND 1 USE THE TEMPERATURE AND HUMIDITY DATA TO ADJUST THE TONER CONCENTRATION SET POINTS IF REQUIRED 3 SLOW THE MAIN DRIVE MOTOR AND CALIBRATE THE GAMMA SENSOR USING THE WHITE PATCH PRINT BLACK PATCH ON TOP OF WHITE PATCH USE THREE CYCLES TO DEVELOP THREE 5 VDC PATCHES EACH 50 VOLTS APART ADJUST THE BLACK DEVELOPER 4 HUHIBI HUMIDITY SENSE SIGNAL BIAS STAT PRINT THREE CYAN PATCHES GND CHANGE DEVELOPER BIAS BY 50 V TEMPERATURE HUMIDITY PWB 8 3 FOR EACH PATCH ADJUST DEVELOPER BIAS IF OUT OF RANGE PRINT AND MEASURE ADDITIONAL CYAN PATCHES AND 5
111. AL 5 NC60 Part No PART No Hard Drive 810 M 9884154 9884154 Repack Kit 600K62160 eese T 2 99 GENERAL PROCEDURES DocuPrint NC60 6 67 Optional Kits PRODUCT CODES C55 C55mp Product Code USCO ACO 120V 8A C55 XE 220 240V 5 C55 USCO ACO 120V 8A C55mp XE 220 240V 5A C55mp ACO 220V 240V 5A C55 ACO 220 240V 55 PHYSICAL CHARACTERISTICS C55 C55mp Width 18 5 inches 470 MM 16 5 inches 419 MM 16 5 inches 419 MM Appx 89 lbs Appx 40 KG CAPABILITIES C55 C55mp Printing Speed letter size Black 12 ppm Color 3 ppm Warm Up Time 180 seconds Resolution 600 x 600 x 1 with 24 MB of RAM With PostScript Contone 600 x 600 x 4 with 24 MB of RAM GENERAL PROCEDURES Product Specifications Paper Feed System Cassette amp Manual Feed Cassette Capacity 250 sheets 20 Ib 80 gsm paper Tray 2 Optional 250 sheets 20 Ib 80 gsm paper Print Media throughput materials The sizes in bold typeface are detected automatically One of the other sizes can be assigned using the Off Line Menus Letter 8 4x11 4 210x297 mm Legal 8 5x14 A5 148x210 mm B5 176x250 mm Executive 7 25x10 5 Invoice 5 5x8 5 SP Folio 216x315 mm 8x10 Paper Exit System Face down on the top cover Capacity 150 sheets Print Materials Information For complete details see the User s Guide Part Number 1222 Comments Descr
112. AMMA MD Process Control Off On CONTROL PATCH MD C55 C55mp IOT Software Version 75 and up Refer to GP 3 2 TONER IOT Software Version 94 and up Switches new Toner Control program off and on Should be left on SLPGM Software Version 94 and up Perform copy quality setup when waking up from power save Off On MD IOT Software Version 94 and up Fast Black Off and On CL COUNT MD stores cleaning cycle count e Fuser Motor Speed T value to speed Paper Feed Motor Speed T value to J speed 1 Enter Background diagnostics and press the Menu 3 key until CONTROL KDVBIAS is displayed on the Message Display 2 Use the Previous 5 Next 6 keys to select the parameter to be changed 3 Press the Enter 7 key the display will indicate the present value 4 Press Previous 5 Next 6 to change the value GENERAL PROCEDURES BACKGROUND DIAGNOSTICS 5 store the change insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored Table 9 Control Defaults Description C55 C55mp NC60 ontrol Gamma MD On Process Contro Y DVBias M DVBias C DVBias ontrol Patch MD atch Control On Off ontrol PF Motor 3409 Paper Feed Mot Speed 3729 ontrol FS Motor Fuser Motor Speed NC6
113. ANER SOLENOIDS 5 14 DocuPrint C55 C55mp NC60 TITLE PAGE RIGHT SIDE COMPONENTS 2 PL 5 1 CLUTCHES MAGNETIC ROLL TONER MAGNETIC ROLL CLEANER qu M M 5 15 INNER DRIVE COMPONENTS PL 6 1 DRIVE COVER ASSEMBLY 5 16 PL 6 2 SLIDE CAM ASSEMBLY INNER DRIVE FRAME 5 17 6 3 INNER DRIVE FRAME COMPONENTS 5 18 XEROGRAPHIC CONNECTORS PL 7 1 DEVELOPER CONNECTORS BRACKET 6 0 5 19 PL 7 2 PRINT DRUM CONNECTORS BRACKETS 5 20 PAPER FEED ASSEMBLY PL 8 1 PAPER FEED ASSEMBLY PART 1 OF 5 21 PL 8 1 PAPER FEED ASSEMBLY PART 2 OF 5 22 8 1 PAPER FEED ASSEMBLY PART OF 5 23 TRANSFER DRUM COMPONENTS 1 PL 9 1 FUSER TD CLEANER DRIVES 5 24 PL 9 2 TRANSFER FRAME LEFT 5 25 PL 9 3 STRIPPER FINGERS 5 26 PL 9 4 TRANSFER DRUM CLEANER CLUTCH AND SHAFT 5 27 2 99 5 1 5 PARTS LIST SECTION TITLE PAGE TRANSFER DRUM COMPONENTS 2 PL 10 1 TRANSFER FRAME LEFT SIDE COMPONENTS 5 28 PL 10 2 TRANSFER FRAME UPPER COMPONENTS 5 29 PL 10 3 TRANSFER FRAME RIGHT SIDE COMPONENTS 5 30 PL 10 4 TRANSFER FRAME COMPONENTS FRONT 5 31 TRANSFER DRUM PL 11 1 TRANSFER DRUM ASSEMBLY 5 32 ROS PL 12 1 ROS COMPONENTS
114. ARE NC60 6 63 ENTERING SERIAL NUMBER SERVICE SUPPLIES DATA USING CENTREWARE C55 C55mp 6 62 ENTERING SERIAL NUMBER SERVICE SUPPLIES DATA USING CENTREWARE NC60 6 63 ENTERING ALPHANUMERIC DATA USING THE CONTROL PANEL C55 C55mp 6 62 ENTERING ALPHANUMERIC DATA USING THE CONTROL PANEL NC60 6 63 CONTINUED GENERAL PROCEDURES SECTION CONTENTS TITLE PAGE CONSUMABLES C55 C55mp 6 64 CONSUMABLES 60 6 65 OPTIONAL KITS C55 C55mp 6 66 OPTIONAL KITS NC60 6 67 PRODUCT CODES C55 C55mp 6 68 PRODUCT CODES NC60 6 69 PHYSICAL CHARACTERISTICS C55 C55Mp 6 68 PHYSICAL CHARACTERISTICS NC60 6 69 CAPABILITIES C55 C55mp 6 68 CAPABILITIES NC60 6 69 OTHER SPECIFICATIONS C55 C55mp 6 68 OTHER SPECIFICATIONS NC60 6 69 CONTROLLER SPECIFICATIONS C55 C55Mp 6 70 CONTROLLER SPECIFICATIONS NC60 6 70 TOOLS et 6 71 CHANGE TAG INDEX 55 55 6 72 INTRODUCTION 6 72 CLASSIFICATION 6 72 TAGS A E 6 72 CHANGE TAG INDEX NC60 6 75 INTR
115. AY 1 2 3 2 TRAY 2 2 3 1 1 JAM 2 4 E2 TRAY 2 JAM 2 5 E3 BYPASS JAM 2 5 E4 INPUT JAM 2 6 ES FUSER JAM 2 7 E6 DRUM JAM 2 8 E7 PRINT DRUM JAM 2 10 E8 OUTPUT JAM 2 10 E9 CLOSE PRINTER 2 10 EA COLOR DEV MISINSTALLED 2 11 EB BLACK DEV MISINSTALLED 2 11 EC PRINT DRUM MISINSTALLED 2 11 F1 DISK ERROR FLOPPY 2 12 F2 DISK I O ERROR FLOPPY 2 12 F3 ACTION FAILED FLOPPY 2 12 H1 HARD DISK ERROR 2 13 H2 HARD DISK CONTROLLER ERROR a N 2 13 H3 HARD DISK FULL 2 14 H4 FORMAT HARD DRIVE 2 14 DocuPrint C55 C55mp NC60 TITLE PAGE J1 ADD YELLOW TONER 2 15 J2 ADD MAGENTA TONER 2 16 J3 ADD CYAN TONER 2 17 J4 ADD BLACK TONER 2 18 J5 REPLACE COLOR DEVELOPER CARTRIDGE 2 19 J6 REPLACE BLACK DEVELOPER CARTRIDGE 2 19 J7 TONER COLLECTOR FULL 2 20 J8 REPLACE PRINT DRUM 2 20 J9 REPLACE
116. BIAS ON L 24 VDC C BIAS ON L 24 VDC M BIAS ON L 24 VDC Y BIAS ON L 24 VDC DocuPrint C55 C55mpINC601 CHARGE DC POWER RED LARGE GRID DC POWER RED SMALL TRANSFER DC POWER BLACK BLACK DEVELOPER BIAS RED CN803 CYAN DEVELOPER BIAS RED 1 MAGENTA DEVELOPER BIAS RED 1 1 1 1 5 1 YELLOW DEVELOPER BIAS RED 3 2 99 7 9 PCU PWB HVPS PWB GRID BIAS GRID BIAS GRID LOW SIGNAL MID SIGNAL VOLTAGE 0v 24V 550 24V 0v 650 24V 24V 750 THE TRANSFER CONTROL SIGNAL INCREASES THE TRANSFER BIAS FOR TRANSPARENCIES THIS SIGNAL IS APPROXIMATELY 2 5V FOR PAPER AND 4 6V FOR TRANSPARENCIES XEROGRAPHICS CHAIN 9 LEVEL 2 SHEET 1 OF 10 BSDs Chain 9 Xeroaranhics N CHARGE 1 LVPS DICOROTRON PWB j gt PL 3 1 NEW DRUM DETECT SIGNAL CN704 CN703 CNI07 2 DRUM LINK PWB DRUM DETECT H CHARGE CONNECTION GRID CONNECTION 9 3 MAIN DRIVE PCU PWB MAIN MOTOR PL 4 1 MAIN MOTOR CLOCK A 4 MAIN MOTOR CLOCK A 24 VDC INTERLOCKED MAIN MOTOR CLOCK B MAIN MOTOR CLOCK B LVPS PWB 9 4 CHARGING 5 PHOTORECEPTOR ASSEMBLY CHARGE DICOROTRON CHARGE DC POWER RED LARGE 6 GRID DC POWER RED SMALL THE DRUM LINK IS USED TO DETECT WHEN A Status NEW DRUM MODULE 15 INSTALLED MELTS Codes Description OPEN AND STARTS THE DRUM COUNT 7 2 THE MAIN MOTOR CLOCK SIGNALS ARE FROM 17 J8 A New Drum Module needs to be installed TO
117. BMM BEARING SNAP BAND GEAR 24 SPRING GEAR 17 42T FEED SLEEVE LOWER DRIVE LINK UPPER DRIVE LINK WASHER DRIVE ARM FEED ROLLER SPRING LINK SPRING CAM CLUTCH BOSS GEAR PARTS LIST SECTION PL 27 2 PL 27 3 TRAY 2 COMPONENTS 3 OF 3 PARTS LIST SECTION PL 27 3 2 99 5 38 ITEM NOOA NN Mate et anon PART 48E53670 809E5790 NOT SPARED NA 22 21900 13 13430 SPARED SPARED SPARED SPARED 16 13280 SPARED 22 21010 SPARED 130 8490 SPARED 49 84460 DESCRIPTION FRONT COVER ROLLER SPRING ROLLER DRIVE ROLLER BEARING E RING BMM SCREW M3X16 SCREW 6 WIRE HOLDER CORD BUSHING PAPER FEED FRAME FEED ROLLER SNAP BAND TRAY EMPTY SENSOR REP 27 4 SCREW 4 6 DRIVE SENSOR BRACKET DocuPrint C55 C55mp NC60 PART PL PART PL PART PL PART PL PART PL PART PL NUMBER LOC NUMBER LOC NUMBER LOC NUMBER LOC NUMBER LOC NUMBER LOC 101E13090 1 1 121E13400 9 1 13 12570 8 3 162K28000 32 20 28780 4 4 31 8820 27 2 101E13680 10 1 121E13410 51 13 12570 10 1 162 28010 3 2 20 28790 4 4 32 11450 6 2 101 13700 2 1 121E13420 5 1 13 12580 10 3 162K29280 1 1 20 8090 114 32 11460 7 1 101 13720 10 4 121 13430 51 13 12590 9 2 162 29290 102 22 20990 81 32 11470 7 1 105K16390 3 1 121E13440 9 2 13E13350 4 4 162029300 7 1 22E21000 8 2 32E11480 7 2 105K16400 3 1 121 13450 82 13E1
118. C60 FINAL ACTION Purpose To ensure the image quality is acceptable printer performance and appearance is satisfactory and to complete administrative tasks PROCEDURE 1 Install close all covers and doors 2 Run the Print Quality sample set a C55 C55mp Enter the Off Line mode press Menu and scroll to lt SERVICE gt Select TEST PATTERNS and print the PQ set NC60 Menu Up until Service Menu Item Down until Print PQ Set and press Enter 3 If possible ask the customer to print one of their representative prints to examine and comment on DocuPrint C55 C55mp NC60 Wrap Up Procedure 1 Record your service activities in the service log 2 Record the Total meter reading from the Diagnostic Test Pattern in the service log 3 Record the ESS software level from the Diagnostic Test Pattern in the service log 4 55 55 Off Line Print Settings Record the NIC software level from the Settings page in the service log 5 Putthe Printer PQ set and service log into the service log folder NOTE It is very important to save the PQ set There is information on the Diagnostic sheet Toner Concentration setpoints which will be needed if the NVM is reset or the PCU PWB is replaced 2 99 1 5 SERVICE CALL PROCEDURES FINAL ACTION Notes SERVICE CALL PROCEDURES 2 99 NOTES 1 6 DocuPrint C55 C55mp NC60 TITLE PAGE TROUBLESHOOTING TIPS 2 2 1 TR
119. D OVERHEAT THERMOSTAT COPY TRANSPORTATION AND FUSING CHAIN 10 LEVEL 2 SHEET 2 2 BSDs 2 99 Chain 10 Copy Transportation and Fusing 7 20 DocuPrint C55 C55mp NC60 ESS IF PWB 1 PL 3 1 HARD DRIVE PL 2 3 FLAT CABLE FLOPPY DRIVE 3 2 FLAT CABLE ACCESSORIES HARD DRIVE MEDIA SERVER CHAIN 13 LEVEL 2 SHEET 1 OF 1 2 99 BSDs DocuPrint C55 C55mp NC60 7 21 Chain 13 Accessories 15 1622 15 1 io CN116 CN117 CN118 cm m gt O amp O D CN104 CN105 11 gt 8 CN101 CN102 5 Figure 7 1 PCU Connectors CN101 Pin Destination 1 Registration Clutch 2 Grounding Roller Clutch 3 FeedSolenid 4 Registration Clutch 5 FeedSolenid 5 PaperEmptySensor 8 CN304 1 6 PaperEmptySensr 9 CN3042Con PWB X 10 CN304 5 Conn PWB 8 Paperin Reg Sensor 11 CN3043Conn PWB _ 9 Paper In Reg Sensor 12 04 4 CN103 13 CN307 6Conn PWB Pin Destination 14 CN307 8Conn PWB CN315 5 Conn PWB CN315 4 Conn PWB CN315 3 Conn PWB CN307 3 Conn PWB CN307 2 Conn PWB CN307 1 Conn PWB CN307 4 Conn PWB 6 Grounding Roller Clutch CN102 Pin Destination 1 CN1007 1 Waste Bot Full 2 1007 3 Waste Bot Ful 3 1007 2 Waste Bot Ful
120. DC STROBE2 i 3 PAPER SIZE 2 5 VDC 1 PAPER SIZE 3 5 PAPER SIZE 4 5 VDC CONNECTOR PWB 4 7 3 PAPER FEED DRIVE PCU PWB PAPER FEED PL42 MOTOR D MOTOR CLOCK A PI D MOTOR CLOCK A 5 24 VDC INTERLOCKED D MOTOR CLOCK B CASSETTE PWB D MOTOR CLOCK B PSO THRU PS4 PCU PWB CO Oo BYPASS Paper Paper Paper Paper Paper Paper SWITCH PAPER FEED Loaded Size 0 Size 1 Size 2 Size 3 Size 4 Status DES MOTOR 01 C 01 M 01 Y 02 K 02 C Codes Description 6 No Tray OFF L OFF L OFF L OFF L OFF L No Tray 1 in Printer Executive 1 _ON A ON H OFFALY OFF D E1 Sheet fed from Tray 1 did not reach Letter ON H OFF L ON H OFF L OFF L Registration Sensor A4 ON H OFF L OFF L ON H OFF L E3 Sheet fed from Bypass not reach Legal ON H OFF L OFF L OFF L Registration Sensor Other ON H OFF L OFF L OFF L OFF L 7 2 THE FEED MOTOR CLOCK SIGNALS ARE FROM 10 TO 23 VDC PAPER FEED 10 5 11 A4 CHAIN 7 LEVEL 2 SHEET 1 2 BSDs 2 99 Chain 7 Paner Feed 7 6 DocuPrint 55 6 T2 7 1 TRAY EMPTY SENSING T2 CASSETTE T2 T2 FEED 1 PWB CASSETTE SOLENOID T2 TRAY EMPTY PL 274 PWB PL 27 1 SENSOR 2 PL 27 1 PL 27 1 45 VDC CN3 1 5 6 24 VDC INTERLOCKED 3 T2 TRAY EMPTY S
121. Developer Motor 2 99 4 13 REPAIRS ADJUSTMENTS REP 4 6 REP 4 7 TONER SOLENOIDS PARTS LIST ON PL 4 6 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following Print Drum Module Color Developer Module Black Developer Module Right Side Cover REP 1 3 Top Cover REP 1 1 Rear Cover REP 1 2 REPAIRS ADJUSTMENTS REP 4 7 2 Figure 1 Remove the Drive Cover Cover Figure 1 Removing the Drive Cover 2 99 4 14 E2 3 Figure 2 Loosen the Tension springs Tension Springs T Figure 2 Removing the Springs DocuPrint C55 C55mp NC60 4 Figure 3 Remove the 3 pins and the Block 5 Figure 4 Remove the Inner Drive Frame 6 Figure 5 Remove the appropriate Toner Solenoid Inner Drive Frame E20 Figure 5 Removing the Toner Solenoid Figure 3 Removing the Pins and Block E5 Figure 4 Removing the Inner Frame 2 99 REPAIRS ADJUSTMENTS DocuPrint C55 C55mp NC60 4 15 REP 4 7 REP 4 8 ROLLER 4 Figure 2 Remove the Magnetic Roller CLEANING SOLENOID Outer Drive Cleaning Solenoid Frame PARTS LIST ON PL 4 6 REMOVAL Clutch Covers WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following Print Drum Module Color Developer Module Black Developer Module Right Side Cover REP 1 3 Top Cover REP 1 1 f Rear Cove
122. E QuadDot Smooth Screen Contone ENH ALIGNMENT PROCESS BLACK Mode Telnet Status Telnte Menu Enable POSTSCRIPT PageSize Policy PCL EMULATION Orientation Line Wrap Set Font FACTORY RESET This area used b and support pers SELECT FILE SETUP Mode Quantity Tray Visit our web site at Http xerox networkprinters com products c55 2 99 6 30 DocuPrint C55 C55mp MENU NC60 Menu Up until Menus Print Xerox DocuPrint NC60 Color Laser Printer Menu Map Job Menu Setial Menu Novell Menu Cancel Job Port Enable Novell Enable Item Down until Print Form Feed Port Timeout Notify Restart Pnnter Serial PDL Novell PDL Men Password Menu Binary PS Novell Binary PS Enter Password Novell Mode Print ow Contro Frame Type Processing a cns Delete pros Med PollingInterval Tray Menu PServer Name Menu Map Tray I Cost Size Priniary Server NDS Tree LPR Binary PS NDS Context ray Sequence i PCL Menu DLC DLL Enable Print Menu This is the Menu page It shows the first two layers of Font Number Startup Page Pitch ontig the Menu structure on the NC60 Point Size NetBEUI Enable PCL Font List NetBEUI PDL Symbol Set NetBeui Bin PS E DNA Orientation AppSocket Enabl Menu Map Bom eee AppSocket PDL Fault History Line Terminat AppSocket Bin PS Tips amp Tricks System Menu Etalk Enable Disk Directory Language HTTP Enable Print Quantity P
123. E C is Gamma patch bias Bias Gamma KL 800 K low humidity patch bias displayed on the Message Display 1 Enter Background diagnostics and press Gamma 505 high numidity patch bias 2 Use the Previous 5 Next 6 keys to the Menu 3 key until TC BIAS PLAIN CL Bias Gamma 800 norm humidity patch bias select the color and range to be changed is displayed on the Message Display Bias Gamma CL 800 C low humidity patch bias ONERE ei Mesh fe cms TC Bias OHP BS H 2200 high humidity bias 3 2 Enter y e the display will select the bias and range to be changed TC Bas OHPBSN 2 9 5 Bias OHP BS L 4 Press Previous 5 Next 6 to change the 3 Press the Enter 7 key the display will Bias OHP DT H 200 TX high humidity bias offset value ba prasentvalie Bias OHP DT N 5 To store the change insert a sheet of paper 4 Press Previous 5 Next 6 to change the Bias OHP DT L into the bypass slot to actuate the Bypass value C55 C55mp Switch then press the Form Feed 1 key 5 To store the change insert a sheet of paper Bias 5 1200 Paper high humidity bias sursis uu 2 on and then into the bypass slot to actuate the Bypass Bias P P BS N 1305 Paper norm humidity bias 9 Switch then press the Form Feed 1 key Bias P P BS L 1400 Paper low humidity bias The On Line LED will switch on and then TC Bias P P DT H 0 Pape
124. E gt EXIT THIS MENU gt PATTERN TYPE lt STRIPE PATTERN TYPE QUANTITY gt NUMBER OF COPIES lt 1 99 gt TRAY Must have Tray 2 Installed TRAY TRAY 1 gt TRAY 2 EXIT THIS MENU gt PATTERN TYPE RUN TEST JOB YES NO C55 C55mp Only TOP MENU SERVICE Continued PATTERN TYPE EXIT THIS MENU gt SERVICE TEST PATTERNS DIAGNOSTICS TEST PATTERNS DIAGNOSTICS YES continued NO EXIT THIS MENU TEST PATTERNS EXIT THIS MENU SERVICE LOSSY COUNTER BINARY LOSSY COUNTER gt BINARY LOSSY COUNTER CONT TONE lt gt LOSSY COUNTER EXIT THIS gt SERVICE SOFTWARE SHOW SW LEVEL DATA SERVICE SHOW MEMORY SHOW MEMORY MB SERVICE ERROR LOGS ACTIVE FAULTS ERROR LOGS lt FAULTS lt XXX XXX ERROR LOGS FAULTS IN LOG LIST OF LAST 50 FAULT HISTORY PRESS ENTER FAULTS ERROR LOGS EXIT THIS gt SERVICE ADJUSTMENTS LEFT MARGIN ADJUSTMENTS LEFT MARGIN it mm ADJUSTMENTS TOP MARGIN TOP MARGIN gt it mm GENERAL PROCEDURES 2 99 SERVICE 6 16 DocuPrint 55 55 55 55 55 55 TOP MENU TOP MENU SERVICE SERVICE Continued Continued LAYER 4 LAYER 4 SERVICE ADJUSTMENTS CLEANING CYCLE SERVICE SHOW SETPOINTS BLACK TC ADJUSTMENTS CLEANING CYCLE NEVER SHOW
125. E64320 NOT SPARED 7E48480 NOT SPARED 23E14950 20E28790 NOT SPARED DESCRIPTION DRIVES FRAME RETAINING RING 7MM PULLEY MAIN DRIVE BELT A REP 4 2 PIN SHAFT WASHER BEARING BEARING GEAR SUPPORT PLATE SCREW M3X6 GEAR RETAINING RING MAIN DRIVE BELT B REP 4 2 MAIN DRIVE PULLEY RIGHT SIDE FRAME DocuPrint C55 C55mp NC60 PL 4 5 INTERLOCK SWITCHES DEVELOPER DRIVE COMPONENTS DocuPrint C55 C55mp NC60 2 99 5 13 ITEM A O 11 12 13 14 15 16 17 PART NOT SPARED 23E14930 NOT SPARED 23E14920 20E28770 7E48460 7 48450 SPARED 49 72000 809 2110 SPARED SPARED 110 7560 162 35610 SPARED 809 2090 110 7550 SPARED DESCRIPTION DRIVES FRAME BELT C REP 4 3 RETAINING RING 5MM BELT D REP 4 3 UPPER IDLER PULLEY SHUTTER IDLER LOWER IDLER PULLEY SCREW 6 BRACKET SPRING SCREW M2X10 SCREW M3X14 INTERLOCK SWITCH REP 4 4 HARNESS SCREW M3X12 SPRING LASER INTERLOCK SWITCH REP 4 4 RIGHT SIDE FRAME PARTS LIST SECTION PL 4 5 PL 4 6 SOLENOID ROLL CLEANER SOLENOIDS PARTS LIST SECTION PL 4 6 X AM 7 7 10 SR Q M 2 99 5 14 ITEM 10 11 12 SPARED SPARED 121 1 3350 SPARED 121 1 3360 121 13370 121 13380 SPARED 7 4854
126. ECTOR REMOVAL WARNING Switch the Main Power off and discon nect the Power Cord 1 Figure 1 Grasp the two latches and open the Transfer Assembly Transfer Assembly Figure 1 Opening the Transfer Assembly 2 Figure 2 Lift and remove the Toner Collector Toner Collector Figure 2 Removing the Toner Collector DocuPrint C55 C55mp NC60 GP 5 FUSER REMOVAL WARNING Switch the Main Power off and discon nect the Power Cord 1 Figure 1 Grasp the two latches and open the Transfer Assembly Transfer Assembly TUA C7 Figure 1 Opening the Transfer Assembly 2 Figure 2 Release the Latch and open the Fuser Cover C4 Figure 2 Opening the Fuser Cover 2 99 6 43 3 Figure 3 Release the Latch Lever on the right side of the Fuser 4 Lift and remove the Fuser Module Latch Figure 3 Removing the Fuser Module NOTE Be careful not to tilt the fuser GENERAL PROCEDURES GP 4 GP 5 3 1 FUSER SPEED C55 C55mp 66 FIRMWARE ONLY C55 C55mp Only PURPOSE NOTE This adjustment only applies to Firmware version 66 The purpose of this adjustment is to set the speed of the Fuser to prevent the trail edge of the last color Yellow or Black from being misregistered or smeared ADJUSTMENT 1 Enter Normal Diagnostics Press Menu amp Enter Power ON 2 Ifthe message display indicates PCU DIAG MODE 66 continue with the adjustment
127. ED NA 12E8420 NOT SPARED NOT SPARED NOT SPARED NOT SPARED 118E13750 17E8350 19E37480 NOT SPARED NA 32E11480 PO ITEM 14 PO ITEM 14 15E59940 809E1730 11E7360 116E7370 PO ITEM 14 162K35620 DESCRIPTION UPPER LINK LEFT SIDE FRAME RETAINING RING 7MM LOWER LINK LOWER LINK SPRING SCREW TIE ROD SCREW 4 6 INSULATOR SHEET FOOT PAD BASE PLATE LEFT GUIDE SCREW 6 EARTH PLATE GROUND SPRING DETECT SPRING PHOTORECEPTOR DETECT LEVER DETECT SPRING CLIP SCREW M3X6 HARNESS DocuPrint C55 C55mp NC60 PL 8 1 PAPER FEED ASSEMBLY PART 1 OF 3 1 2 18 20 23 PL 8 2 ITEM 1 1 PL 8 3 ITEM 1 20 21 22 23 2 99 DocuPrint C55 C55mp NC60 5 21 PART 22K53880 P O ITEM 1 55E38931 118E13780 1E46940 809E1760 P O ITEM 1 13E13370 809E5640 6E61510 22E20990 600K65260 P O ITEM 12 P O ITEM 12 P O ITEM 12 P O ITEM 12 809E1720 118E13760 8R7748 38E17380 P O ITEM 1 809E2000 22E21030 DESCRIPTION PAPER FEED ASSEMBLY REP 8 2 LOWER GUIDE LOWER SHEET LOWER GUIDE SHEET GUIDE SPRING RETAINING RING BEARING GUIDE SPRING ROLLER SHAFT GROUNDING ROLLER TONER SLIDE BOX ASSY SENSOR COVER SENSOR WASTE TONER ARM WASTE TONER SPRING SLIDE SPRING INSULATOR TONER BOTTLE CUST PURCHASE ITEM PAPER GUIDE REP 8 1 SCREW 8 SPRING ROLLER PARTS LIST SECTION PL 8 1 PL 8 2 PAPER FEED ASSEMBLY PART 2 OF 3
128. ENT NOTE After assembling the components hand crank the feeder through several cycles Energize the Feed Solenoid several times by hand and check that the Feed Solenoid engages the Feed Clutch and stops the rollers in the flat down position 2 99 4 54 REP 27 6 TRAY 2 FEED ROLLERS PARTS LIST ON PL 27 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Tray 2 Module REP 27 1 2 Remove the Tray 2 Feed Solenoid and Feed Clutch REP 27 5 3 Figure 1 Remove the Tray 2 Feed Rollers Feed Rollers F5 Figure 1 Removing the Tray 2 Feed Rollers DocuPrint C55 C55mp NC60 REP 27 7 TRAY 2 DRIVE ROLLER AND DRIVE CLUTCH PARTS LIST ON PL 27 3 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Tray 2 Module REP 27 1 2 Remove the Tray 2 Feed Solenoid and Feed Clutch REP 27 5 3 Figure 1 Remove the Tray 2 Drive Clutch Clutch F4 Figure 1 Removing the Tray 2 Drive Clutch DocuPrint C55 C55mp NC60 4 Figure 2 Remove the Tray 2 Drive Roller F6 Figure 2 Removing the Tray 2 Drive Roller 2 99 4 55 REPAIRS ADJUSTMENTS REP 27 7 ADJ 3 1 1 DENSITY AND COLOR BALANCE C55 C55mp PURPOSE To adjust the Density and Color Balance of the print generated by the ESS This procedure actually consists of three adjustments ADJ 3 1 1A Color Density C55 C55mp ADJ 3 1 1B Black Density
129. ESS This will vary somewhat from printer to x eivetica Bold printer Helvetica Obiique Heivetica Bold blique Helvetica Narrow Heivetica Narrow Bold Helvetica Narrow Oblique Heivetica Narrow BoldOblique Palatino Roman Palatino Bold Palatino Italic Palatino Boldltalic Courier Courier Bold Courier Oblique Courier BoldOblique NewCenturySchlbk Roman NewCentur Schlbk Bold NewCenturySchlbk Italic NewCenturySchlbk BoldlItalic ITC Bookman Light ITC Bookman Demi ITC Bookman Lightltalic ITC Bookman Demiltalic THE DOCUMENT COMPANY Visit our web site at Http xerox networkprinters com products c55 Xerox The Document Company the stylized X DocuPrint and all Xerox product names are trademarks of XEROX CORPORATION Adobe Postscript and the Postscript logo are trademarks of Adobe Systems Incorporated which may be registered in certain jurisdictions Adobe PostScripl Times Helvetica and Palatino are trademarks of Linolype Hell AG anro its subsidiaries ITC Avant Garde Gothic Zapf Chancery Zapf Dingbats and ITC Bookman are registered trademarks of International Typeface Corporation GENERAL PROCEDURES 2 99 PS FONT 6 28 DocuPrint C55 C55mp PS FONT LIST NC60 Fress Display Reads Menu Up until Menus Print Item Down until Print PS Font List Processing PostScript This page lists the PostScript fonts which are resident on the ESS This may vary from printer to printer
130. FUSER MODULE 2 20 JA REPLACE OIL PAD 2 21 TO FUSER THERMISTOR ERROR 2 21 T1 UNDER TEMPERATURE 2 22 T2 OVER TEMPERATURE 2 23 U0 IOT ROM ERROR 2 23 U1 IOT RAM ERROR 2 24 U2 IOT NVM RAM ERROR 2 24 U3 IOT ESS COMMUNICATION ERROR ise tee 2 24 U4 OPTICS FAULT 2 25 U5 POLYGON MOTOR FAULT 2 25 U6 MOTOR FAULT DEVELOPER 2 26 U7 MOTOR FAULT MAIN 2 27 2 99 2 1 2 STATUS INDICATOR RAPs TITLE PAGE W1 COLOR DEVELOPER MODULE NEAR END OF USE 2 28 W2 BLACK DEVELOPER MODULE NEAR END OF USE 2 28 W3 PRINT DRUM NEAR END OF USE 2 28 W4 FUSER MODULE NEAR END OF USE 2 29 W5 FUSER OIL BOTTLE PAD NEAR END OF USE 2 29 OF1 DEAD PRINTER RAP 2 30 OF2 CONTROL PANEL RAP 2 32 OF3 TRAY 1 PAPER SIZE SENSING RAP 2 35 OF4 TRAY 2 PAPER SIZE SENSING RAP 2 36 OF5 LOAD PAPER 2 37 OF6AESS RAP C55 C55mp 2 38 OF6BESS RAP NC60 2 39 OF7 ESS BOOT FAILURE ERROR CODES NC60 2 40 OF8 ARCING RAP 2 41 STATUS INDICATOR RAPs SECTION CONTENTS TROUBLESHOOTING
131. G 9MM RETAINING RING 7MM ROS LATCH RELEASE LEVER RETAINING RING 5MM SCREW SCREW M3X8 SPRING FUSER SPRING FRAME COVER LOCK SHAFT LEFT FUSER STOP SCREW M3X6 RIGHT FUSER STOP PARTS LIST SECTION PL 12 1 PL 13 1 BLACK TONER DISPENSER ASSEMBLY 142231 ITEM PART DESCRIPTION 1 50K35390 TONER DISPENSER ASSEMBLY 2 P O ITEM 1 SCREW 8 3 P O ITEM 1 COVER 4 P O ITEM 1 SEAL 5 P O ITEM 1 CARTRIDGE BASE PLATE 6 P O ITEM 1 SEAL 7 P O ITEM 1 COVER 8 P O ITEM 1 COVER LOCK PAWL 9 P O ITEM 1 COVER 10 P O ITEM 1 SCREW M3X5 11 P O ITEM 1 HOPPER 12 P O ITEM 1 SEAL 13 11 7400 LOCK LEVER 14 809E1990 SHUTTER SPRING 15 1E43750 LOCK FRAME 16 55E37730 SHUTTER 17 28 12150 RETAINING RING 4MM 18 P O ITEM 1 PADDLE 19 P O ITEM 1 PADDLE 20 P O ITEM 1 PADDLE 21 P O ITEM 1 AUGER 22 13E12540 BEARING 23 13E12560 BEARING 24 7E48390 UPPER TONER GEAR 25 7E48400 LOWER TONER GEAR 26 7E48410 GEAR 27 35E41680 TONER SEAL 28 P O ITEM 1 SCREW M3X6 29 127E10920 TONER MOTOR BLACk 30 7E48430 DRIVE GEAR 31 P O ITEM 1 TONER HOPPER PARTS LIST SECTION 2 99 PL 13 1 5 34 DocuPrint C55 C55mp NC60 PL 14 1 PAPER CASSETTE COMPONENTS PART 50K40300 NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED DESCRIPTION PAPER TRAY ASSEMBLY A
132. IS MOVING THROUGH THE FUSER 24 VDC INTERLOCKED 1 10 4 OIL SENSING OIL SENSOR PL XX 1 CN307 CN103 2 Z TIME sa I STROBE 1 9 ig SORE m OIL SENSOR FUSER FAN CONNECTOR PWB PCU PWB Status Description Codes Sheet did not reach Exit Sensor Sheet on Exit Sensor at power on COPY TRANSPORTATION AND FUSING CHAIN 10 LEVEL 2 SHEET 1 2 2 99 BSDs DocuPrint C55 C55mp NC60 7 19 Chain 10 Copy Transportation and Fusing 10 5 FUSER HEAT CONTROL 1 FUSER ASSEMBLY FUSER FUSER THERMISTOR ON L CN304 CN103 CN107 703 T a a a ya v li u Ts HEAT ROD 2 lt 4 SENSE L 3 NEW FUSER DETECT SIGNAL 4 THE PCU USES INPUT FROM THE THERMISTOR TO GATE THE TRIAC AND SWITCH THE HEAT ROD ON VOLTAGE 103 9 COLD FUSER O VDC HOT FUSER APPX 3 5 VDC THE AC ON L SIGNAL SWITCHES THE AC OFF WHEN THE INTERLOCKS ARE OPEN OR WHEN A MALFUNCTION OCCURS THE FUSER LINK IS USED TO DETECT WHEN A NEW FUSER ASSEMBLY IS INSTALLED IT MELTS OPEN AND RESETS THE FUSER COUNT 115 VAC PRINTERS AC1 115 VAC AC2 NEUTRAL 220 VAC PRINTERS AC1 110 VAC AC2 110 VAC Slate Description Codes P 2 The Thermistor is open f The temperature is below 85 The temperature is above 240 C e oe f 7 CONNECTOR A SSS THERMISTOR OVERHEAT THERMOSTAT WOO PWB lt lt PCU PWB FUSER ASSEMBLY HEAT RO
133. K SWITCH CN1007 212 SYNC GND VIDEO DATA LASER DIODE ON L 5 VDC GND LASER LOCK POLYGON MOTOR LOCK L 5 VDC POLYGON MOTOR ON L 5 VDC GND 24 VDC INTERLOCKED ROS ASSY PL 12 1 5 ESS PWB ROS ASSY Signal Description Status Description STS Status sends Status signals to 55 Codes CMD Command ESS sends commands to the 04 Laser Diode failure SRDY Status Ready ESS is ready to receive status signals U5 Polygon Motor failure CRDY Command Ready IOT is ready to receive command signals READY Ready IOT is ready to print 6 Reset IOT requests ESS reset HSYNC Horizontal Sync sends line sync to ESS VSYNC Vertical Sync IOT sends page sync to ESS LASER DATA Data ESS sends raster data to the IOT INTERLOCK PAGE Page ESS is sending a page of data SWITCH 7 PCU PWB LASER SCANNING CHAIN 6 LEVEL 2 SHEET 1 OF 1 2 99 BSDs DocuPrint C55 C55mpINC601 7 5 Chain 6 Scannina 7 1 PAPER EMPTY SENSING TRAY EMPTY 1 SENSOR PL 8 2 TRAY EMPTY 5 VDC 7 4 PAPER FEED FEED SOLENOID PL 8 2 24 VDC INTERLOCKED FEED SOLENOID ON L 24 VDC 2 7 5 BYPASS SENSING 7 2 PAPER SIZE SENSING SWITCH BYPASS SENSED 98 CASSETTE L 5 VDC CNS02 1 Mn CN201 CN107 PAPER SIZE 0 H 5 VDC PAPER SIZE 1 H 5 V
134. LLERS IS DETERMINED XEROGRAPHICS BY THE GAMMA SENSOR DURING THE PROCESS CONTROL SETUP CHAIN 9 LEVEL 2 SHEET 5 10 2 99 BSDs DocuPrint C55 C55mp NC60 7 13 Chain 9 Xerographics 4 J3 m oa 5 24 VDC INTERLOCKED CYAN TONER SOLENOID L 24 VDC INTERLOCKED YELLOW TONER SOLENOID ON L CN118 CN1009 2 TONER SENSE SIGNAL 2 GND 5 VDC MAGENTA TONER SENSE SIGNAL GND 5 VDC CYAN TONER SOLENOID PL 4 6 MAGENTA TONER SOLENOID PL 4 6 YELLOW TONER SOLENOID PL 4 6 COLOR DEVELOPER ASSEMBLY e Ae OOOO PCU PWB COLOR TONER PL 4 2 MOTOR CN116 TONER MOTOR CLOCK A PL4 3 TONER MOTOR CLOCK B YELLOW TONER SOLENOID MAGENTA TONER SOLENOID CYAN TONER SOLENOID WHEN ONE OF THE TONER SOLENOIDS IS ENERGIZED THE TONER MOTOR RUNS AND THE TONER IS DISPENSED INTO THE DEVELOPER HOUSING THE TONER SENSE SIGNALS MEASURE THE TONER CONCENTRATION IN THE DEVELOPER HOUSINGS THE COLOR DEVELOPER LINK IS USED TO DETECT WHEN A NEW COLOR DEVELOPER MODULE IS INSTALLED IT MELTS AND RESETS THE Y C AND M DEVELOPER COUNT THE COLOR TONER MOTOR IS CONTROLLED BY THE SENSE SIGNALS THE MOTOR PROVIDES DISPENSE DRIVE FOR ALL THREE COLORS THE CLOCK A AND CLOCK B SIGNALS ARE APPROXIMATELY 12 VDC WHEN MEASURED TO GROUND THE CLOCK A AND CLOCK B SIGNALS ARE APPROXIMATELY 22 VAC WHEN MEASURED ACROSS A amp B Status Description Codes
135. LSO AVAILABLE AS CUSTOMER OPTION 9853034 INSTRUCTION LABEL ROTATION PLATE RETARD PAD SIZE LABEL A REAR GUIDE CASSETTE CASE SPRING LEFT SNUBBER SIDE GUIDE RIGHT SNUBBER LABEL DISCHARGE BRUSH STOPPER SIDE PLATE ROTATION LOCK SPRING SIZE LABEL B DocuPrint C55 C55mp NC60 2 99 5 35 PARTS LIST SECTION PL 14 1 PL 27 1 TRAY 2 COMPONENTS 1 OF 3 PARTS LIST SECTION PL 27 1 2 99 5 36 ITEM OANDOARWNDN amp 13 14 15 16 17 18 19 48 53780 48 53790 48 53770 SPARED SPARED SPARED SPARED SPARED 162 35720 SPARED 160K41070 7E51250 6E61680 NOT SPARED 80935800 809E5810 117E18520 NOT SPARED 11E7610 DESCRIPTION REAR COVER RIGHT COVER LEFT COVER FRAME BASE PLATE LEFT FRAME SCREW 4 6 E RING 6MM POSITION PIN SENSOR HARNESS SCREW 6 CASSETTE PWB REP 27 3 LOCK PAWL LOCK SHAFT RIGHT FRAME LOCK SPRING LEVER SPRING INTERFACE CABLE SCREW JOINT LEVER DocuPrint C55 C55mp NC60 PL 27 2 TRAY 2 COMPONENTS 2 3 DocuPrint C55 C55mp NC60 2 99 5 37 ITEM PART 121E14310 121E14320 NOT SPARED NOT SPARED NOT SPARED NOT SPARED 7E51260 NOT SPARED NOT SPARED NOT SPARED 12E8450 NOT SPARED NOT SPARED 31E8820 NOT SPARED NOT SPARED NOT SPARED NOT SPARED DESCRIPTION DRIVE CLUTCH REP 27 7 FEED SOLENOID REP 27 5 E RING 4MM E RING
136. LUTCH ON L 24 VDC SENSOR PWB PL 10 4 CN601 45 VDC CN311 CN307 STROBE TRANSPARENCY DETECTED L 66 VDC 8 3 TRANSFER TACKING GROUNDING 4 ROLLER SOLENOID PL 8 3 24 VDC INTERLOCKED GROUNDING ROLLER ON L 24 VDC 5 Status Description GAMMA Codes SENSOR E1 Sheet fed from Tray 1 did not reach Registration Sensor E2 Sheet fed from Tray 2 did not reach Registration Sensor Sheet fed from Bypass did not reach Registration Sensor CONNECTOR 4 Sheet on Registration Sensor or Transparency Sensor PWB 6 power on E6 Sheet made Registration Sensor did not reach Gamma Sensor TRANSPARENCY SENSOR PCU PWB REGISTRATION GROUNDING SENSOR ROLLER 7 REGISTRATION SOLENOID CLUTCH REGISTRATION CHAIN 8 LEVEL 2 SHEET 1 OF 1 BSDs 2 99 Chain 8 Reaistration 7 8 DocuPrint C55 C55mpINC601 9 1 COROTRON POWER AND DEVELOPER BIAS GENERATION CN106 1 PCU PWB PL 4 2 2 Charge 1 Control 81 2 L 9 1 I 3 Transfer Control 1 3 1 7 4 4 I I I I I I 6 I I I I 3 I 5 2 Bias l Control 1 6 0 1 7 HIGH VOLTAGE POWER SUPPLY PWB PL 4 2 CHARGE ON L 24 VDC GRID BIAS LOW ON Grid GRID BIAS MID ON Switching TRANSFER L 24 VDC TRANSFER CONTROL SIGNAL 24 VDC INTERLOCKED GND GND BIAS CONTROL SIGNAL K
137. Lower Frame A43A Figure 3 Reinstalling the Transfer Drum Lower Frame REPAIRS ADJUSTMENTS REP 9 4 REP 9 5 TRANSFER DRUM CLEANER BRUSH CLUTCH PARTS LIST ON PL 9 4 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Remove the Transfer Drum Cleaner REP 9 4 3 Figure 1 Remove the Transfer Drum Cleaner Brush Clutch Assembly A35 Figure 1 Removing the Transfer Drum Cleaner Brush Clutch REPAIRS ADJUSTMENTS REP 9 5 9 6 REPLACEMENT NOTE When reassembling the clutch be sure to engage the spring in the sleeve cutout 2 99 4 40 REP 9 6 TRANSFER DRUM CLEANING BLADE PARTS LIST ON PL 9 4 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Remove the Transfer Drum Cleaner REP 9 4 3 Figure 1 Remove the Transfer Drum Cleaning Blade Cleaning Blade A36 Figure 1 Removing the Transfer Drum Cleaning Blade DocuPrint C55 C55mp NC60 REP 9 7 TRANSFER DRUM CLEANING BRUSH PARTS LIST ON PL 9 4 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Remove the Transfer Drum Cleaner REP 9 4 3 Figure 1 Remove the Transfer Drum Cleaner Brush Clutch Assembly A35 Figure 1 Removing the Transfer Drum Cleaner Brush Clutch DocuPrint C55 C55mp NC60 4 Fig
138. MBER None REFERENCE 2 99 6 72 TAG 3 DESCRIPTION PCU and ESS PWBs modified to allow CISPR B certification in Rank Xerox ESS also upgraded to optimize memory timing CLASS NA USE MFG SERIAL NUMBERS NAME ESS and IOT Firmware PURPOSE Firmware upgrade to allow CISPR B certification in Rank Xerox KIT NUMBER None REFERENCE TAG 4 DESCRIPTION Seals added to black toner hopper to prevent toner leakage during initial loading CLASS NA USE MFG SERIAL NUMBERS NAME Black Toner Hopper PURPOSE Seals added to prevent toner leakage KIT NUMBER None REFERENCE DocuPrint C55 C55mp 5 DESCRIPTION was upgraded to PCU Firmware Version 75 at the manufacturing site E Prom soldered to PCU PWB CLASS NA USE MFG SERIAL NUMBERS NAME IOT Firmware PURPOSE Firmware upgrade KIT NUMBER None REFERENCE TAG 6 DESCRIPTION Field upgrade of IOT PCU Firmware Version 75 soldered to PCU PWB CLASS NA USE MFG SERIAL NUMBERS NAME IOT Firmware PURPOSE Firmware upgrade KIT NUMBER None REFERENCE DocuPrint C55 C55mp TAG 7 DESCRIPTION Strip of aluminum tape added to Waste Toner bottle Assembly to aid in recognition of full toner bottle CLASS NA USE MFG SERIAL NUMBERS NAME Waste Toner Change PURPOSE To aid in recognizing full bottle KIT NUMBER None REFERENCE 2 99 6 73 GENERAL PROCEDURES Tags NOTES GENERAL PROCEDURES 2 99
139. NC60 ADJUSTMENT 1 Figure 2 Insert a screwdriver in the hole just above the Yellow Toner Clutch and manually energize the Magnetic Roller Cleaning Solenoid 2 Turn the Developer motor counterclockwise while watching the Magnetic Roller Cam Shafts Insert Screw driver Yellow Toner Clutch K5 Figure 2 Energizing the Solenoid 2 99 4 65 Figure 3 Loosen the screws and move the solenoid until the arm stops the clutch when the solenoid is energized Figure 3 Adjusting the Solenoid REPAIRS ADJUSTMENTS ADJ 4 1 ADJ 6 1 MAGNETIC ROLLER CLEANER CAMS PURPOSE The purpose of this adjustment is to ensure that the Magnetic Roller Cleaner Cams raise the Cleaner Blades when the Magnetic Roller Solenoid is energized and lower the Cleaner Blades when the solenoid is deenergized CHECK Switch the power off Open the printer and remove the Print Drum Color Developer Module and Black Developer Module Observe the four Y M C K Magnetic Roller Cams Figure 1 The M C and K cam lobes should be in the same radial position as the Y cam lobe If they are not the same perform the adjustment Figure 1 Checking the Shafts REPAIRS ADJUSTMENTS ADJ 6 1 ADJUSTMENT 1 Remove the Outer Drive Frame REP 4 8 steps 1 2 and 3 Figure 2 Remove the three idler gears Rotate the M C and K cams until they are aligned with the Y Cam 4 Reinstall the three idler gears Perform the ADJ 4 1 che
140. ODUCTION 6 75 CLASSIFICATION 6 75 6 75 GENERAL PROCEDURES SECTION CONTENTS 2 99 6 2 DocuPrint C55 C55mp NC60 DIAGNOSTICS NOTE The diagnostic operation is the same for both the C55 and NC60 printers however the keys which are pressed to exercise the diagnostics have different names same location NC60 key number will be enclosed in and will follow the C55 key names There are two diagnostic modes the Normal mode and the Special mode The Normal mode is used to Test Input components Test the Laser components View the Charge Transfer and Bias voltage values Test the Motors Test the Clutches Run the IOT test pattern Initialize the NVM Set the consumable counter values DocuPrint C55 C55mp NC60 ENTERING THE NORMAL DIAGNOSTIC MODE 1 Press the Menu 3 and Enter 7 keys at the same time then switch on the Main Power The C55 Control Panel will indicate the following m m OnLine Form Media Menu Select Previous Next Enter eed Server El Pel D The NC60 Control Panel will indicate the following P PCU DIAG MODE XX 4 0 m m E gm gm m OnLine Enter Menu 2 Message Display indicates that you are in the PCU Diagnostic Mode and displays the ROM version number
141. OME SENSOR REGISTRATION SENSOR BYPASS SWITCH PS0 TRAY TEMPERATURE SENSOR HUMIDITY SENSOR 2 TRAY EMPTY SENSOR so St 24 ESL INTERLOCK SWITCH PHOTORECEPTOR DETECT WASTE TONER BOTTLE SENSOR PS1PS2 PS3 54 ES ES T2 T2 T2 S2 S3 54 Figure 6 1 Input Component Location LED USED BLACK K SWITCH 424 V INTERLOCK SCAN 00 SWITCH BYPASS SWITCH SWITCH TRAY EMPTY SCAN 01 SENSOR PAPER SIZE 0 TRANSPARENCY JAM 2 99 6 4 MAGENTA M REGISTRATION SENSOR PAPER SIZE 1 PHOTORECEPTOR DETECT T2 PAPER SIZE 1 TRANSFER DRUM HOME SENSOR CLEANER JAM SENSOR YELLOW Y EXIT SENSOR PAPER SIZE 2 WASTE TONER COLLECTOR SENSOR T2 PAPER SIZE 2 GAMMA SENSOR Interlock must be closed DocuPrint C55 C55mp NC60 OPTICAL 5 5 TEST This Diagnostic routine is used to check the operation of the Raster Output Scanner ROS 1 Enter Normal diagnostics and press the Menu 3 key until OPTICAL SYS TEST is displayed on the Message Display 2 Press the Form Feed 1 key to start the test 3 The Form Feed lamp will flash during the test 4 The Polygon Motor and the Laser Diode will switched on for 30 seconds The On Line lamp will come on when the Horizontal Sync signal is generated 5 To stop the test press the Media Server 2 key DocuPrint C55 C55mp NC60 VOL TEST MAIN This Diagnostic routine is used to check the Charge Trans
142. PATTERNS 35 Halftone This test pattern consists of page 35 area coverage halftone pattern This pattern are useful in troubleshooting problems the black developer subsystem IMAGE QUALITY SPECIFICATIONS TEST PATTERNS 2 99 3 28 Black 35 Halftone DocuPrint C55 C55mp NC60 Blank Print When selected each developer housing is switched on a small indicates which color is running remainder of the print is blank This print can be useful when troubleshooting residual image or offsetting problems DocuPrint C55 C55mp NC60 2 99 3 29 IMAGE QUALITY SPECIFICATIONS TEST PATTERNS GENERATED TEST PATTERNS The IOT contains one internally generated test pattern It is used to help isolate image quality problems If the IOT test pattern prints OK but test patterns sent from the ESS are bad the problem must be associated with the ESS Anytime the IOT test pattern prints bad the problem is associated with the IOT IMAGE QUALITY SPECIFICATIONS TEST PATTERNS 2 99 3 30 DocuPrint C55 C55mp NC60 DEFINITIONS Image Quality Defect Definitions NOTE When referring to a print from this machine the front of the machine is the location where a user of the machine would normally stand to read the control panel Prints exit from the front to the rear and are deposited face down on the top cover The lead edge of the print is the print edge that comes out first Backg
143. PWB If the problem still exists replace the Control Panel PWB Refer to BSD 2 1 and check the following signals e CN103 22 Read Write for an open e CN103 23 Register Select for an open or a short to ground e CN103 24 Display Enable for an open or a short to ground e CN103 25 Data 3 for an open e CN103 26 Data 2 for an open Refer to BSD 10 2 and check CN103 18 Strobe 2 for a short to ground Refer to BSD 10 4 and check CN103 19 Strobe 1 for a short to ground If all appear OK replace the Control Panel PWB If the problem still exists replace the PCU PWB 2 99 2 32 OF2 2 The Message Display is blank no during IOT Boot PROCEDURE Switch the power off wait 10 seconds and switch the power on while listening to the The IOT runs boots up when the printer is switched on Y N Set up the meter to measure 5 VDC Measure between CN310 10 and CN310 11 The meter indicates 5 VDC Y N Go to OF1 1 5 VDC RAP Refer to BSD 2 1 and check the 5 VDC CN310 11 and DC COM CN310 10 from the Connector PWB to the Control Panel If OK replace the Control Panel PWB Refer to BSD 2 1 and check the following signals e CN103 22 Read Write for a short to ground e CN103 26 Data 2 for a short to ground e CN103 27 Data 1 for an open e CN103 28 Data 0 for an open Refer to BSD 6 and check the following signals e CN104 1 STS Status for an open or a short to ground e CN104 5
144. Press Menu 8 to scroll to NV RAM INITIAL b Insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored 4 Enter the Consumable Usage a Press Menu 3 to scroll to COUNTER SET DRUM b Press Enter 7 Use Menu 3 to step to the digit to be changed Use Next 6 Previous 5 to change the value d Insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored e Press Previous 5 to select the next consumable to be entered f Repeat steps b through e until all consumable values have been entered REPAIRS ADJUSTMENTS ADJ 3 3 5 Enter the Page Counts a Press Menu 3 to scroll to PCU DIAG MODE Enter Special Diagnostics PCU DIAG MODE displayed press On Line 0 then press Enter 7 release both Use Menu 3 to scroll to COUNTER SET2 TTL Press Enter 7 Use Menu 3 to step to the digit to be changed Use Next 6 Previous 5 to change the value Insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored Press Previous 5 to select the next Page Count to be entered Repeat steps d through g until all Page Counts have been re
145. RED 115E5830 NOT SPARED NOT SPARED 1E46930 6E58160 N A 48E43530 55E38910 809E5660 120E15800 101E13700 DESCRIPTION EXIT ASSEMBLY EXIT SENSOR GUIDE ROLLER GUIDE RETAINING RING 3MM WASHER GEAR IDLER GEAR OUTPUT DRIVE ARM SPRING BEARING BELT SPRING SCREW M3X4 STATIC ELIMINATOR SCREW M3X8 SCREW M3X6 OUTPUT FRAME OUTPUT SHAFT TOP FRONT COVER REP 2 1 SHIELD SPRING ACTUATOR SENSOR COVER PARTS LIST SECTION PL 2 1 PL 3 1 LVPS ESS PARTS LIST SECTION PL 3 1 10 11 14 FOR ESS COMPONENTS REFER TO PL 3 2 2 99 5 6 ITEM O O ON 11 12 13 14 15 16 17 SPARED NOT SPARED NOT SPARED NOT SPARED NOT SPARED 160K32850 NOT SPARED NOT SPARED NOT SPARED 105K16400 105K16390 P O ITEM 10 160K32790 P O ITEM 10 P O ITEM 10 NOT SPARED NOT SPARED 160K49683 160K63720 DESCRIPTION GUIDE SCREW M3X6 SHROUD COVER SHROUD ESS IF BOARD LVPS ASSY 110V REP 3 1 LVPS ASSY 220V REP 3 1 BRACKET CASSETTE PWB REP 3 2 SCREW M3X6 LVPS PWB SCREW 4 6 SCREW M3X4 ESS PWB C55 REP 3 4 ESS PWB NC60 REP 3 4 DocuPrint C55 C55mp NC60 3 2 55 55 55 5 ITEM PART DESCRIPTION 1 160K40980 SLIC PWB 2 160K27110 TOKEN RING CARD OPTIONAL 160K40220 ETHERNET CARD OPTIONAL 3 160K40550 PCL FONT
146. REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Remove the Waste Toner Sensor cover and the Waste Toner Sensor 3 Unhook the spring slide it out the bottom and remove the Waste Toner Box from the Paper Feed Assembly Sensor Sensor Cover Waste Toner Box D13 Figure 1 Removing the Toner Box DocuPrint C55 C55mp NC60 Remove the Solenoids and Keep the parts together 4 Figure 2 Clutches shown Be especially careful with the springs they are different Figure 2 Removing the Clutches and Solenoids 5 Figure 3 Remove the remaining hardware and remove the Right Feeder Frame Right Feeder Frame Figure 3 Removing the Feeder Frame 2 99 4 33 6 Figure 4 Remove the Tension Lever and Remove the Lower Registration Roller Registration Roller D22 Figure 4 Removing the Lower Registration Roller REPLACEMENT NOTE When reassembling the Waste Toner Box make sure it slides back and forth smoothly REPAIRS ADJUSTMENTS REP 8 11 8 12 FEED ROLLER PARTS LIST ON PL 8 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Remove the Waste Toner Sensor cover and the Waste Toner Sensor 3 Unhook the spring slide it out the bottom and remove the Waste Toner Box from the Paper Feed Assembly Sensor Cover and Arm Sensor
147. RT DESCRIPTION 1 REF PL9 1 PART OF TRANSFER FRAME ITEM 1 ASSEMBLY 2 P O ITEM 1 RETAINING RING 7MM 3 P OITEM 1 RETAINING RING 4MM 4 13 12520 BEARING 5 19K4100 STRIPPER FINGER ASSY REP 9 1 6 6 61550 SHAFT 7 809E2100 STRIPPER FINGER SPRING 8 19 36010 STRIPPER FINGER 9 29 27440 STRIPPER FINGER PIN PARTS LIST SECTION 2 99 PL 9 3 5 26 DocuPrint C55 C55mp NC60 PL 9 4 TRANSFER DRUM CLEANER CLUTCH AND SHAFT 112 39 27 12 25 30 39 2812 26 DocuPrint C55 C55mp NC60 ITEM 29 30 31 32 33 34 35 37 38 39 2 99 5 27 PART REF PL9 1 ITEM 1 15E59970 P O ITEM 28 26E60290 35E43370 35E41720 42E1390 35E41710 35E41690 35E41700 48E53750 P O ITEM 1 13E12520 809E2190 809E2200 NOT SHOWN 809E2180 7E48580 P O ITEM 28 8E5780 16E12500 809E2210 7E48590 7E48600 29E25290 15E59960 5K4960 600K71720 600K75290 P O ITEM 28 P O ITEM 28 P O ITEM 27 P O ITEM 27 P O ITEM 27 P O ITEM 27 P O ITEM 27 P O ITEM 27 P O ITEM 27 P O ITEM 27 P O ITEM 27 DESCRIPTION PART OF TRANSFER FRAME ASSEMBLY TD CLEANING BLADE REP 9 6 SCREW M3X6 AUGER SEAL CLEANER BRUSH SEAL REP 9 7 TD CLEANING BRUSH CLEANER BLADE SEAL SEAL SEAL CLEANER CASE RETAINING RING 4MM BEARING LEFT SPRING RIGHT SPRING SHEET CLEANER SPRING IDLER GEAR RETAINING RING CLEANER BOSS CLEANER SLEEVE CLEANER SPRING CLEANER GEAR AUGER GEAR PIN GROUND PLATE
148. SD T2 7 2 in Section 7 and check the following e Paper Size 0 Sensor signal CN109 1 for an open e 5 VDC CN109 5 If no problem is found replace the PCU PWB f the problem still exists replace the T2 Cassette PWB Check for a broken Sensor Flag on the Tray 2 Cassette If the problem still exists replace the PCU PWB If the problem still exists replace the Cassette PWB 2 99 2 3 TO 10 5 11 4 14 Figure 2 2 Length Stop Location STATUS INDICATOR RAPs C1 C2 1 1 Paper fed from Tray 1 did not reach the Registration Sensor INITIAL ACTION Remove the cassette and check that the paper is loaded correctly and is in good condition Switch the power off wait 10 seconds and switch the power on Recheck for the fault PROCEDURE Check the following Obstructions in the paper path e Dirty Feed Rolls e Dirty Drive Rollers e Mechanical drive problem Enter normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 00 Press Form Feed 1 Open the Printer Actuate and deactuate the Registration Sensor while observing the Magenta LED The Magenta LED switches on and off Y N Go to BSD 8 1 in Section 7 and trouble shoot the Registration Sensor signal 5 VDC and GND CN102 9 7 8 for an open If no open exists replace the PCU PWB If the problem still exists replace the Registration Sensor Press Media Server 2 Select Scan
149. SPRING RIGHT LOCK PAWL UPPER RIGHT LOCK PAWL LOWER TRANSFER TERMINAL SCREW M3X10 TRANSFER DRUM SPRING RIGHT TRANSFER DRUM BEARING COVER SCREW SCREW EARTH PLATE LOCK SPRING PIN BEARING SPRING DRUM CLEANING JAM SWITCH DRUM CLEANING SWITCH RETAINER BEARING ELECTRODE DocuPrint C55 C55mp NC60 PL 10 4 TRANSFER FRAME COMPONENTS FRONT 152 21 22 11 13 16 20 21 12 13 14 15 16 17 17A 18 19 20 21 22 PART REF PL10 1 ITEM 1 P O ITEM 1 P O ITEM 1 7 48470 6E61630 29E27490 49E84430 PART OF 8A 600K65270 P O ITEM 1 162K29340 130E8010 162K29350 38E18350 110E7570 P O ITEM 1 809E2000 105K17050 NOT SPARED 101E13720 115E5860 15E64460 38E18371 64K1330 DESCRIPTION PART OF TRANSFER FRAME ASSEMBLY SCREW M3X10 SCREW M3X8 COVER PAWL LOCK SHAFT PIN PWB SUPPORT CONNECTOR PWB GAMMA SENSOR REPAIR KIT SCREW M3X6 CONNECTOR PWB HARNESS TRANSPARENCY SENSOR REP 10 3 TD POS HARNESS PAPER FEED GUIDE FRAME BYPASS SWITCH REP 10 1 PINCH ROLL PINCH ROLL SPRING TRANS DISCHARGE PS REP 10 2 NEUTRALIZATION COROTRON COVER CONTACT TONER SHEET PAPER GUIDE SHEET TRANSFER DRUM LOWER FRAME THE GAMMA SENSOR REPAIR KIT INCLUDES A 4 PIN GAMMA SENSOR AND A NEW CONNECTOR BOARD THE OLD CONNECTOR BOARDS HAVE A 3 PIN CONNECTOR DocuPrint C55 C55mp NC60 5 31 PARTS LIST SECTION PL 10 4 PL 11 1 TRANSFER DRUM ASSEMBL
150. Section 7 and check the Charge On Signal CN106 2 for an open Check the following e Obstructions in the paper path e Dirty Feed Rolls e Mechanical drive problem STATUS INDICATOR RAPs E6 E7 PRINT DRUM JAM RAP INITIAL ACTION Open the Printer and clear the jam If problem reoccurs refer to E4 RAP STATUS INDICATOR RAPs E7 E8 E9 E8 OUTPUT JAM RAP Paper was on the Exit Sensor too long INITIAL ACTION We have seen some machines where the actuator for the Exit Sensor has become stuck during shipping When this happens the sensor does not change state and the E8 jam occurs If you remove the sensor cover PL 2 1 by removing the two screws that secure it you can ensure that the actuator is free and that the sensor is secured in the proper position in the sensor cover Open the Printer and remove the Fuser Assembly Check for any obstructions in the fuser paper path Switch the power off wait 10 seconds and switch the power on Run another print to recheck for the fault PROCEDURE Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 00 Press Form Feed 1 Open the Printer then open the Fuser Cover Actuate and deactuate the Exit Sensor while observing the Yellow LED The Yellow LED switches on and off Y N Go to BSD 10 2 in Section 7 and trouble shoot the Exit Sensor signal CN308 1 for a short to ground If no short exists replace the PCU PWB If the problem sti
151. Section 7 and trouble shoot the Developer Motor On signal CN117 2 for an open If no open exists replace the PCU PWB If the problem still exists replace the Developer Drive Motor Press Media Server 2 to stop the MOTOR TEST program Set up the meter to read 5 VDC Connect the meter to CN117 1 and ground Press Form Feed 1 to switch on the motors while observing the meter The meter reads 5 VDC before the motor program starts and 0 VDC when the motor program is running Y N Go to BSD 9 5 in Section 7 and trouble shoot the Developer Motor Lock signal CN117 1 for an open If no open exists replace the PCU PWB If the problem still exists replace the Developer Drive Motor Go to BSD 9 5 in Section 7 and troubleshoot the 117 4 for an open If OK replace the PCU PWB If the problem still exists replace the Developer Drive Motor 2 99 2 26 DocuPrint C55 C55mp NC60 U7 MOTOR FAULT MAIN RAP The Transfer Drum Home Position Sensor did not detect Transfer Drum rotation C55 C55mp Mechanical bind is the most common cause of this fault specifically binding of the auger in the Print Drum This is usually but not always accompanied by a clicking noise from the top of the machine If a clicking noise is heard enter Normal Diagnostics General Procedures and attempt to run the Motor Test Note the sounds of the machine Stop the test remove the print drum close the printer
152. Sense GND for an open 0 CN105 5 Temp Sense for an open or short to ground If the wiring checks OK replace the Tem perature Humidity Sensor 2 99 IMAGE QUALITY RAPs DocuPrint C55 C55mp NC60 3 3 IMAGE QUALITY DEFECTS Defect Name Description Possible Causes Corrective Action 2 BACKGROUND BLACK 1 Developer Failure 1 Replace the Black Developer Module 2 New developer assembly did not initialize 2 Run a Diagnostic Sheet and check the Toner Concentration Setpoints for newly installed developer assembly If the Setpoints at 70 default replace the developer assembly 3 No Black Developer Bias 3 Refer to BSD 9 1 and check the Black Developer Bias voltage If the voltage is present check the Black Developer Bias lead for an open f no bias is present replace the High Voltage Power Supply If the problem still exists replace the black developer module 3 BACKGROUND COLOR 1 Developer Failure 1 Replace the Color Developer Module 2 No Grid Low signal 2 Refer to BSD 9 1 and check the Grid Bias Low signal CN106 8 for a short to ground If OK replace the color developer housing 3 Temperature RH Sensor failure 3 If the readings on the diagnostic sheet are out of range RH 0 or RH gt 100 or Temp 0 refer to the chart below Diag Refer to BSD 9 19 and check Sheet CN105 1 Humidity Sense for a short to ground RH gt 100 105 1 Humidity Sense for an open CN105
153. THER FAULTS RAPs OF6B OF7 ESS BOOT FAILURE ERROR CODES NC60 During the ESS Boot process several tests and checks are performed If a failure occurs and the ESS can communi cate with the Control Panel an error code will be displayed If the ESS failure prevents communication with the Control Panel the error will be indicated by a flashing Fail LED on the ESS PWB There will be a one second pause then a number of flashes which represents the failure If partial communication has been established you may also see a flashing Magenta LED on the Control Panel OTHER FAULTS RAPs OF7 Message Table 1 Boot Error Codes LED Flash Description Rate 0001 ESS Major ESS failure Replace ESS 0001 BASE RAM Base Ram failure Replace ESS 0001 BASE ROM 0001 ASIC 0001 DMA 0001 COMM 1000 IOT 0010 DISK 0101 SIMM1 0102 SIMM2 0103 SIMM3 0104 SIMM4 2000 XIE RAM 3000 TOKENRING 4000 NIC 0040 ROM BOARD 6000 FLOPPY 7000 DPTEK 5000 MEMORY kkkkkkkkkkkkkkk kkkkkkkkkkkkkkk 6 Paralel or Seral Por faure Replace Ess ESS IOT Communication Check CN104 on PCU PWB failure If OK replace the ESS Hard Disk failure Check Hard Disk connectors If OK replace the Hard Disk 10 Simm 1 board failure Check connection If OK replace Simm 1 11 Simm 2 board failure Check connection If OK replace Simm 2 12 Simm 3 board failure Check connection If OK replace Simm 3 13 Simm 4 board failure Check connectio
154. TION Modifications to the printer are identified by a tag number which is recorded on a tag matrix card There are two tag matrix cards One is inside the ESS PWB cover and indicates the Systems Configuration The second card the IOT TAG Matrix is attached to the printer frame on the inside of the left rear side viewed from the printer front CLASSIFICATION CODES A tag number may be required to identify differences between parts that cannot be interchanged or differences in diagnostic repair installation or adjustment procedures A tag number may also re required to identify the presence of optional hardware special non volatile memory programming or whether mandatory modifications have been installed Each tag number is given a classification code to identify the type of change that the tag has made The classification codes and their descriptions are listed in the table below Description Classification Code N Tag not installed in the field Repair Tag GENERAL PROCEDURES TAGS TAG 1 DESCRIPTION was upgraded to PCU Firmware Version 66 This upgrade was performed during final integration in the US CLASS NA USE MFG SERIAL NUMBERS NAME IOT Firmware PURPOSE Firmware upgrade KIT NUMBER None REFERENCE TAG 2 DESCRIPTION was upgraded to PCU Firmware Version 66 at the manufacturing site CLASS NA USE MFG SERIAL NUMBERS NAME IOT Firmware PURPOSE Firmware upgrade KIT NU
155. TS LIST ON PL 3 1 NOTE If the ESS PWB is being replace with one from another printer rather than a new PWB the serial number from the other printer may still be stored in the ESS memory If this is the case refer to the replacement notes in this procedure REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord Disconnect all of the Connectors Loosen the two thumb screws Remove the ESS PWB Remove any customer RAM and reinstall in the new PWB REPLACEMENT 1 Install the new PWB 2 Notify the customer so that they can setup the network values NOTE 1 If the customer is using CentreWare have the customer write their printer serial number over any existing serial number NOTE 2 If this printer is connected as a parallel printer you cannot enter the serial number use GP 3 5 to perform a factory reset This will erase any existing serial number gt N gt REPAIRS ADJUSTMENTS REP 3 2 3 3 3 4 REP 4 1 MAIN DRIVE MOTOR PARTS LIST ON PL 4 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Right Side Cover REP 1 3 b Top Cover REP 1 1 c Rear Cover REP 1 2 2 Figure 1 Remove the two screws and the E ring and remove the Harness Cover Harness Cover TO1 Figure 1 Removing the Harness Cover REPAIRS ADJUSTMENTS REP 4 1 Figure 2 Loosen the Idler if required 6 Disconnect CN112 and remo
156. TUP 6 20 DocuPrint C55 C55mp STARTUP NC60 Fress Display Reads Menu Up until Menus Print Menu DocuPrint NC60 Network Color Laser Printer Item Up until Print Startup Page From a different line of thinking the new pace of printing This is the startup page It can be set to print automati cally once the printer has finished the warm up cycle This page displays Configuration data Connective data and a brief Help Configuration Connectivity Help Information Serial Number Parallel Yes To print the Configuration Sheet Software Version 1 80 47 Serial Yes Press MENU up or down to PRINT Engine Software Version 94 NetworkCardType Ethemet 10 Press ITEM up or down to CONFIG SHEET Total Memory 64 EtherTalk Enabled Yes Press ENTER Total RAM Installed 48MB Novell IPX Type NDS BEM To print the Menu Map Interpreters Postscript Level 3 and PCL 5C LPR Enabled Yes Press MENU up or down to PRINT Total Pages 832 AppSocket Enabled Yes Press ITEM up or down to MENU Tray Paper Size Letter 8 2 x 11 in NetBEUI Enabled Yes Press ENTER Tray 2 Paper Size Not Installed To print the Tips amp Tricks Sheet Hard Disk Installed Yes Press MENU up or down to PRINT Media Server Yes Press ITEM up or down to TIPS amp TRICKS System Location Press ENTER Print Server Name XRX 0000AA790054 Primary Server Printer URL Address http xerox networkprinters com products NC60 Visit our web site at h
157. To enter Alphanumeric data using the control panel 1 Scroll to the location requiring the data entry 2 Press Up to move the prompt to the right 3 Press Item Down to move the prompt to the left 4 The following alphanumerics are available A Z 9 0 5 Use the Value Up Value Down keys to scroll through the characters 6 Once the proper character is displayed use Item Up or Item Down to move the prompt to the next character 7 When Enter finished entering changes press GENERAL PROCEDURES Software Upgrading CONSUMABLES C55 C55m p Consumables XE US XCL ACO Life 596 Part No PART No Area Coverage 4 Toner Collector 8R7759 8R7748 7000 Pages wmeeewm The first oil bottle will fill the sump Expect 5000 to 6500 pages on the first oil kit The Kit includes 2 oil bottles and one wiper roller GENERAL PROCEDURES 2 99 Consumables 6 64 DocuPrint C55 C55mp CONSUMABLES NC60 Consumables XE US XCL ACO Life 596 Part No PART No Area Coverage 4 Toner Collector 8R7759 8R7748 7000 Pages The first oil bottle will fill the sump Expect 5000 to 6500 pages on the first oil kit The Kit includes 2 oil bottles and one wiper roller 2 99 GENERAL PROCEDURES DocuPrint NC60 6 65 Consumables OPTIONAL 5 55 55 Optional Kits XE US XCL ACO Part No PART No eese GENERAL PROCEDURES 2 99 Optional Kits 6 66 DocuPrint C55 C55mp OPTION
158. Transfer Drum Nip too large 1 Perform Transfer Drum Nip Adjustment ADJ 11 1 20 DIRT TONER OR CONTAMINATION ON 1 Toner in the paper path 1 Clean the paper path THE REVERSE SIDE OF THE PRINT IT MAY BE REPEATING 2 Dirty Fuser Pressure Roll repeats every 3 66 2 Replace the Fuser Module inches 3 Transfer Drum Cleaning failure 3 Replace the Transfer Drum Cleaning Blade and Brush 4 Dirty Printer Sump Full 4 Refer to BSD 9 21 and check the Waste Toner Full signal CN102 3 for a short to ground 5 High volume Printer 5 Increase the cleaning cycles Refer to GP 3 4 in Section 6 2 99 IMAGE QUALITY RAPs DocuPrint C55 C55mp NC60 3 11 IMAGE QUALITY DEFECTS Defect Name Description Possible Causes Corrective Action 21 FUZZY IMAGE Bias is incorrect Trail edge of color is light Refer to BSD 9 1 and check the Bias control signal between CN106 6 and CN802 1 for an open 2 Developer failure 2 Replace the Color Developer Module 3 ESS Failure 3 Replace the ESS 22 LIGHT DENSITY IN A SINGLE COLOR Perform the Density and Color Balance Adjustment ADJ 3 1 5 No Black Developer Bias Black only is light 5 Refer to BSD 9 1 and check the Black Developer Bias lead for a short to ground 6 Transfer to Print Drum Nip incorrect 6 Refer to The Transfer Drum Nip adjustment ADJ 11 1 and perform the check 7 Bias Control Signal Black only is light 7 Refer to BSD 9 1 and check the Bi
159. VDC 2 LINE DISPLAY 32 CHARACTERS LED DRIVER DECODER L mia mo mz 2 MODE SELECTION CHAIN 2 LEVEL 2 SHEET 1 OF 1 2 99 BSDs DocuPrint C55 C55mnINC601 7 3 Chain 2 Mode Selection B D E F G H J ESS IF PWB PL 3 1 PCU PWB ESS PWB PL3 2 Bia 1 Power On Self Test POST C55 C55mp aba PWB m 1 ROM CHECK SUM CR1 i 93 Q 2 NVM TEST 7 3 DRAM TEST 4 TIFF PWB TEST MESSAGE DISPLAY 5 LOCALSERIAL SLIC PWB TESTED lt gt Power On Self Test POST 6 FONT SIMM CHECKSUM 7 NETWORK INTERFACE CARD TESTED CR4 C55 ROM CHECK SUM 8 FLOPPY TEST C55mp 2 9 HARD DISK TEST CRS CN104 du Aa RAM CHECK SUM 10 ESS PWB COMMUNICATES WITH PCU PWB POWER 5 CHECK SUM 7 RECURSO 6 ALL SENSORS CHECKED FOR PAPER Power On Self Test POST NC60 POWER 8 i go Sis lt 1 MAIN MOTOR ON FCD ERU LEDS ON npp SHEA Ay E PROCESS CONTROL SETUP BEGINS BOOT 1 SEQUENCE BEGINS NC60 READY DURING ESS BOOT NC60 BOOT 1 INITIALIZE 1960 CPU 12 Log eee 7 MESSAGE DISPLAY INDICATES CCW 3 BASE RAM CHECK 32 MB MOVING ROM CHECK ASIC amp DMA CONTROLLER CHECK ESS BOOT NC60 BOOT 1 COMPLETE PARALLEL AND SERIAL PORT CHECK MESSAGE DISPLAY SELF TEST ALL MESSAGE DISPLAY INDICATES LEDS ON j saw INITIALIZING MESSAGE DISPLAYED ALL LED S ON ALL PIXELS ON ESS SELF TEST COMPLETE MESSAGE BOOT 2 SEQUENCE BEGINS DISPLAY INDICATES
160. Y 15 P O ITEM 1 16 P O ITEM 1 17 P O ITEM 1 OUTER PLATE TR DRUM GEAR SCREW 4 12 ITEM PART DESCRIPTION 112 19 20 21 23 1 20K8090 TRANSFER DRUM ASSEMBLY REP 9 8 2 P O ITEM 1 RETAINING RING 3 P OITEM 1 TR DRUM COLLAR 4 P O ITEM 1 WASHER 5 P OITEM 1 SEAL 6 ITEM 1 DRUM 7 1 BRAKE PLATE 8 ITEM 1 SCREW 4 6 9 P OITEM 1 BRAKE PAD 10 1 SEAL 11 P O ITEM 1 PLATE 12 P OITEM 1 DISK 13 P OITEM 1 BRAKE SPRING 14 P O ITEM 1 SCREW M3X8 18 P O ITEM 1 HUB 19 P O ITEM 1 SETSCREW 4 6 20 600K71710 NIP WHEEL ADJUSTMENT KIT 21 P O ITEM 20 NIP WHEEL 22 P O ITEM 20 WASHER 23 P O ITEM 20 SCREW PARTS LIST SECTION 2 99 PL 11 1 5 32 DocuPrint C55 C55mp NC60 PL 12 1 ROS COMPONENTS DocuPrint C55 C55mp NC60 gt 6 2 7 PAD 4 Pd Pee Matt gt A 57 C t 2 99 5 33 O 11 12 13 14 15 16 17 18 19 20 21 PART NOT SPARED 122K1760 NOT SPARED NOT SPARED NOT SPARED 15E64340 809E2240 NOT SPARED NOT SPARED 7 48300 11 7370 SPARED SPARED SPARED 809 1790 809 1750 48 43570 6 61620 17 7740 SPARED 17 8370 DESCRIPTION UPPER FRAME ROS REP 12 1 SCREW SCREW 4 8 RIGHT MAIN FRAME SPRING PLATE FRAME SPRING RETAINING RIN
161. Y TONER CLUTCHES AND MAGNETIC ROLLER CLEANER CLUTCH 4 17 5 2 MAGNETIC ROLLER CLUTCHES 4 18 DocuPrint C55 C55mp NC60 TITLE PAGE DRIVES INNER 1 REP 6 1 DRUM TERMINALS 4 21 REP 6 2 SLIDE CAMS 4 22 PAPER FEED REP 8 1 PAPER GUIDE U SHAPED 4 24 REP 8 2 PAPER FEED ASSEMBLY 4 25 REP 8 3 TRAY EMPTY SENSOR 4 26 REP 8 4 REGISTRATION SENSOR 4 26 8 5 FEED CLUTCH amp SOLENOID 4 27 REP 8 6 REGISTRATION CLUTCH 4 28 REP 8 7 GROUNDING ROLLER CLUTCH 4 29 REP 8 8 PAPER DRIVE ROLLER 4 30 REP 8 9 GROUNDING ROLLER 4 31 REP 8 10 UPPER REGISTRATION ROLLER 4 32 REP 8 11 LOWER REGISTRATION ROLLER 4 33 8 12 FEED ROLLER 4 34 REP 8 13 WASTE TONER SENSOR 4 35 TRANSFER DRUM 1 9 1 STRIPPER FINGER ASSEMBLY sassa 4 36 9 2 TRANSFER DRUM CLEANING SOLENOID 4 37 REP9 3 TRANSFER DRUM CLEANER 4 38 REP 9 4 TRANSFER DRUM CLEANER ASSEMBLY 4 39 9 5 TRANSFER DRUM CLEANER BRUSH CLUTCH 4 40 REP 9 6 TRANSFER DRUM CLEANING BLADE 4 40 2 99 4 1 4 REPAIRS ADJUSTMENT TITLE PAGE TRANSFER DRUM 1 cont REP 9 7 TRANSFER DRUM CLEANING BRUSH
162. Y is displayed then press Enter 4 Press Next until TRANSPARENCY MODE is displayed then press Enter 2 99 6 46 5 Six choices are available they are wee DEFAULT This is the best setting for Xerox NONE This setting is used if you have configured the IOT using Hidden diagnostics This setting is best for minimizing E4 E6 Jams with maximum transparency brightness 2 This setting is best for minimizing transfer breakdown with maximum transparency brightness This setting is best for minimizing E4 E6 Jams with minimum oil finger offsetting defects 1 4 This setting is best for minimizing transfer breakdown with minimum oil finger offsetting defects 6 Select the choice which best represents your situation and press Enter DocuPrint C55 C55mp GP 3 3B TRANSPARENCY MODE NC60 PURPOSE The purpose of this procedure is to optimize the Transfer Bias for transparencies This procedure has been designed to address the following problems Mistacking on the Transfer Drum 6 4 Jams Transfer Breakdown very high frequency small diameter deletions Fuser oil fingers offset 2 5 mm wide x 5 50 mm long brighter areas on the transparency that resemble human fingers when projected ADJUSTMENT 1 2 Press Menu Up until Service is displayed Press Down until Mode Transparency is displayed Press Value Up to display the current setting DocuPrint NC60 4
163. a Diagnostic Sheet and check the Toner Concentration Setpoints for newly installed developer assembly If the Setpoints are at 70 default replace the developer assembly 6 Nocharge 6 Refer to BSD 9 4 and check the RED leads to the Print Drum Module for an open 7 Temperature RH Sensor failure 7 f the readings on the diagnostic sheet are out of range RH 0 or RH gt 100 or Temp 0 refer to the chart below Diag Refer to BSD 9 19 and check Sheet CN105 1 Humidity Sense for a short to ground RH 100 CN105 1 Humidity Sense for an open CN105 2 Humidity Sense GND for an open 0 CN105 5 Temp Sense for an open or short to ground If the wiring checks OK replace the Tem perature Humidity Sensor 2 99 IMAGE QUALITY RAPs DocuPrint C55 C55mp NC60 3 9 IMAGE QUALITY DEFECTS Defect Name Description Possible Causes Corrective Action 15 DARK DENSITY SINGLE COLOR 1 Color Balance out of adjustment 1 Perform the Density and Color Balance Adjustment ADJ 3 1 2 Print Drum Module failure 2 Replace the Print Drum Module 3 Developer Module failure 3 Replace the Developer Module 4 No Black toner regulation 4 Refer to BSD 9 7 and check the Black Toner GND CN107 2 for an open 16 DARK LINES OR STREAKS LEAD EDGE 1 Dirty Charge Scorotron 1 Cleanthe Charge Scorotron TO TRAIL EDGE 2 Charge Scorotron Cleaner out of position 2 Position Cleaner to extreme left 3 Scratched Print D
164. age to the paper Repeat steps 2 through 6 until you have three transfers from three different areas of the transfer drum Figure 3 Remove the paper and measure the width Nip of the Image on the paper Make the measurement 35 MM from the edge of the paper TDOS Figure 3 Measuring the Nip 9 The Nip should be 2 5 MM 10 If the Nip is not within specification perform the adjustment DocuPrint C55 C55mp NC60 ADJUSTMENT 1 Figure 4 Locate the two adjustment cams on the left and right side of the Transfer Drum You will need to rotate the Transfer Drum Gear until the adjustment screw and cam are visible through the cutout on the right side Figure 4 Rotating the Gear 2 99 4 69 4 5 Figure 5 Note the number of the flat that is close the Print Drum Then loosen the two screws securing the left and right adjustment plates A higher number will decrease the Nip A lower number will increase the Nip Move the plate as required Repeat the check NOTE You may be able to re use the Cyan image on the Print Drum by rotating it slightly If not create another image TDO6 Figure 5 Adjusting the Nip REPAIRS ADJUSTMENTS ADJ 11 1 ADJ 12 1 ROS POSITIONING PURPOSE The purpose of this adjustment is position the ROS assembly so that the image is placed on the Print Drum properly CHECK Print test pattern A Fold the print and check the registration lines in the corners
165. an open If the ON signal CN115 4 does not go low during print replace the PCU PWB Cleaning Cam timing incorrect refer to the Magnetic Roller Cleaning Cams adjustment ADJ 6 1 and perform the check Refer to BSD 9 9 and check the Magenta Developer Clutch for an open If the ON signal CN115 6 does not go low during print replace the PCU PWB Cleaning Cam timing incorrect refer to the Magnetic Roller Cleaning Cams adjustment ADJ 6 1 and perform the check Refer to BSD 9 9 and check the Yellow Developer Clutch for an open If the ON signal CN115 8 does not go low during print replace the PCU PWB Cleaning Cam timing incorrect refer to the Magnetic Roller Cleaning Cams adjustment ADJ 6 1 and perform the check 1 Replace paper 2 Perform the Density and Color Balance Adjustment ADJ 3 1 Run 300 prints to break in the new developer housing Enter Special diagnostics scroll to ID Level set offending color to 80 DocuPrint C55 C55mp NC60 Defect Name Description Possible Causes Corrective Action 14 DARK DENSITY ALL COLORS 1 Color Balance out of adjustment 1 Perform the Density and Color Balance Adjustment ADJ 3 1 2 Developer near end of life 2 Check remaining from the Menus Replace as required 3 Print Drum Module failure 3 Replace the Print Drum Module 4 Print Drum Arcing 4 Referto OF8 Arcing RAP in Section 2 5 New developer assembly did not initialize 5 Run
166. ance with the customer 2 f adjustment is required refer to the appropriate procedure Density And Color Balance Adjusment Test Page 1 Adjust Color Density 30 Halftone CYAN MAGENTA YELLOW 3CMY 2cMY 1 Curent 1CMY 2 Adjust Color Density 30 Halftone BLACK GRAYSCALE 3K 2K K 2K Decrease Increase 3 Adjust Color Balance Choose The circle Which Best Matches The Gray Reference abcdef abedef abcdef abedef abcdef abcdef abedef Density Rate Set Points Range 80 100 Current Current Black Level 90 0 Current Cyan Level 90 Developer bias Range 251 550 Current Black Level 327 Current Cyan Level 275 Current Magenta Level 381 Current Yellow Level 284 Current Magenta Level 90 Current Yellow Level 90 Gray Reference Xerox Corporation 1999 ver 1 0 Figure 1 Density and Color Balance Test Pattern NC60 ADJ 3 1 2A Color Density NC60 CHECKING THE COLOR DENSITY 1 Run a print of the Color Balance Test Pattern Menu Down until Color Adjust then press Item Down 2 Analyze the test page and choose the number which represents the Color Density the customer desires Keep mind that this is a 3096 gray Darker is not always better ADJUSTING THE COLOR DENSITY 1 Perform the Color Density Check 2 Press Up until Color Density is displayed 3 Press Value Up or Value Down to
167. aper Size IP Address Res Select Tray Paper Type IP Address Media Server Page Policy Subnet Mask Select File Policy Timeout Default Gateway Print Quantity Hold Timeout Port Timeout Select Tray Manual Timeout Service Menu Print Quantity Config Sheet Startup Page Diag Summary Print PS Errors Print PQ Set Defaults Test Patterns Power Saver Print Quantity Color Adjust OHP Mode Color Density Select Tray Black Density Margin Left Color Balance Margin Top Cancel Changes Cleaning Cycle Color Defaults Patch Control Imaging Show Page Counts Edge Smoothing Show Setpoints Color Mode CRU Usage Blk OverPrint Lossy Counter Halftone Type Faults Active Ehn Alignment Fault History S W Levels Fast Black Process Black Parallel Menu Port Enable Port Timeout Parallel PDL Binary PS Bidirectional THE DOCUMENT COMPANY 2 99 GENERAL PROCEDURES DocuPrint NC60 6 31 MENU 55 55 Press Display Reads Eme STATU me feras Eme eon me gt Eme 8008 me gt fener PROGESSNG This is a demo of some PCL 5C capabilities GENERAL PROCEDURES PCL DEMO Doc Print 55 Color Laser Printer Now you can do so much more THE DOCUMENT COMPANY Visit our web site at Http xerox networkprinters comy products c55 2 99 6 32 DocuPrint C55 C55mp FAULT HISTORY NC60 Xerox DocuPrint NC60 Color Laser Printer Press Display Rea
168. as Control Signal CN106 6 for an open or short to ground 23 LIGHT DENSITY ALL COLORS 1 Developer seals still in place 1 Remove shipping material from developer assemblies 2 Poor Transfer 2 Check contact between right transfer drum bearing and Transfer contact on frame Check Transfer Drum Nip ADJ 11 3 Print Drum Arcing 3 Refer to OF8 Arcing RAP in Section 2 4 Printer not level 4 Level printer 5 Weak Laser Diode output 5 Replace ROS assembly IMAGE QUALITY RAPs 2 99 IMAGE QUALITY DEFECTS 3 12 DocuPrint C55 C55mp NC60 Defect Name Description Possible Causes Corrective Action 24 LIGHT LINES DELETIONS LEAD TO TRAIL 1 Dirty Charge Scorotron 1 Cleanthe Charge Scorotron EDGE 2 Foreign material between ROS and Print 2 Clean the ROS to Print Drum path using a Drum defect is present in all colors lint free cloth 3 Print Drum scratched 3 Replace the Print Drum Module 4 Transfer Drum to Print Drum Nip to small 4 Perform the Transfer Drum Nip check ADJ 11 1 5 Foreign material scraping the paper on the 5 Check for foreign material Transfer Drum for example paper from a previous jam 6 Foreign material in Developer Housing 6 Replace the Developer Module 7 Stripper Finger Marks If marks line up with Stripper fingers clean Stripper Fingers replace paper 8 OilSpill Printer tipped or moved 8 Remove fuser and check for oil leakage If oil has leaked check the follo
169. aste Toner Box D13 Figure 1 Removing the Toner Box REPAIRS ADJUSTMENTS REP 8 8 4 Figure 2 Remove the E Rings Gears and Bearings Remove the Paper Drive Roller Drive Roller Gear Paper Drive Roller D14 Figure 2 Removing the Paper Drive Roller 2 99 4 30 REPLACEMENT NOTE When reassembling the Waste Toner Box make sure it slides back and forth smoothly DocuPrint C55 C55mp NC60 REP 8 9 GROUNDING ROLLER PARTS LIST ON PL 8 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Remove the Waste Toner Sensor cover and the Waste Toner Sensor 3 Unhook the spring slide it out the bottom and remove the Waste Toner Box from the Paper Feed Assembly Sensor Cover and Arm Sensor Waste Toner Box D13 Figure 1 Removing the Toner Box DocuPrint C55 C55mp NC60 4 5 Figure 2 Remove E Ring and remove the Grounding Roller Assembly Grounding Roller Assembly D15 Figure 2 Removing the Grounding Roller Assembly Figure 3 Remove E Rings and springs and remove the Grounding Roller Grounding Roller GAS lt ao Figure 3 Removing the Grounding Roller 2 99 4 31 REPLACEMENT NOTE When reassembling the Grounding Roller Assembly make sure it moves freely NOTE When reassembling the Waste Toner Box ma
170. ay and LEDs are off No motors or fans are heard when the printer is switched on Y N The printer booted when it was switched on The display is now a circling asterisk Replace the Floppy Drive If the printer does NOT have a hard drive replace the ESS Interface PWB If the printer has a Hard Drive switch the printer off Reconnect CN102 and CN103 Disconnect CN101 from the Hard Drive Switch the printer on The printer is still dead the display and LEDs are off No motors or fans are heard when the printer is switched on Y N C DE 2 99 2 31 C DE The printer booted when it was switched on The display is now a circling asterisk Replace the Hard Drive Replace the ESS PWB Switch the printer off Disconnect CN108 from the PCU PWB Connect the meter between CN108 1 and CN108 2 The meter should be connected to the connector side NOT the PWB side Switch the printer on The meter indicates 5 VDC Y N Refer to BSD 1 2 and Check CN108 to CN707 for an open If no open is found remove the Low Voltage Power Supply REP 3 1 Remove Fuses F701 F702 and F703 Use the Ohmmeter to check these fuses If any of the fuses test bad install a new fuse reassemble the printer and recheck If all fuses check OK replace the Low Voltage Power Supply Replace the PCU PWB If the problem still exists replace the Connector PWB OTHER FAULTS RAPs OF1 OF2 CONTROL PANEL RAP This RAP is used
171. caled 25 999 75 1011 Univers Md Scal Univers Bdlt Scal Univers Malt Sca Univers BdCdlt Univers BdCd Univers MdCd Univers Bd tinivers CG Omega Bd CG Omega It CG Omega Bdit 25 999 75 012 25 999 75 013 25 999 75 014 25 999 75 015 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 mar0ou Garmond Antiqua Gartnond KrsvHIb Garmond Krsv Garmond Ib Clarendon Cd AntiqueOlv AntiqueOlv it Antiqueolv Bd Albertus Md Albertus Xb Wingdings Symbol ABX6 amp 12300 gt Times New Bdlt Times Bd Times New It Times New Arial It Arial Bd It Arial Bd Arial 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 25 999 75 Omega led 25 999 75 THE DOCUMENT COMPANY Visit our web site at Http xerox networkprinters com products c55 GENERAL PROCEDURES 2 99 PCL FONT 6 26 DocuPrint 55 55 PCL FONT NC60 Menus Print Menu Up until Item Down until Print PCL Fonts
172. ce the printer has finished the warm up cycle This page displays Configuration data Connective data and a brief Help Configuration Connectivity Help Information Software Version 3 5 2 Parallel Enabled Yes To print the Settings Page Software Part Number 537 E56350 Serial Enabled Not Installed Press ON LINE Serial Number D3V 030361 LocalTalk Enabled Not Installed Press MENU Total Memory 30 MB Network Card Type Ethernet Select PRINT SETTINGS YES Total RAM Installed 24 MB EtherTalk Enabled Yes To print the Menu Page Interpreters Postscript and PCL 5C Novell IPX Type Bindery Press ON LINE Total Pages 7534 LPR Enabled Yes Press MENU Tray 1 Paper Size Letter 85 x 11 in Appsocket Enabled Yes Select PRINT MENU YES Tray 2 Paper Size Not Installed NetBEUI Enabled Yes Hard Disk Installed No Printer URL Address http 13 139 1 10 Media Server Enabled Not Installed AppleTalk Name DocuPrint C55 System Location Print Server Name XRX522AC4 Primary Server THE DOCUMENT COMPANY Visit our web site at Http xerox networkprinters com products c55 Xerox The Document Company the stylized X DocuPrint and all Xerox product names are trademarks of XEROX CORPORATION Adobe Postscript and the Postscript logo are trademarks of Adobe Systems Incorporated which may be registered in certain jurisdictions abd PANTONE CALIBRATED are trademarks of Pantone Inc GENERAL PROCEDURES 2 99 STAR
173. ck Figure 2 Aligning the Cams 2 99 4 66 DocuPrint C55 C55mp NC60 ADJ9 1 EA TONE DOWN PROCEDURE PURPOSE The purpose of this procedure is to Tone Down the color developer It is also used to put the printer back in operation after an EA fault INITIAL ACTION Refer to GP 3 2 in Section 6 and make sure that the Patch Control is switched off CHECK 1 Enter Normal diagnostics Scroll to the TEST PRINT program and press Form Feed 1 to run a test print While the print is running observe the KT2 YT __ values 2 f any of the three color C M Y toner concentration values are below 10 that color is overtoned Continue with Step 3 to correct the overtoned condition 3 With TEST PRINT displayed press Enter 7 Use the Menu 3 key to scroll to MULTI OFF Press Next 6 until the display indicates MULTI ON This will put the TEST PRINT program in the multicopy mode 5 Use the Menu 3 key to scroll to TONER ON Press Next 6 until the display indicates TONER OFF This will shut off all toner dispensing 6 Press Media Server 2 to return to TEST PRINT then press Form Feed 1 to make multiple Test Prints 7 Observe the CT 2 YT values The values should begin to count up as toner is used and not replenished DocuPrint C55 C55mp NC60 10 11 13 14 15 When the lowest value reaches 10 press Media Server 2 to sto
174. concentration setpoints will not match those for the developer housings in the printer The printer will then attempt to adjust the toner concentration to values that may be out of range for the housings The can result in incorrect toner concentration values or the machine may hang up with the Adjusting Print Quality message When taking a U2 service call you must carefully follow the steps in ADJ 3 3 and determine the current Toner Concentration Setpoints before you actual Initialize the NVM INITIAL ACTION Switch the power off wait 10 seconds and switch the power on Recheck for the U2 fault If the problem still exists refer to ADJ 3 3 NVM Initialization U2 in section 4 2 99 2 24 IOT ESS COMMUNICATION ERROR RAP A communication error between the ESS and the IOT was detected INITIAL ACTION Switch the power off wait 10 seconds and Switch the power on Recheck for the fault If the problem still exists replace the PCU PWB If the problem still exists replace the ESS PWB DocuPrint C55 C55mp NC60 04 OPTICS FAULT A ROS problem was detected The laser did not come on INITIAL ACTION Switch the power off wait 10 seconds and switch the power on Recheck for the fault Check to ensure that the printer covers are closed Inspect the Laser Interlock smaller of the two switches to ensure that it is actuated PROCEDURE Locate connector 1007 This is a small DC two wire conne
175. condition of the Fuser Connectors Check the operation of the shutter that covers the fuser connectors Reinstall the Fuser Module Switch the power off wait 10 seconds and switch the power on Recheck for the fault PROCEDURE Set up the meter to read 5 VDC Measure between CN103 9 and ground When the fuser is cold the reading should be around 0 1 VDC When the fuse is hot the reading should be approximately 3 5 VDC The readings are OK Y N Go to BSD 10 5 in Section 7 and trouble shoot the Fuser Thermistor signal and 5 VDC for an open or a short to ground CN103 9 CN306 3 2 If the wiring is OK replace the Fuser Assembly If the problem still exists replace the PCU PWB Replace the PCU PWB STATUS INDICATOR RAPs JA TO T1 UNDER TEMPERATURE RAP NOTE This RAP applies to both 115 and 220 volt printers The 220 volt readings will be in parenthesis After the proper warm up time has elapsed the fuser temperature is less than 85 INITIAL ACTION Remove the Fuser Module and check the condition of the Fuser Connectors Also check to ensure that the ball which actuates the Low Oil Sensor is moving freely The ball could be stuck in the down position which will prevent the fuser from warming up If the ball is not free you may be able to correct the problem by removing the rubber stopper in the tank above the ball and using a scribe or screwdriver to loosen the ball NOTE This is only a te
176. cs Menu description of the internal test patterns is provided below PQ SET The Print Quality Set PQ Set consists of three test patterns and are printed in sequence They are e Test Pattern A e Density and Color Balance Test Pattern e Diagnostic Test Pattern Test Pattern A This pattern produces an image of varying densities and colors and assists the user in identifying a variety of image quality defects including mottle streaks density problems deletions and banding These types of defects are referred to as cosmetic defects DocuPrint C55 C55mp NC60 2 99 3 19 8mm 7 Abc Defg Abc Defg Hijk Lmnop Qrstuvw XYZ 123456789 Abc Defg Hijk Lmnop Qrstuyw XYZ 123456789 9090 0050 c gogo c _ c gogo EJ 9090 c gogo Pattern A 600 x 600 Pattern A 600 x 600 Test Pattern A 600 x 600 gogo gogo gza gogo gogo 9090 IMAGE QUALITY SPECIFICATIONS TEST PATTERNS NOTES IMAGE QUALITY SPECIFICATIONS 2 99 NOTES 3 20 DocuPrint C55 C55mp NC60 Density and Color Balance Test Pattern This test pattern is used to set the density and to determine if the printer color is balanced properly It will allow the customer to judge the color balance and correct the color balance if necessary Refer to ADJ 3 1 Density and Colo
177. ction or any loose wiring before replacing the Color Developer Module If the problem still exists replace the PCU PWB DocuPrint C55 C55mp NC60 EB BLACK DEV MISINSTALLED RAP The Black Developer Module was installed incorrectly or the contacts are dirty INITIAL ACTION Remove the Black Developer Module Check for binding in the housing Check to be sure that the seal has been removed Check the Developer Module connector to be sure it is clean Reinstall the Black Developer Module If the problem persists check connector CN107 for a good connection or any loose wiring before replacing the Black Developer Module If the problem still exists replace the PCU PWB 2 99 2 11 EC PRINT DRUM MISINSTALLED RAP The Print Drum Module was installed incorrectly or is not making a good connection INITIAL ACTION Remove then reinstall the Print Drum Module This problem is usually caused by a poor connection on the left side of the Print Drum Module Three contacts are cammed out when the Print Drum Module is installed These contacts make a connection with the Drum Link PWB located on the left side of the Print Drum Module Check to make sure there is a good connection and the contacts cam out Refer to BSD 9 2 in Section 7 and check the Drum Detect H signal If the problem persists replace the Print Drum Module If the problem still exists replace the PCU PWB STATUS INDICATOR RAPs EA EB EC
178. ctor located above and to the right of the PCU PWB Set up the meter to read 5 VDC Connect the meter to CN1007 2 this pin goes to the ROS assembly harness and ground Open and close the Printer while monitoring the meter The meter reads 0 VDC when the Printer is open and switches to 5 VDC when the Printer is closed Y N Go to BSD 6 in Section 7 and troubleshoot the Laser Interlock Switch circuit CN113 12 for an open If no open exists replace the PCU PWB If the problem still exists replace the Laser Interlock Switch Go to BSD 6 in Section 7 Connector CN113 and check the following pins for a good connection A DocuPrint C55 C55mp NC60 gt CN113 11 GND CN113 10 SYNC CN113 8 VIDEO DATA CN113 7 LASER DIODE ON L 5 VDC If the wiring appears OK replace the PCU PWB If the problem still exists replace the ROS 2 99 2 25 U5 POLYGON MOTOR FAULT A ROS problem was detected The Polygon Motor did not come up to the proper speed INITIAL ACTION Switch the power off wait 10 seconds and Switch the power on Recheck for the fault PROCEDURE Go to BSD 6 in Section 7 Connector CN113 and check the following pins for a good connection CN113 5 LASER LOCK e CN113 4 POLYGON MOTOR LOCK L 5 VDC e CN113 3 POLYGON MOTOR ON 1 5 VDC CN113 2 GND 113 1 24 VDC INTERLOCKED If the wiring appears OK replace the PCU PWB If the problem s
179. d outer E Rings from the left side of the left transfer drum Pivot Pin 9 Push the pin in slightly until you can remove the left side of the Exit assembly Do not remove the pin at this time 10 Locate the ground wire between the Exit Assembly and the Sensor bracket Remove the screw securing the ground wire to the Oil Sensor bracket Exit Assembly TO4A Figure 6 Removing the Left E Rings REPAIRS ADJUSTMENTS REP 9 9 11 12 13 Figure 7 Remove the outer E Ring from 14 Figure 8 Support the Transfer Drum the right side of the right transfer drum Pivot Assembly and remove the two pins Remove Pin the Transfer Assembly Move the Exit Assembly to the right and remove the Inner E Ring Push the pin in slightly until you can remove the right side of the Exit Assembly Do not remove the pin at this time Set the Exit Assembly aside TO4B Figure 8 Removing the Pins and Transfer Assembly Figure 7 Removing the Right E Rings REPLACEMENT NOTE The longer pin goes on the left side The large E Rings are used on the inside 2 99 4 46 DocuPrint C55 C55mp NC60 REP 10 1 BYPASS SWITCH PARTS LIST ON PL 10 4 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Figure 1 Disconnect the connector and remove the Bypass Switch Bypass Switch Figure 1 Removing the Bypass Switch 2 99 DocuPrint C55 C55mp NC60
180. der to troubleshooting when using the circuit diagrams Switches Relays B v6 Safety interlock switch circuit open ev Safety interlock switch circuit closed SWitch relay with momentary contacts shown normally open o amp Switch relay with momentary contacts shown normally closed pi Magnetically actuated Switch Miscellaneous Symbols A flag that identifies a wire that has been referred to in the text 8 2 Indicates a Diagnostic Code used to check a particular component Y Identifies a test point test hole or test stake on a PWB AD Auditron Key Counter connection HAY OO ow This symbol used with a number indicates that the actual number may be equal to or very near the value of the designated number Triac used to switch AC power Light Emitting Diode LED Led Phototransistor Sensor Motor Thermistor Bead used to sense temperature A Driver which is used to switch on DC Components Analog to Digital Converter Relay Solenoid DocuPrint C55 C55mp NC60 2 99 INTRODUCTION Signal Continuation Flow 2o Indicates the continuation of a signal line interrupted horizontal direction Represents the continuation of a standby power line interrupted in the vertical direction In all cases the supply is from Standby Power lt lt Indicates a feedback signal e Indicates a common spl
181. dity Temperature counts These read ings are used to adjust the copy quality to the environment If these readings are extreme 0 or 255 the Temperature Humidity sensor is not working properly Fuser Temp This count represents fuser temperature The following values are normal Transparencies 160 Warm up 150 Paper 140 Print Counts The number of Total Black Cyan Magenta and Yellow prints made on the NC60 Consumables Usage Status These readings track the prints and images used by the various consumables These readings will be reset to zero when a new consumable is installed Adjustments These readings are stored in the ESS If the ESS is replaced these values will need to be re entered IMAGE QUALITY SPECIFICATIONS TEST PATTERNS Process Control Status If Black Cyan Magenta or Yellow indicate Under Limit Error Process controls thinks the prints are too light even at the highest bias Over Limit Error Process controls thinks the prints are too dark even at the lowest bias Irregular Error The Gamma Sensor did not see the expected difference between the 3 patches during setup Possible causes for Under Limit and Irregular errors tend to be the same Transfer Nip too small or poor transfer in general e Toner concentration in the developer assembly is too low Arcing may be causing excessive toner consumption e Very low Relative Humidity Magenta is especially sensitive to this pr
182. djusting Print Quality and attempt to tone up NOTE If a new color developer housing has been installed make sure the 3 seals have been removed from the left side of the housing INITIAL ACTION Check with the customer to see if they have already added Yellow Dry Ink Add Yellow Dry Ink if required Adding too much toner can cause the toner to cake and not be dispensed C55 C55mp Put the printer in the Off Line mode Select the SERVICE Menu and print a Diagnostic Test Sheet Determine the Engine Software version from the Diagnostic Test Sheet If the Software level is Version 66 replace the PCU PWB All Printers switch the power off wait 10 seconds and switch the power on Allow the Printer to try to tone up to recheck for the fault PROCEDURE Enter IOT normal diagnostics Scroll to the MOTOR TEST program and Press Form Feed 1 to switch on the motors while observing the Color Toner Motor The Color Toner Motor is rotating normally A DocuPrint C55 C55mp NC60 Y N Refer to BSD 9 11 in Section 7 and troubleshoot the Color Toner Motor lines CN116 1 2 for an open or a short to ground If no wiring problem exists replace the PCU PWB f the problem still exists replace the Color Toner Motor Exit from diagnostics Set up the meter to read 24 VDC Measure between CN115 16 and ground Switch the power off wait 10 seconds and switch the power on while monitoring the meter The meter swings f
183. ds Fault History Sheet Menu Up until Menus Page Count Description 1725 E7 PRINT DRUM JAM OPEN PRI 1678 E4 INPUT JAM OPEN PRINTER Item Down until Print 1650 ES FUSER JAM OPEN PRINTER Fault History 01600 E4 INPUT JAM OPEN PRINTER 1590 EI TRAY 1 JAM JAM OPEN PRINTER 1575 EI TRAY 1 JAM JAM OPEN PRINTER Processing 1500 E4 INPUT JAM OPEN PRINTER Fault History 1456 E8 OUTPUT JAM OPEN PRINTER 1389 E7 PRINT DRUM JAM OPEN PRI 1350 E4 INPUT JAM OPEN PRINTER i 1300 E5 FUSER JAM OPEN PRINTER This page lists the last 50 Faults which have occurred on 1256 E4 INPUT JAM OPEN PRINTER the NC60 1202 EI TRAY 1 JAM JAM OPEN PRINTE j 1190 TRAY 1 JAM JAM OPEN PRINTE 1180 E4 INPUT JAM OPEN PRINTER 1156 E8 OUTPUT JAM OPEN PRINTER 1150 E7 PRINT DRUM JAM OPEN PRI 1125 E4 INPUT JAM OPEN PRINTER E5 FUSER JAM OPEN PRINTER E4 INPUT JAM OPEN PRINTER TRAY 1 JAM OPEN PRINTE TRAY 1 JAM OPEN PRINTE E4 INPUT JAM OPEN PRINTER E8 OUTPUT JAM OPEN PRINTER E7 PRINT DRUM JAM OPEN PRI E4 INPUT JAM OPEN PRINTER E5 FUSER JAM OPEN PRINTER PUT OPEN PRINTER TRAY 1 JAM OPEN PRINTE TRAY 1 JAM OPEN PRINTE PUT OPEN PRINTER E7 PRINT DRUM JAM OPEN PRINTER JAM OPEN PRINTER 5 FUSER JAM OPEN PRINTER PUT JAM OPEN PRINTER El TRAY 1 JAM OPEN PRINTER El TRAY 1 JAM OPEN PRINTER JAM OPEN PRINTER
184. ds to the Print Drum Module for an open Replace the Print Drum Module DocuPrint C55 C55mp NC60 2 99 2 41 OTHER FAULTS RAPs OF8 NOTES OTHER FAULTS RAPs 2 99 NOTES 2 42 DocuPrint C55 C55mp NC60 TITLE PAGE IQ1 IMAGE QUALITY DEFECT 3 2 1 BACKGROUND OVERALL 3 3 2 BACKGROUND 3 4 3 BACKGROUND 3 4 4 BACKGROUND 3 5 5 BACKGROUND 3 5 6 BACKGROUND YELLOW 3 5 7 BLACK 3 6 8 3 7 9 BLANK PRINT 3 7 10 BLANK PRINT 3 8 11 BLANK PRINT MAGENTA 3 8 12 BLANK PRINT 3 8 13 COLOR nm Sade e ae 3 8 14 DARK DENSITY ALL COLORS 3 9 15 DARK DENSITY SINGLE COLOR 3 10 16 DARK LINES OR STREAKS LEAD EDGE TO TRAIL EDGE 3 10 17 DARK 8 3 11 18 DELETIONS 3 11 19 DELETIONS HOLLOW CHARACTERS 3 11 20 21 22 23 24 DIRT TONER OR CONTAMINATION ON THE REVERSE SIDE OF THE PRINT 3 11 27 22420221 3 12 LIGHT DENSITY A SINGLE COLOR 3 12 LIGHT DENSITY ALL COLORS
185. e Display the Temperature Change C55 C55mp NC60 transparency values W U 139 Warmup intermediate setpoint C4 Testing the heater OHP 20 Transparency intermediate setpoint 1 20 Transparency intermediate setpoint With HEATER TEST displayed press the C2 20 Transparency intermediate setpoint Form Feed 1 Key OHP C3 146 Transparency intermediate setpoint a The printer will begin to warm up and C4 160 Transparency control setpoint display the fuser values W U 112 Warmup intermediate setpoint b Use the Next 6 Previous 5 keys to W UCt 112 intermediate setpoint toggle between the paper and C2 129 Warmup intermediate setpoint WU C4 Warmup control setpoint c Press Media Server 2 to exit from the Heater test 2 99 GENERAL PROCEDURES DocuPrint C55 C55mp NC60 6 13 BACKGROUND DIAGNOSTICS TC BIAS Table 11 Transfer Defaults TS LIFE This Diagnostic routine is used to set the low This Diagnostic routine is used to set the toner normal and high Transfer Bias for the ltem Default Description concentration offset This offset is used to following C55 C55mp NC60 compensate for developer aging Plain ordinary paper Bias Gamma 505 Khigh humidity patch bias 1 Enter Background diagnostics and press transparencies Bias Gamma KN 800 norm humidity patch bias the Menu 3 key until TS LIF
186. e Previous Next to change the margin value increases the margin decreases the margin The value can be varied 4 mm Press Enter when the adjustment is complete Perform the CHECK DocuPrint C55 C55mp ADJ 3 2 2 MARGINS SIDE TO SIDE and NC60 PURPOSE To adjust the top and left margins with respect to a portrait page using the Control Panel CHECK 1 Run a print of Test Pattern A a Press Menu Up until Service is displayed b Press Item Down until Test Patterns is displayed c Press Value Up until Pattern A is displayed press Enter 2 Figure 1 Measure the Margins a The distance from the Lead Edge of the copy paper to the 8 mm line should be 8 mm b The distance from the Side Edge of the copy paper to the 8 mm line should be 8 mm DocuPrint NC60 Lead Edge 8mm Side Edge E E e Figure 1 Margins Measurement 2 99 4 61 ADJUSTMENT 1 Access the adjustment menu a Press Menu Up until Service is displayed Press Item Down until Margin Left or Margin Top is displayed Press Value Up to change the margin value increases the margin decreases the margin The Left value can be varied 10 to 5 mm The Top value can be varied 10 to 3 Press Enter when adjustment is complete 2 Perform the CHECK REPAIRS ADJUSTMENTS ADJ 3 2 1 ADJ 3 3 NVM INITIALIZE U2 PURPOSE To obtain the consumable usage and toner
187. e Transfer Drum Cleaner Solenoid On Off Stripper Solenoid Developer Roll Cleaning Solenoid e Registration Clutch e Grounding Roller Solenoid MULTI F ON OFF Multiple copies On Of Commons COLOR ON OFF Color print On Off N N F TONER N ON OFF Display Toner On Off CASSETTE stp Feed Standard Optional Cassette 4 Pressing the On Line 1 key will energize the Toner Solenoids in sequence The first time the On Line key is pressed energizes the Cyan solenoid second On Line the Magenta solenoid and third On Line the Yellow solenoid 5 To stop the test press the Media Server 2 key GENERAL PROCEDURES NORMAL DIAGNOSTICS The display will indicate KT CT MT YT as the various toner concentrations are checked 4 To change the default values press the Enter 7 key when TEST PRINT is displayed 2 99 6 6 NOTE When multi is selected hold Media Server 2 down until the printer stops DocuPrint C55 C55mp NC60 NV RAM INITIAL This Diagnostic routine is used to initialize the Non Volatile RAM CAUTION Before initializing the NVM you must obtain the toner concentration setpoints These setpoints must reentered after initializing the NVM Refer to ADJ 3 3 1 Enter Normal diagnostics and press the Menu 3 key until NV RAM INITIAL is displayed on the Message Display 2 Insert a sheet of paper into the bypass slot to actuate the Bypass Switch then pres
188. e above check OK replace the Black Developer Cartridge If the problem still exists replace the PCU PWB STATUS INDICATOR RAPs J5 J6 J7 TONER COLLECTOR FULL RAP The Toner Collector is full or not installed correctly INITIAL ACTION Remove the Toner Collector and ensure that it is not full Check to ensure that the channel that the sensor looks through is not blocked with toner Reinstall the Toner Collector PROCEDURE Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 02 Press Form Feed 1 Open the Printer Remove and reinstall the Toner Collector while observing the Yellow LED The Yellow LED switches on and off Y N Go to BSD 9 21 in Section 7 and trouble shoot the Waste Toner Sensor signal 5 and CN102 3 1 2 for an open If no open exists replace the PCU PWB If the problem still exists replace the Waste Toner Sensor Install a new Toner Collector STATUS INDICATOR RAPs J7 J8 J9 J8 REPLACE PRINT DRUM RAP The Print Drum is at end of life is not in place or is not installed correctly NOTE This code is normally preceded by a W3 code INITIAL ACTION Check the Print Drum Cartridge life C55 C55mp Press On Line then press Menu use Next to scroll to the MAINTENANCE menu press Enter Use Next to scroll to PRINT DRUM press Enter NC60 Press Menu Up until Service Item Down until CRU Usage Press Value Up to scroll t
189. e display off All LED s on all pixels on 4 Boot 2 sequence begins displayed as tests are conducted 1 2 3 4 5 6 7 8 60 ESS LED S Hard Disk Test POWER SIMM 1 through SIMM 4 test XIE RAM test Optional NIC card slot test 10MB Ethernet test Internal NIC Option Flash ROM test Floppy Test DP TEK test The Fail LED lites when the ESS fails Self Memory test Test ESS Ready The Power LED lites when there is 5 VDC available on the ESS GENERAL PROCEDURES 2 99 BOOT SEQUENCE 6 40 IOT COPY QUALITY SETUP Main Motor and Fuser Motor on Cleaner Solenoid energizes Cleaner Assembly moves against Transfer Drum Black Developer Clutch energizes and Black toner concentration is checked If necessary the Black Toner Motor Switches on and tones the black developer Cyan Developer Clutch energizes and Cyan toner concentration is checked If necessary the Color Toner Motor and Cyan Toner Solenoid switch on and tone up the cyan developer Step 4 is repeated for Magenta and Yellow Main Motor pauses with white patch under Gamma Sensor and the Gamma Sensor is calibrated Three Black patches printed on top of white patch 50 volts apart Gamma sensor measures patches and sets Black developer bias Three Cyan patches printed 50 volts apart Gamma sensor measures patches and sets Cyan developer bias Step 8 is repeated for Magenta and Y
190. e ee 1 145 VDC I T2 FEED SOLENOID ON 21 T 1 1 24 VDC 1 1 1 1 7 2 1 1 GND 1 1 1 2 p 1l lt L ELI EI DIM IUDA SED mE rr Fr 2 T2 DRIVE T2 7 2 PAPER SIZE SENSING CASSETTE CLUTCH PWB PL 27 1 PL 27 1 3 T2 CASSETTE 5 24 VDC INTERLOCKED i eni T2 DRIVE CLUTCH ON 3 T2 PAPER SIZE 0 H 5 VDC 1 L 24 VDC T2 PAPER SIZE 1 H 5 VDC 2 23 T2 PAPER SIZE 2 H 5 VDC s 1 GND L6 up aed as ica aT n 61 5 VDC 5 4 CASSETTE PWB PWB osuere i S0 THRU S4 2 j Paper T2 T2 T Loaded Paper Paper Paper Description Size 0 Size 1 Size 2 5 03 C 03 M 03 Y No Tray 2 in Printer No Tray ON H E2 Sheet fed from Tray 2 did not reach Registration Sensor 50 51 Executive ON H T2 TRAY EMPTY SENSOR T2 FEED T2 DRIVE 10 5 11 A4 CLUTCH SOLENOID 7 T2 PAPER FEED CHAIN 7 LEVEL 2 SHEET 2 0F 2 2 99 BSDs DocuPrint C55 C55mnINC601 7 7 Chain 7 T2 Optional Paper Feed 8 1 REGISTRATION SENSING 1 REGISTRATION SENSOR PL 8 2 PAPER REGISTERED L 5 VDC GAMMA PWB PL 10 2 GAMMA SENSOR 2 _ 82REGISTRATION REGISTRATION CLUTCH PL 8 3 1 3 8 4 TRANSPARENCY SENSING TRANSPARENCY REGISTRATION C
191. e plastic bag insert it into the top of the fuser align the arrow on the roller to the arrow on the fuser and lock it in place by rotating toward you 5 Install the Fuser components c Remove the Oil Bottle from the plastic bag and pull off the cap Save the second oil bottle for use when the printer warns you that the oil is low a Press the green release button located just behind the right side of the front cover to open the cover This is where the fuser is located f Close the fuser top If the top does not b Pullon the gold string to remove the gold d Insert the oil bottle into the top of the close easily check to see if the cleaner plastic pins from the fuser fuser and click into place roller is installed properly and locked in place 2 99 GENERAL PROCEDURES DocuPrint C55 C55mp NC60 6 59 GP 15 1 INSTALL 6 Install the Print Drum a Locate the Print Drum the item wrapped in a foil bag Hold the drum by the gold color handles with the arrow near the handle pointing to the white arrow 1 on the machine frame Lower the Print Drum and slide forward to align with arrow 3 DO NOT LOCK IN PLACE GENERAL PROCEDURES GP 15 1 INSTALL Be sure that you have NOT LOCKED the Print Drum or permanent damage will occur Pull the tape marked with an arrow to remove the paper covering d Push both latches forward to lock the drum in place 2 99 6 60 DocuPrint C55 C55mp NC60 7 Print th
192. e power on while monitoring the meter The meter swings from 24 VDC to 0 Y N Go to BSD 9 10 in Section 7 and trouble shoot the Cyan Toner Solenoid signal and 24 VDC Interlocked CN115 12 11 for an open If no open exists replace the PCU PWB If the problem still exists replace the Cyan Toner Solenoid Check the Cyan Dispense Shaft to see if it rotates when the Solenoid energizes If not look fora mechanical problem gears etc Check the ground to the Cyan Toner Concentration Sensor CN118 6 to CN1009 17 BSD 9 10 If the ground is OK replace the PCU PWB 2 99 2 17 STATUS INDICATOR RAPs J4 ADD BLACK RAP The black toner concentration sensor has detected low black toner in the black developer assembly When this occurs the Printer will dead cycle and attempt to tone up NOTE new black developer housing has been installed make sure the packing material has been removed INITIAL ACTION Check with the customer to see if they have already added Black Dry Ink Add Black Dry Ink if required Adding too much toner can cause the toner to cake and not be dispensed Check the Black toner hopper to ensure that it is latched closed and is opening the shutter to the developer housing C55 C55mp Put the printer in the Off Line mode Select the SERVICE Menu and print a Diagnostic Test Sheet Determine the Engine Software version from the Diagnostic Test Sheet If the Software level is
193. e test sheet o Plug the power cord into the printer and power source a Close the front and the back printer panels Install the Manual Feed Tray into the Manual Feed Slot on the Front Panel For details on how to use this tray see Chapter 3 in the User s Guide b Remove all tape from tray 1 and add paper d Switch the printer e The printer will adjust itself and print a test print For a new printer this takes about 10 minutes 2 99 GENERAL PROCEDURES DocuPrint C55 C55mp NC60 6 61 GP 15 1 INSTALL UPDATING PRINTER NIC SOFTWARE C55 C55mp ONLY PURPOSE To update the Network or the Printer software Updating the NIC software using CentreWare Open Xerox DocuPrint Open CentreWare Select Tools Upgrade Printer Select Network then select the software It should have an XFN extension Select OK Updating the Printer software using CentreWare Open Xerox DocuPrint Open CentreWare Select Tools Upgrade Printer Select Printer then select the software It should have an XFC extension Select OK Updating the NIC software using the Media Server Insert the floppy containing the software select the XFN file and press Enter Updating the Printer or NIC software using DOS If the C55 C55mp is configured as a parallel printer you can upload printer and NIC software from DOS For Printer upgrade from the DOS prompt type Copy FILENAME XFC LPT For NIC upgrade
194. e the last call use the larger of the consumable numbers e f consumable has been changed since the last call use the smaller of the consumable numbers b Determining the Page count value to use e Use the large of the page count numbers c Determining the Toner Concentration setpoints to use e f the values in NVM agree with the values on the diagnostic sheet enter these as the setpoints e If the values in NVM do not agree with the values on the diagnostic sheet and the developer CRU has not been changed the NVM is corrupt use the setpoints on the diagnostic sheet e If the values in NVM do not agree with the values on the diagnostic sheet and the developer CRU has been changed use the NVM values as the setpoints NOTE The Toner concentration setpoints are critical for good copy quality These numbers determine the amount of toner in the developer housings DocuPrint C55 C55mp NC60 2 99 4 63 REPAIRS ADJUSTMENTS ADJ 3 3 ADJ 3 3B INITIALIZING THE CAUTION Do not continue with the initialization procedure until you have determined the Consumable Usage and Toner Concentration values Always start at the beginning of this procedure ADJ 3 34 Once you have determined the Consumable and Toner Concentration values continue with the Initialization 1 Enter Normal diagnostics Menu 3 Enter 7 Power On Write down the IOT software version 2 Initialize the NVM a
195. eck the connector from the PC to ensure it is seated properly Check for any bent or deformed pins If the problem still exists replace the ESS PWB 2 99 2 38 e Customer is using NIC Examine the NIC card for any obvious problems Look for bent or deformed pins Set up the meter to measure 5 VDC and check for 5 VDC between pins 1 and 2 top 2 pins of the NIC connector 5 Volts is available Y N Replace the ESS PWB Replace the NIC PWB SLIC Figure 1 ESS PWB DocuPrint C55 C55mp OF6B 55 RAP NC60 This RAP is used when you suspect a problem with the NC60 ESS PROCEDURE Switch the Printer off Enter IOT normal diagnostics 3 7 then Power On Use 3 to scroll to TEST PRINT and press 1 to run an IOT test print The Test Print is produced Y N Refer to Section 2 Table of contents and fix the IOT Problem Switch the printer off wait 10 seconds then switch the printer on Refer to Figure 1 and Locate the POWER and FAIL LEDs on the rear of the ESS PWB Observe these two LEDs through the two cutouts The POWER LED is on Y N Refer to BSD 1 2 and check the 5 to the ESS PWB CN104 16 20 If OK replace the ESS PWB The FAIL LED is off Y N When the Fail LED is on it indicates a ESS boot failure replace the ESS Power on Version number was displayed Y N Replace the ESS The Control Panel displayed s then displayed Initializing and the copyrig
196. ed If necessary the Color Toner Motor and Cyan Toner Solenoid switch on and tone up the cyan developer Step 4 is repeated for Magenta and Yellow Main Motor pauses with white patch under Gamma Sensor and the Gamma Sensor is calibrated Three Black patches printed on top of white patch 50 volts apart Gamma sensor measures patches and sets Black developer bias Three Cyan patches printed 50 volts apart Gamma sensor measures patches and sets Cyan developer bias Step 8 is repeated for Magenta and Yellow Repeat Steps 3 4 and 5 to recheck toner concentration 2 99 6 39 C55 ESS LED S cre cra crs POWER CR5 lites when there is 5 VDC available on the ESS CR3 lites when the ESS passes Self Test All LED s lite when the ESS fails Self Test GENERAL PROCEDURES BOOT SEQUENCE SEQUENCE NC60 The following is the boot sequence for the NC60 printer The ESS also boots while the printer is booting ESS BOOT SEQUENCE BOOT SEQUENCE ROM Checksum RAM Checksum NVM Checksum All Sensors Checked for Paper Main Motor On Process Control Setup Begins Circles CCW during ESS Boot 1 ESS Ready 1 Power and Fail LEDs on 2 Fail LED off 3 Boot 1 sequence begins Initialize i960 CPU Base RAM check 32 MB ROM Check ASIC amp DMA Controller Check Parallel and Serial Port Check Message Display indicates POWER ON VERSION n nn Messag
197. ellow Repeat Steps 3 4 and 5 to recheck toner concentration DocuPrint NC60 GP1 PRINT DRUM REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Figure 1 Grasp the two latches and open the Transfer Assembly Transfer Assembly C7 Figure 1 Opening the Transfer Assembly 2 Figure 2 ROS Release the latch and open the C8 Figure 2 Opening the ROS DocuPrint C55 C55mp NC60 3 Figure 3 Release the two green latches and slide the Print Drum module out of the printer Latches Figure 3 Print Drum Removal 2 99 6 41 GP2 COLOR DEVELOPER REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Print Drum GP 1 2 Figure 1 Grasp the two handles lift and remove the Color Developer module C10 Figure 1 Color Developer Removal GENERAL PROCEDURES GP 1 GP2 GP3 BLACK DEVELOPER 4 Figure 2 Lift and remove the Black REMOVAL Developer Module WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Print Drum Module GP 1 Remove the Color Developer Module GP 2 Figure 1 Release the latch and swing the Black Toner Hopper to the right Black Toner Hopper Black Developer Module C6 Figure 2 Removing the Black Developer Module C5 Figure 1 Moving the Black Toner Hopper GENERAL PROCEDURES 2 99 GP 3 6 42 DocuPrint C55 C55mp NC60 GP4 TONER COLL
198. entered 2 99 4 64 6 Enter the Toner Concentration Setpoints a Press Media Server 2 then use Menu 3 to scroll to TONER LEVEL YTON Press Enter 7 Use Next 6 Previous 5 to change the value Insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored Use Previous 5 to step to the next setpoint to be changed Repeat steps b through e until all four Toner Concentration setpoints have been stored 7 H the IOT software level is version 66 go Section 6 in the service manual and perform the Fuser Speed adjustment GP 3 1 8 Exit from Diagnostics by switching the power off waiting 10 seconds and switching the power back on DocuPrint C55 C55mp NC60 ADJ 4 1 MAGNETIC ROLLER CLEANER SOLENOID PURPOSE The purpose of this adjustment is to ensure that the Magnetic Roller Cleaner Solenoid arm stops the Magnetic Roller Clutch when the solenoid is energized CHECK Switch the power off Locate the 4 K C M Y Magnetic Roller Cam Shafts Figure 1 Switch the power on while observing the 4 Cam Shafts The Shafts should rotate 180 when the Magnetic Roller Cleaning Solenoid is energized and another 180 when the solenoid deenergizes If the shafts rotate continuously when the solenoid is energized perform the adjustment Figure 1 Checking the Shafts DocuPrint C55 C55mp
199. er open and 0 VDC with the Printer closed Y N Go to BSD 10 5 and troubleshoot the AC on L signal and 24 VDC Inter locked CN107 20 16 for an open If the wiring is OK replace the PCU PWB If the problem still exists replace the Low Voltage Power Supply 2 99 2 22 C D Measure between CN107 18 and ground The meter reads 0 VDC while the fuser is trying to warm up Y N Go to BSD 10 5 and troubleshoot the Fuser on L signal CN107 18 for an open If the wiring is OK replace the PCU PWB If the problem still exists replace the Low Voltage Power Supply Measure between CN107 22 and ground The meter reads 0 VDC while the fuser is trying to warm up Y N Go to BSD 10 5 and troubleshoot the Heat Rod Sense L signal CN107 22 for a short to ground If the wiring is OK replace the PCU PWB If the problem still exists replace the Low Voltage Power Supply Replace the Low voltage power supply Go to BSD 10 5 in Section 7 and troubleshoot the Fuser connectors CN1004 1008 1009 for an open circuit If OK replace the Fuser Module DocuPrint C55 C55mp NC60 T2 OVER TEMPERATURE RAP The fuser temperature is greater than 240 C INITIAL ACTION Remove the Fuser Module and check the condition of the Fuser Connectors Reinstall the Fuser Module Switch the power off wait 10 seconds and switch the power on Recheck for the fault PROCEDURE Allow the fuser to cool Set up the mete
200. er Module Right Side Cover REP 1 3 Top Cover REP 1 1 Rear Cover REP 1 2 f 2 Figure 1 Remove the screws and remove the Transfer Charge and Grid leads E1 Figure 1 Removing the High Voltage Leads DocuPrint C55 C55mp NC60 3 Figure 2 Remove the Drive Cover 4 Figure 3 Remove the Drum Terminals Drum Cover Terminals E2 Figure 2 Removing the Drive Cover Figure 3 Removing the Drum Terminals 2 99 REPAIRS ADJUSTMENTS 4 21 REP 6 1 6 2 SLIDE CAMS PARTS LIST ON PL 6 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Figure 1 Remove the following a b Print Drum Module Color Developer Module Black Developer Module Right Side Cover REP 1 3 Top Cover REP 1 1 Rear Cover REP 1 2 f 2 Figure 1 Remove the Drive Cover Figure 1 Removing the Drive Cover REPAIRS ADJUSTMENTS REP 6 2 3 Figure 2 Remove the Tension springs 4 Figure 3 Remove the 3 pins and the Block Tension Springs Block E4 E5 Figure 3 Removing the Pins and Block Figure 2 Removing the Springs 2 99 4 22 DocuPrint C55 C55mp NC60 5 Figure 4 Remove the Inner Drive Frame and the Slide Lever Springs Slide Lever Springs Inner Drive Frame E5 Figure 4 Removing the Inner Frame and Springs DocuPrint C55 C55mp NC60 6 Figure 5 Remove the pin a
201. es between 1200 1400V The Transparency default is 2000V and varies depending on the temperature and relative humidity The voltage varies for each of the 4 colors when running transparencies Black default is 2000V Cyan default is 2200V Magenta default is 1400 Yellow default is 2600 As the humidity changes the voltage is also changed to compensate Developer Bias The default bias is 400V The four developer bias voltages are set during the Process Control cycle at power on The voltage range is from 250 to 550 volts In general the higher the bias the darker the print If the values get too high or too low the charge voltage may change to compensate The Magenta voltage tends to be higher These values will also change when the color balance procedure is performed DocuPrint C55 C55mp General Information Software Version X X X Current ESS Software version Software Part Number XXXXXXXXX ESS PWB part number Engine Software Version XX current IOT Software version Serial Number XXX XXXXXX Printer Serial Number Total RAM Installed 24 MB Total Ram installed in Printer Base 8 MB Soldered on the ESS PWB always 8M onto Status J8 J9 16 MB This is the DRAM in the upper two slots They Cyan Okay must be matched and must be the larger of the SIMM s Magenta Okay DocuPrint C55mp Printer Diagnostics Color Laser Printer General Information Software Version x x x Software Part Number xxxxx
202. ete the procedure if required 2 No Yellow bias or constant Yellow Toner 2 Refer to BSD 9 1 and check the Yellow Dispensing Developer Bias voltage If no voltage is present replace the High Voltage Power Supply If the voltage is OK check the Yellow Developer Bias lead CN803 5 for an open If the wiring is OK refer to BSD 9 10 and check the Yellow Toner Solenoid CN115 16 for a short to ground If no short is present replace the color developer module 2 99 IMAGE QUALITY RAPs DocuPrint C55 C55mp NC60 3 5 IMAGE QUALITY DEFECTS Defect Name Description Possible Causes Corrective Action 7 BLACK PRINT NO IMAGE IS PRESENT Drum Module not seated 1 Reseat the Drum Module THE PAGE IS BLACK 2 Print Drum module arcing 2 Listen for arcing and watch message display The print may be a combination of all colors for scrambled characters If present replace the Print Drum module ESS holding laser on 3 Slide ESS out of printer Run IOT Test pattern If OK replace ESS If prints are still black reinstall ESS and continue with this procedure No power to Charge Scorotron 4 Check the wiring between the High voltage Power Supply and the Charge Spring Clip to ensure a good connection No Charge on signal 5 Refer to Section 7 BSD 9 1 and check the Charge on Signal CN106 2 for an open If signal does not go low during print replace the PCU PWB 6 Broken Charge Scorotron 6 Replace the Print Drum Module 7 High v
203. fer and Developer Bias voltages 1 Enter Normal diagnostics and press the Menu 3 key until VOL TEST MC is displayed on the Message Display 2 Press the Next 6 Previous 5 keys until the Message Display steps to the voltage to be tested 3 Press the Form Feed 1 key to start the test The On Line LED will flash 4 Use the Next 6 Previous 5 keys to change the voltage value 5 To stop the test press the Media Server 2 key MainMC Output fixed Charge No Display TC Bias 1800 1500 One step change Transfer 3000 apx 11 volts 28 600 care 298 600 One step change 20 volts KD BIAS Black Bias CD BIAS One step change Cyan Bias 20 volts 5 _ One step change Magenta Bias 2997600 apx 20 volts YD BIAS 3 One step change Yellow Bias 298 6900 20 volts This is the bias that is supplied to the roll when the color is not being developed 2 99 6 5 MOTOR TEST This Diagnostic routine is used to test the operation of the motors 1 Enter Normal diagnostics and press the Menu 3 key until MOTOR TEST is displayed on the Message Display 2 Press the Form Feed 1 key to start the test 3 The following motors will operate e Main Motor e Paper Feed Motor e Fuser Motor e Developer Motor Color Toner Motor Black Toner Motor Note 1 e Polygon Motor 4 To stop the test press the Media Server 2
204. ff Enter IOT normal diagnostics Menu Enter then Power On Scroll to TEST PRINT and press Form Feed to run an IOT test print The Test Print is produced Y N Refer to Section 2 Table of contents and fix the IOT Problem Switch the printer off WARNING Have the customer disconnect all network and workstation inputs to the printer Remove the Left Cover If the Printer has a NIC card remove it Locate the five LEDs 1 5 on the rear of the ESS PWB They are just below the parallel port When the printer is switched on you should see the LEDs light in the following sequence CR5 on All LEDs on CR5 and on Switch the Printer on while observing the LEDs If you need to do it several times be sure to wait 10 seconds after power off before switching the Printer back on The LEDs operated normally Y N A B OTHER FAULTS RAPs OF6A A B CR5 came on Y Refer to BSD 1 2 and check the 5 VDC to the ESS PWB CN104 16 20 If OK replace the ESS PWB Replace the ESS PWB Enter the Off Line mode and make a test print A Test Print was produced Y N Replace the ESS PWB Determine the Port being used then select from one of the following e Customer is using SLIC Check the connector from the PC to ensure it is seated properly Check for any bent or deformed pins Replace the SLIC PWB If the problem still exists replace the ESS PWB e Customer is using Parallel Ch
205. ff and Yellow is ON Y N Refer to BSD T2 7 2 and check the T2 Paper Size 1 signal CN109 2 for an open If OK replace the T2 Cassette PWB If problem still exists replace the PCU PWB emove the cassette and put the Length Stop in the Letter 11 position Insert the cassette and observe the LEDs Cyan is On Magenta is Off and Yellow is On Y N Refer to BSD T2 7 2 and check the T2 Paper Size 1 signal CN109 2 for an open If OK replace the T2 Cassette PWB If problem still exists replace the PCU PWB emove the cassette and put the Length Stop in the A4 position Insert the cassette and observe the LEDs C 2 99 2 36 Cyan is On Magenta is and Yellow is Off Y N Refer to BSD T2 7 2 and check the T2 Paper Size 2 signal CN109 3 for an open If OK replace the T2 Cassette PWB If problem still exists replace the PCU PWB emove the cassette and put the Length Stop in the Legal 14 position Insert the cassette and observe the LEDs Cyan is Off Magenta is On and Yellow is Off Y N Replace the T2 Cassette PWB Replace the PCU PWB 10 5 11 4 14 Figure 2 4 Length Stop Location DocuPrint C55 C55mp NC60 OF5 LOAD PAPER RAP This RAP is used to troubleshoot a constant load paper message INITIAL ACTION Remove the cassette and check the actuator for the Tray Empty Sensor to ensure it is not broken Switch the power off wait 10 seconds and
206. from the DOS prompt type Copy FILENAME XFN LPT is the printer LPT port The printer will recognize the files as software GENERAL PROCEDURES Software Upgrading ENTERING SERIAL NUMBER SERVICE SUPPLIES DATA USING CENTREWARE C55 C55mp ONLY PURPOSE To enter the printer serial number service phone number and supplies phone number NOTE If the printer is configured as a parallel printer you cannot enter this data using CentreWare Open Xerox DocuPrint Open CentreWare DP Services Select the appropriate Printer Select Printer Properties System In the System Properties window select the Support Tab Enter the required data Select OK 2 99 6 62 ENTERING ALPHANUMERIC DATA USING THE CONTROL PANEL C55 C55mp ONLY PURPOSE To enter Alphanumeric data using the control panel 1 Enter the Off Line mode 2 Scroll to the location requiring the data entry 3 Press Select to move the prompt to the right 4 Press Media Server to move the prompt to the left 5 The following alphanumerics are available 2 9 0 will delete the prompt character and all characters to the right 6 Use the Next Previous keys to scroll through the characters 7 Once the proper character is displayed use Select or Media Server to move the prompt and store the character 8 When finished entering data press Enter DocuPrint C55 C55mp UPDATING PRINTER NIC SOFTWARE NC60 ONLY PURPOSE To update the Netw
207. ge between colors from within the driver This feature enables you to adjust the amount of Red Green and Blue in all your documents Image Enhancement ImageFix Occasionally scanned images images downloaded from a digital camera are too dark or light lacking contrast ImageFix automatically corrects imperfect photographs by re balancing and optimizing the image as it prints to provide optimal image quality Win 95 98 NT only IntelliRes Web sites use low resolution images to speed downloading and viewing on a monitor However when these images are printed the result is often unsatisfactory IntelliRes automatically analyzes these coarse photos and smoothes them for more pleasing printed output Internet Printing Distribute and Print Use your E mail enabled print driver to distribute documents to several printers at once with a single mouse click By simply entering the E mail address of each destination printer and selecting print from your Window s application a job can be sent to a printer anywhere Remote Administration Use the NC60 embedded Web server to perform any printer administration function You can display status and diagnostics as well as configure the printer from any location Remote Monitoring Use any web browser to monitor and maintain your printer You can query your consumable status or even configure the printer to automatically send an E mail message when it needs attention If you have
208. gure 1 Remove the following a Drum Module b Color Developer Module Black Developer Module A45 Figure 3 Removing the Toner Motor Figure 2 Removing the Toner Hopper A46 Figure 1 Removing the Modules 2 99 REPAIRS ADJUSTMENTS DocuPrint C55 C55mp NC60 4 51 REP 13 1 REP 27 1 TRAY 2 MODULE PARTS LIST ON PL 27 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord CAUTION Three people are required to remove the printer from the Tray 2 Module 1 Figure 1 Remove the Tray 2 Module a Remove the Tray 2 Cassette b Disconnect the connector Turn the screw clockwise to release the latches d Two persons should lift the printer from the Tray 2 Module while one person holds the screw clockwise F1 Figure 1 Removing the Tray 2 Module REPAIRS ADJUSTMENTS REP 27 1 27 2 REPLACEMENT NOTE Figure 2 Before reinstalling the Tray 2 Module press the lever several times to ensure that the Drive Gear raises when the lever is pressed When latching the Tray 2 Module ensure that both latches are engaged Push lever F8 Figure 2 Reinstalling the Tray 2 Module 2 99 4 52 REP 27 2 TRAY 2 FEEDER ASSEMBLY PARTS LIST ON PL 27 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Tray 2 Module REP 27 1 2 Figure 1 Remove the Tray 2 Paper Feed Assembly a Disconnect the co
209. h Voltage Power Supply Transfer Current 7 The voltage should be 1200 to 1600 V 8 Press Media Server 2 to switch the Power Supply off NOTE Do not keep the power supply on any longer than necessary GENERAL PROCEDURES GP 9 3 Left Terminal Connecting The Meter K7 Figure 1 Checking the Transfer Voltage 2 99 6 52 DocuPrint C55 C55mp NC60 GP 9 4 DEVELOPER BIAS VOLTAGE CHECK PURPOSE The purpose of this check is to ensure that the Developer Bias Voltage is within specifications Note During normal operation the Developer Bias voltage is determined by the Process Control Setup It will be between 450 and 650 volts when the color is being developed 1 Setup the multimeter to read 500 VDC 2 Enter Normal Diagnostics Menu 3 Enter 7 Power ON 3 Use Menu 3 to scroll to VOL TEST MAIN CH 4 Use Next 6 Previous 5 to scroll to VOL TEST DV BIAS 5 Press Form Feed 1 to switch on the High Voltage Power Supply Developer Bias 6 Figure 1 Connect the Meter to the Bias voltage to be checked K6 7 The voltage should be 400 50 V 8 Press Media Server 2 to switch the Power Supply off Figure 1 Checking the Developer Bias NOTE Do not keep the power supply on any 9 9 longer than necessary NOTE During print expect the voltage to be from 250 to 500 volts 2 99 GENERAL PROCEDURES DocuPrint C55 C55mp NC60 6 53 GP 9 4 NOTES GENERAL PROCEDURES
210. he Printer 2 Figure 1 Remove the Fuser Assembly 3 Place a sheet of paper between the Stripper Fingers and the Transfer Drum Figure 1 Removing the Fuser Assembly REPAIRS ADJUSTMENTS REP 9 1 Figure 2 Remove the screw and remove the Spring Clip Remove the screw and remove the Stripper Arm Remove the Stripper Finger Assembly and the Transparency Jam Sensor Actuator Stripper Finger Assembly Figure 2 Removing the Stripper Finger Assembly 2 99 4 36 REPLACEMENT NOTE If the Transparency Sensor Jam Actuator comes off of the Stripper Finger Assembly rotate the Stripper Arm and reinstall the actuator over the flats on the Stripper Shaft Do not attempt to snap the actuator onto the shaft NOTE When replacing the Transparency Sensor Jam Actuator make sure it is blocking the Jam Sensor and moves freely NOTE If you have difficulty reinstalling the Stripper Finger Assembly because of the Transparency Jam Sensor Actuator remove the Transparency Jam Sensor reinstall the Stripper Finger Assembly then reinstall the Transparency Jam Sensor When reinstalling the Transparency Jam Sensor raise the actuator and make sure the Transparency Jam Sensor Actuator is blocking the Transparency Jam Sensor If you do not install the sensor correctly a Drum Jam will occur at power on NOTE Operate the Stripper Solenoid several times by hand and check the operation of the Stripper Fingers DocuPrint C55 C5
211. hile observing the Black LED The Black LED switches on and off Y N Check for an obstruction that is keeping the Transparency Jam Sensor actuator raised C D DocuPrint C55 C55mp NC60 C D If OK refer to BSD 9 17 and check the Transparency Jam Sensor signal CN314 2 for a short to ground If no short exists replace the PCU PWB If the problem still exists replace the Transparency Jam Sensor Open the printer and remove the Transfer Discharge Corotron from the left side of the printer You will need to squeeze the corotron handle to release the corotron With Scan Row 05 still selected actuate and deactuate the Cleaner Jam Switch while observing the Magenta LED The Magenta LED switches on and off Y Check for an obstruction that is keeping the Cleaner Jam Switch actuated If OK refer to BSD 9 18 and check the Cleaner Jam Switch signal CN318 2 for a short to ground If no short exists replace the PCU PWB If the problem still exists replace the Cleaner Jam Switch Exit from the Switch Scan Program Scroll to the MOTOR TEST program and switch on the motors while observing the Fuser Drive Motor The Fuser Drive Motor is rotating normally Y N Go to BSD 10 1 in Section 7 and trouble shoot the Fuser Drive Motor for an open If the motor was noisy check the clock lines for an open or short If the lines are OK replace the PCU PWB If the problem still exists replace the Fuser Drive Motor DocuPrint C
212. ht statement Y N A B DocuPrint NC60 A B Check the plug in RAM to ensure it is seated properly and is at least 32 MB If the problem still exists replace the ESS Press 2 until Service Menu is displayed Press 5 until Config Sheet is displayed then press 1 to make a test print A Test Print was produced Y N Replace the ESS PWB Determine the Port being used then select from one of the following Customer is using the Serial interface Check the connector from the PC to ensure it is seated properly Check for any bent or deformed pins If the problem still exists replace the ESS PWB Customer is using the Parallel interface Check the connector from the PC to ensure it is seated properly Check for any bent or deformed pins If the problem still exists replace the ESS PWB Customer is using 10 NIC No Optional NIC Check the NIC connector to ensure it is seated properly Check for any bent or deformed pins If the problem still exists replace the ESS PWB 2 99 2 39 e Customer is using 100 MB NIC or Token Ring Optional NIC e Examine the NIC card for any obvious problems Look for bent or deformed pins Set up the meter to measure 5 VDC and check for 5 VDC between pins 1 and 2 top 2 pins of the NIC connector 5 Volts is available Y N Replace the 55 PWB Replace the NIC PWB Figure 1 ESS PWB O
213. ice of wires P457 ndicates a common splice of wires at gt ndicates the direction of signal flow gt lt Indicates that the wire continues to the adjacent page INTRODUCTION Tag Identification This WITH TAG Symbol is used to identify the components or configura tion that are part of a printer change covered by the Tag number This WITHOUT TAG Symbol is used to identify the components or configuration that are not part of a printer change covered by the Tag number 2 99 DocuPrint C55 C55mp NC60 1 SERVICE CALL PROCEDURES TITLE PAGE CALEB ELO coeptae 1 2 INITIAL AO TION 1 3 SYSTEM CHECKS 1 3 EVERY CALL ACTIVITIES 1 4 SCHEDULED MAINTENANCE 1 4 FINAL ACTION 1 5 2 99 SERVICE CALL PROCEDURES DocuPrint C55 C55mp NC60 1 1 SECTION CONTENTS SERVICE CALL PROCEDURES CALL FLOW CALL FLOW INITIAL ACTION This step is used to gather information about the reason for the call to determine the machine condition and to run print samples SYSTEM CHECKS This step is used to suggest a direction for using the information obtained during Initial Action You can then repair and verify the repair of the problem This step may also provide information to assist in the identification of new problems and suggest actions to take to repair resolve them EVERY CALL ACTIVITIES Th
214. id terminal blue wire right 3 Enter Normal Diagnostics Menu 3 Enter 7 Power ON 4 Use Menu 3 to scroll to VOL TEST MAIN Z Right Terminal CH Caution Connecting The Meter Check to ensure that the red meter lead is not contacting the frame 5 Press Form Feed 1 to switch on the High Voltage Power Supply Figure 1 Checking the Grid Voltage 6 The voltage should be 557 7 V 7 Press Media Server 2 to switch the Power Supply off NOTE Do not keep the power supply on any longer than necessary The constant charge can fatigue the print drum 2 99 GENERAL PROCEDURES DocuPrint C55 C55mp NC60 6 51 GP 9 2 9 3 TRANSFER VOLTAGE PURPOSE The purpose of this check is to ensure that the Transfer Voltage is within specifications NOTE You must have a High Voltage Probe to perform this procedure Note During normal operation the Transfer voltage will be one of two voltages 1500 volts for plain paper and 2800 for transparencies 1 Setup the multimeter to read 1500 VDC 2 Figure 1 Connect the High Voltage Probe to the Transfer terminal black wire left 3 Enter Normal Diagnostics Menu 3 Enter 7 Power ON 4 Use Menu 3 to scroll to VOL TEST MAIN CH 5 Use Next 6 Previous 5 to scroll to VOL TEST TC BIAS Caution Check to ensure that the red meter lead is not contacting the frame 6 Press Form Feed 1 to switch on the Hig
215. ine mode Press the Menu key You are now in the Off Line menus Navigating through the Menus Enter selects an item or enters a sub menu Next moves forward in the sub menus Previous moves back in the sub menus Media Server moves to the Media server menu moves to the top of the menu list The Media Server can be selected from the On Line mode by pressing Media Server DocuPrint C55 C55mp The printer menus are in layers The TOP MENU is Layer 0 and consists of the following Control Menus Maintenance Media Menu 2 99 6 15 The only menu which will described in detail here is the C55 C55mp Service Menu To see how the rest of the Menus layered refer to the C55 C55mp Menu page To run the MENU page Press spayRex wem CONTROLS fener STMWURS Eme fener PROGESSNG GENERAL PROCEDURES OFF LINE MENUS 55 55 MENU lt SERVICE gt SERVICE TEST PATTERNS PRINT PQ SET lt YES gt lt NO gt lt EXIT THIS MENU gt TEST PATTERNS PATTERN TYPE PCL lt PATTERN TYPE lt PCL gt lt TEST PATTERN A gt lt 100 STRIPE gt lt COLOR BALANCE gt lt YELLOW STEP gt lt MAGENTA STEP gt lt CYAN STEP gt lt BLACK STEP gt lt BLANK gt lt GRAY HALFTONE gt lt EXIT THIS MENU gt POSTSCRIPT lt TEST PATTERN A gt PATTERN TYPE lt POSTSCRIPT gt lt COLOR BALANC
216. int C55 C55mp NC60 3 17 IMAGE QUALITY DEFECTS Defect Name Description Possible Causes Corrective Action 43 WRONG COLORS ON ESS TEST Color Balance out of adjustment Perform the Density and Color Balance PATTERNS Adjustment ADJ 3 1 2 Developer Contamination 2 Replace the Developer Module 3 One of the Magnetic Roll Clutches is always 3 Observe the colors on Test Pattern A If only energized one basic color K C M Y is correct that clutch may always be energized Refer to the table below to troubleshoot Correct Refer to BSD and check Color BSD 9 7 CN115 2 Black Magnetic Clutch on for a short to ground BSD 9 1 CN106 13 K Bias On for a short to ground BSD 9 9 CN115 4 Cyan Magnetic Clutch on for a short to ground BSD 9 1 CN106 12 C Bias On for a short to ground Magenta BSD 9 9 CN115 6 Magenta Magnetic Clutch on for a short to ground BSD 9 1 CN106 11 M Bias On for a short to ground Yellow BSD 9 9 CN115 8 Yellow Magnetic Clutch on for a short to ground BSD 9 1 CN106 10 Y Bias On for a short to ground IMAGE QUALITY RAPs 2 99 IMAGE QUALITY DEFECTS 3 18 DocuPrint C55 C55mp NC60 5 5 This section contains descriptions of the ESS and IOT generated test patterns ESS GENERATED TEST PATTERNS The ESS contains several internally generated test patterns to assist in diagnosing image quality problems These test patterns are accessed using the Off Line Diagnosti
217. iption Paper 20 to 24 Ib Best 80 to 90 gsm Paper 16 to 24 Ib Good 60 to 90 gsm Less than 16 Ib Not p 60 gsm or greater rebanim ndad than 24 Ib 90 gsm 3R4446 Transparency 8 x 11 clear Best 3R96002 Lot M Transparency 4 clear Best 2 99 6 68 OTHER SPECIFICATIONS C55 C55mp Electrical Power Requirements OPCO Power Requirements 05 XCL 115V 50 60 Hz 15A 220 240V 50 60 Hz 10 15A Power Consumption 300 W Average 1000 W Maximum Environmental Operating Conditions Minimum 50 F 10 C at 15 relative humidity Maximum 90 F 32 at 8596 relative humidity Recommended 63 to 81 F 17 5 to 27 at 60 to 70 relative humidity Maximum Altitude 6560 feet 2000M Sound Level 47 dbA Standby Max 54 dbA Running Max DocuPrint C55 C55mp PRODUCT CODES NC60 Paper Feed System OTHER SPECIFICATIONS NC60 Product Cassette amp Manual Feed Electrical Power Requirements ity 2 h 20 Ib EE 2 24 5 The sizes in bold typeface are detected Power Consumption automatically One of the other sizes can be 300 W Average 1000 W Maximum PHYSICAL CHARACTERISTICS i i assignedusing Ine Tray Menu Environmental Operating Conditions NC60 Width 18 5 inches 470 MM Minimum P Executive 7 25 10 5 5 176 250 90 F 32 at 85 relative humidity Invoice 5 5x8 5
218. is step consists of every call cleaning and maintenance activities SCHEDULED MAINTENANCE This step is used to check the life remaining on the CRU s FINAL ACTIONS This step is used to ensure that the print quality the printer performance and the printer appearance is satisfactory It will also provide direction to help complete administrative tasks 2 99 1 2 DocuPrint C55 C55mp NC60 INITIAL ACTION Purpose To suggest how to gather information about the service call the machine condition and to direct the user through the call PROCEDURE 1 Ask the customer to describe the problem that causes the service call and the job being run when the problem occurred Inspect any rejected prints for evidence of defects Switch the printer power Off On and check for and note record any fault codes in the Control Panel Display Examine the Machine Service Log under the Left Side Cover for previous problems or activities that may be related to this service call Go to SYSTEM CHECKS DocuPrint C55 C55mp NC60 SYSTEM CHECKS Purpose To suggest a direction for effective repair and verification of repair of problems found in Initial Action PROCEDURE 1 Select the appropriate situation from a g below then diagnose and repair the problem a Replace any obviously broken parts b If this is an Image Quality problem go to IQ1 Image Quality Entry RAP in Section 3 c If there is a Fau
219. isconnect the Power Cord 1 Remove the Front Cover REP 1 4 2 Unhook the Transfer Drum cleaner return spring 3 Figure 1 Remove six screws 4 Carefully pry the Transfer Drum Frame away from the lower frame and remove the Transfer Drum Lower Frame Return Spring Transfer Drum Frame Transfer Drum Lower Frame des Figure 1 Removing the Transfer Drum Lower Frame DocuPrint C55 C55mp NC60 Figure 2 Remove the Toner Shutter Remove the Transfer Drum Cleaner E Ring Remove the E Ring from the Cam Shaft Carefully pry the Transfer Drum Frames apart and remove the Transfer Drum Cleaner Assembly Shutter Transfer Drum Cleaner Assembly A34 Figure 2 Removing the Transfer Drum Cleaner Assembly 2 99 4 39 REPLACEMENT NOTE When reinstalling the Transfer Drum Cleaner into the left frame be sure it is seated correctly If it is not seated properly you will not be able to install the E Ring NOTE Figure 3 When Reinstalling the Transfer Drum Lower Frame rotate the Transfer Drum Flange until the V Shaped cutouts on the Transfer Drum Flanges are inserted in the V of the Lower Transfer Frame The Transfer Drum Flanges do NOT rotate When the Lower Frame is installed properly the Transfer Drum Gear can be rotated in either direction and the Nip Adjustment Wheels will not rotate Transfer Drum Flange V Shaped Cutout Transfer Drum
220. ite patch should be at the tips of the stripper fingers If not replace the Transfer Drum PROCEDURE Switch the Printer off Remove the front cover and tape the Control Panel up so that you can view the operation of the Transfer Drum Cleaning Solenoid Switch the Printer on Observe the Transfer Drum Cleaning Solenoid and the Cleaner Assembly STATUS INDICATOR RAPs 6 If you see solid development during the quality setup go the OF8 Arcing RAP The Transfer Drum Cleaning Solenoid should energize and move the Cleaner Assembly against the Transfer Drum while the patches are generated during the Copy Quality Setup When the Copy Quality Setup is complete the Transfer Drum Cleaning Solenoid should deenergize and move the Cleaner Assembly away from the Transfer Drum If the E6 jam occurs before paper is fed and the patches are not being cleaned the Transfer Drum Cleaner assembly is not camming into the cleaning position If the machine prints OK when printing black only but jams E6 when printing color it is an indication that the Transfer Drum Cleaner assembly is staying cammed against the Transfer Drum The Transfer Drum Cleaning Solenoid and Transfer Drum Cleaner Assembly are operating correctly Y N Check that when the solenoid energizes the camshaft turns 180 degrees and is stopped by the outer tab on the cleaner clutch sleeve Ensure that the solenoid is tight and the actuator catches the inner tab
221. k that the Grounding Roller Solenoid engages the Grounding Roller Clutch and stops the Grounding Roller in the down position 2 99 4 28 DocuPrint C55 C55mp NC60 REP 8 7 GROUNDING ROLLER CLUTCH PARTS LIST ON PL 8 7 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Remove the Grounding Roller Clutch Grounding Roller Gear Grounding Roller Clutch Spring 5 Sleeve Registration Roller Gear Grounding Roller Solenoid D18B Figure 1 Removing the Grounding Roller Clutch DocuPrint C55 C55mp NC60 REPLACEMENT NOTE After assembling the components hand crank the feeder through several cycles Energize the Grounding Roller Solenoid several times by hand and check that the Grounding Roller Solenoid engages the Grounding Roller Clutch and stops the Grounding Roller in the down position 2 99 4 29 REPAIRS ADJUSTMENTS REP 8 7 8 8 PAPER DRIVE ROLLER PARTS LIST ON PL 8 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Remove the Waste Toner Sensor cover and the Waste Toner Sensor 3 Unhook the spring slide it out the bottom and remove the Waste Toner Box from the Paper Feed Assembly Sensor Sensor Cover and Arm W
222. ke sure it slides back and forth smoothly REPAIRS ADJUSTMENTS REP 8 9 8 10 UPPER REGISTRATION ROLLER PARTS LIST ON PL 8 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Remove the Waste Toner Sensor cover and the Waste Toner Sensor 3 Unhook the spring slide it out the bottom and remove the Waste Toner Box from the Paper Feed Assembly Sensor Sensor Cover Waste Toner Box D13 Figure 1 Removing the Toner Box REPAIRS ADJUSTMENTS REP 8 10 4 5 Remove the Solenoids and Keep the parts together Figure 2 Clutches shown Be especially careful with the springs they are different Figure 2 Removing the Clutches and Solenoids Figure 3 Remove the remaining hardware and remove the Right Feeder Frame Right Feeder Frame Figure 3 Removing the Feeder Frame 2 99 4 32 6 Figure 4 Remove the E Ring and Upper Registration Roller Upper Registration Roller D20 Figure 4 Removing the Upper Registration Roller REPLACEMENT NOTE When reassembling the Waste Toner Box make sure it slides back and forth smoothly DocuPrint C55 C55mp NC60 8 11 LOWER REGISTRATION ROLLER PARTS LIST ON PL 8 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide
223. l 4 Paper Empty 1 CN307 12 Conn PWB 7 15 CN3075ConnPWB 2 CN307 11Conn PWB 16 CN3077ConnPWB 3 CN315 1 Conn PWB 4 CN307 14 Conn PWB 18 CN307 10 Conn PWB _ 5 CN307 15 Conn PWB 19 CN307 9 Conn PWB 6 CN307 13 Conn PWB 20 315 7 Conn PWB 21 CN315 6 Conn PWB CONNECTOR WIRING 2 99 PCU Connectors 7 22 DocuPrint C55 C55mp NC60 104 Pin Destination 1 CN104 9ESSPWB 2 CNI045ESSPWB 7 CN105 CN106 7 CN107 DocuPrint C55 C55mp NC60 8 CN201 6CassettePWB 9 CN201 7CassettePWB 10 CN201 8CassettePWB 11 CN201 9 Cassette PWB 12 201 10 Cassette PWB 13 201 1 Cassette PWB 14 CN201 2 Cassette PWB 15 CN703 1 Power Supply 16 CN703 2PowerSupply 18 CN703 4PowerSupply 19 CN703 5 Power Supply 20 CN703 6 Power Supply 21 CN703 7PowerSupply 22 CN703 8PowerSupply 23 CN703 9PowerSupply 24 CN703 10PowerSupply 25 CN703 11 Power Supply 26 CN703 12Power 108 Pin Destination 1 CN707 1PowerSupply 2 707 2 Power Supply CN109 Pin Destination 1 CN3 1Cassette Harness 2 CN3 2Cassette Harness 3 CN3 3Cassette Harness 4 CN3 4Cassette Harness 5 CN3 5Cassette Harness 6 CN3 6Cassette Harness
224. ll exists replace the Exit Sensor Check the following e Obstructions in the paper path e Mechanical drive problem in the feedout area 2 99 2 10 E9 CLOSE PRINTER RAP The Printer is open INITIAL ACTION Open and reclose the printer PROCEDURE Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 00 Press Form Feed 1 Open and close the Printer while observing the Black LED The Black LED switches on and off Y N Go to BSD 1 G1 in Section 7 and troubleshoot the 24 VDC Interlock Switch If no open exists replace the PCU PWB If the problem still exists replace the 24 VDC Interlock Switch Replace the PCU PWB DocuPrint C55 C55mp NC60 EA COLOR DEV MISINSTALLED RAP The Color Developer Module was installed incorrectly or overtoning has occurred INITIAL ACTION Enter IOT normal diagnostics Scroll to the TEST PRINT program and press Form Feed 1 to run a test print While the print is running observe the KT __ values If any of the three color C M Y toner concentration values are below 10 that color is overtoned Refer to ADJ 9 1 EA Tone Down Procedure in Section 4 If the values are NOT too low continue with this RAP Remove the Color Developer Module Check the Developer Module connector to be sure it is clean Reinstall the Color Developer Module If the problem persists check connector CN118 for a good conne
225. lt Code go to Section 2 Table of Contents Locate and perform the RAP associated with the Fault Code d If there is NO fault code associated with the problem go to Section 2 Table of Contents Locate and perform the RAP which most closely matches the problem described by the customer e f the problem is not repeatable operate the printer in the same job conditions the customer used and recheck for a problem in the categories listed here 2 99 1 3 f f the problem still is not reproduced check the printer Fault History C55 C55mp Off Line Menu then scroll to SERVICE ERROR LOGS FAULT HISTORY Scroll through the Fault History and note any repeating faults Refer to the RAP for these fault codes in Section 2 and read the fault code description to see if the code relates to the customer problem If so perform the RAP NC60 Menu Up until Print Menu Up until Fault History then press Enter Look through the Fault History and note any repeating faults Refer to the RAP for these fault codes in Section 2 and read the fault code description to see if the code relates to the customer problem If so perform the RAP 0 If none of the above situations applies go to EVERY CALL ACTIVITIES 2 Verify that the problem is corrected and go to EVERY CALL ACTIVITIES SERVICE CALL PROCEDURES INITIAL ACTION SYSTEM CHECKS EVERY CALL ACTIVITIES Purpose To list service activities required fo
226. m still exists replace the Main Drive Motor Press Media Server 2 to stop the MOTOR TEST program Scroll to the SWITCH SCAN program and select Scan Row 04 Press Form Feed 1 Open the Printer Slowly rotate the Transfer Drum while observing the Magenta LED The Magenta LED switches on and off Y N A B 2 99 2 27 A B Go to BSD 9 13 in Section 7 and trouble shoot the Transfer Drum Home Position signal 5 VDC and ground 103 17 CN313 2 1 3 for an open or a short to ground If the wiring is OK replace the PCU PWB If the Problem still exists replace the Transfer Drum Home Position Sensor Replace the PCU PWB STATUS INDICATOR RAPs 97 W1 COLOR DEV MOD RAP This code indicates that the Color Developer module is near the end of life 1096 remaining When a J5 occurs the customer should install a new Color Developer Module When the new Color Developer Module is installed the J5 and W1 codes will no longer appear If the J5 code still exists refer to the J5 RAP STATUS INDICATOR RAPs W1 W2 W3 W2 BLACK DEV MOD RAP This code indicates that the Black Developer module is near the end of life 10 remaining When a J6 occurs the customer should install a new Black Developer Module When a new Black Developer Module is installed the J6 and W2 codes will no longer appear If the J6 code still exists refer to the J6 RAP 2 99 2 28 W3 PRINT DRUM MOD RAP This code indicates that
227. m still exists replace the Floppy Drive before replacing the ESS PWB DocuPrint C55 C55mp NC60 H1 HARD DISK ERROR RAP The Hard Disk cannot be read C55 C55mp NOTE f no hard disk is installed on this printer print a Settings page Off Line Print Settings to record the customer network settings Tell the customer that you are going to do a factory reset and they will need to reinstall the printer on their network Perform a Factory Heset Off Line Setup Factory Reset NC60 NOTE f no hard disk is installed on this printer print Config sheet Menu Up to Service Menu Up to Config Sheet Enter to record the customer network settings Tell the customer that you are going to do a factory reset and they will need to reinstall the printer on their network Perform a Factory Reset Power Off Press and hold On Line and Enter Switch the power on Continue holding the On Line and Enter keys until the display indicates Power On Version X XX then release the keys This will enable the Reset Menu Menu Up until Reset Menu Up until Factor Defaults Value Up until Yes then press Enter DocuPrint C55 C55mp NC60 INITIAL ACTION Switch the power off wait 10 seconds and switch the power on This will force the ESS to retry reading the Hard Disk If the Hard Disk still cannot be read check the following C55 C55mp Check the Hard Disk to ensure that the new Relay Interface PWB is installed Lo
228. mporary fix You should have the customer order a new fuser assembly If in your judgment this is premature failure follow the applicable warranty replacement procedures Switch the power off wait 10 seconds and switch the power on Recheck for the fault PROCEDURE Switch the power off Locate connector CN1004 CN1008 This is a two wire black and white wires heavy gauge connector that provides AC power to the fuser The connector is located just to the left of the PCU board as you are looking at it Disconnect CN1004 CN1008 Set up the meter to read Ohms Connect the meter between pins 1 amp 2 of CN1008 the Fuser side left connector and measure the resistance The resistance is less than 10 Ohms Y N A B STATUS INDICATOR RAPs T1 A B Go to BSD 10 5 in Section 7 and trouble shoot the Fuser connectors CN1008 1009 for an open circuit If the wiring is OK replace the Fuser Module CAUTION Be careful during the following test High Voltage AC may be present Set up the meter to measure 120 220 VAC Connect between CN1004 2 and CN1004 1 the LVPS side right connector Switch the Power on The reading is approximately 115 220 VAC Y N Switch the printer off Reconnect CN1004 CN1008 Set up the meter to read 24 VDC Measure between CN107 20 and ground Switch the printer on Open and close the Printer while observing the meter The meter reads 24 VDC with the Print
229. n If OK replace Simm 4 Image Enhancement RAM failure Replace ESS 16 Token Ring Card failure Check NIC connection If OK replace Simm 17 Ethernet Card failure Check NIC connection If replace Simm Flash ROM failure Replace ESS 19 Floppy Drive failure Check Floppy connection If OK replace Floppy Drive DP TEK Chip failure Replace ESS Memory not large enough Replace ESS Screen full of Asterisks Refer to 6 2 99 2 40 DocuPrint NC60 OF8 ARCING This RAP is used when Arcing is occurring between the Print Drum and the contacts which supply the Charge voltage INITIAL ACTION Inspect the Toner Collector for layers of color and black toner in the toner collector This is sometimes referred to as the sand art effect It is caused by solid development during the copy quality setup process If the Charge Scorotron or Charge Grid connection is faulty it can result in no or very low charge Since this is a write black printer the print drum will develop a solid image when there is no charge PROCEDURE Check and clean the Charge and Grid contacts located on the right side of the Print Drum Check and clean the Charge and Grid contact points on the frame side of the printer Remove the Fuser Module Clean the bracket that holds the Erase Lamp assembly Look for fibers from the exit discharge brush If the problem persists refer to BSD 9 4 in Section 7 and check the Red lea
230. nd Slide Cam 7 Figure 6 Remove the Shafts and Cams Lever Upper Cam Shaft Pin Slide Cam Lever E6 Lower Cam Figure 5 Removing the Slide Cam Lever Shall E7 Figure 6 Removing the Shafts and Cams 2 99 REPAIRS ADJUSTMENTS 4 23 REP 6 2 8 1 PAPER GUIDE U SHAPED PARTS LIST ON PL 8 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Paper Cassette 2 Remove the Front Cover REP 1 4 3 Figure 1 Open the Transfer Drum Assembly and remove the Fuser A41 Figure 1 Removing the Fuser REPAIRS ADJUSTMENTS REP 8 1 4 Figure 2 Remove the Clutch Cover Clutch Cover Figure 2 Removing the Clutch Cover 2 99 4 24 D7 e Figure 3 Remove two screws and release the two clips 6 Remove the U shaped Paper Guide Screws D8 Figure 3 Removing the Paper Guide DocuPrint C55 C55mp NC60 REP 8 2 PAPER FEED ASSEMBLY PARTS LIST ON PL 8 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Toner Waste Bottle b Right Side Cover REP 1 3 c Paper Guide REP 8 1 2 Figure 1 Remove the Connector Cover Connector Figure 1 Removing the Connector Cover DocuPrint C55 C55mp NC60 3 Figure 2 Remove the screws disconnect the connector and remove the Paper Feed Motor Paper Feed T5 Motor D9 Fig
231. ner Mot 4 5 CN1043ESS WB 6 IH 719 7 104 17 66 CNI048ESSPWB CNI0T28PCUPWB 9 CNiM4H9ESSPWB 12 CNIUT26PCUPWB 10 104 20 ESS PWB CONNECTOR WIRING 2 99 LVPS PWB Cassette PWB Connectors 7 26 DocuPrint C55 C55mp NC60 Parallel Serial Local Port Talk Local Talk 1 Serial E Connector FE Self Test LEDs 8 8 Network 8 TTTITITTTTTTITITITTTIT CN101 Hard Drive CN102 Floppy n _ mmm mmm mm um um umn am 0 IN CN103 Floppy TIF PWB Figure 7 5 C55 C55mp ESS PWB Connectors CN104 5 CN104 2 PCU PWB 11 CN104 5PCUPWB Pin Destination 1 6 CN104 9 PCUPWB 12 104 7 PCU 18 CN7028LVPS 1 CN702 1LVPS CN104 6 PCU PWB 13 CN702 3LVPS 19 CN7O2 9LVPS 2 CN7022LVPS CNI04 11PCUPWB 14 CN7O2 4LVPS 120 CN7O2 10LVPS 3 104 8 PCU PWB 9 CN104 1 PCU PWB 15 CN702 5 LVPS 4 CN104 10 PCU PWB 10 CN104 12 PCU PWB 16 CN702 6 LVPS 2 99 CONNECTOR WIRING DocuPrint C55 C55mp 7 27 ESS PWB Connectors Network Connectors Parallel Port Connector Serial Connector Nes CN
232. ner should be dispensed check the Black toner box for auger binding Check the ground to the Black Toner Concentration Sensor CN107 2 to CN1001 4 BSD 9 7 If the ground is OK replace the PCU PWB 2 99 2 18 DocuPrint C55 C55mp NC60 J5 REPLACE COLOR DEVELOPER CARTRIDGE RAP NOTE This code is normally preceded by a W 1 code The Color Developer Cartridge is at end of life INITIAL ACTION Check the Color Developer Cartridge life C55 C55mp Press On Line then press Menu use Next to scroll to the MAINTENANCE menu press Enter Use Next to scroll to COLOR DEV CART press Enter NC60 Press Menu Up until Service Item Down until CRU Usage Press Value Up to scroll to the Color Dev Cart Check the remaining on the Color Developer Cartridge If the cartridge is at end of life notify the customer and have them install a new Color Developer Cartridge PROCEDURE Check the developer drive motor belts and gears to ensure that they are rotating If the J5 code does not clear when a new Color Developer Cartridge is install go to BSD 9 10 and check the New Developer Sense signal CN118 7 for an open or short to ground If the J5 code exists even though the Color Cartridge has not reached end of life refer to BSD 9 10 and check the following e Cyan Toner Sense signal for an open or a short to ground CN118 10 Cyan Toner 5 VDC for an open 118 3 Magenta Toner Sense signal for an open or
233. nitial Actions The initial actions suggests how to collect data necessary to proceed with the service call System Checks The System Checks procedures details the steps for effective repair and verification of repair of problems found in Initial Action Every Call Activities These are cleaning and maintenance activities which are performed on every call Scheduled Maintenance Scheduled Maintenance consists of checking the life remaining on the CRUs Final Action Final Action ensures that image quality is acceptable and that printer performance and appearance is satisfactory Details included for completing administrative tasks and closing out the service call 2 99 Section 2 STATUS INDICATOR REPAIR ANALYSIS PROCEDURES RAPs This section contains the Repair Analysis Procedures RAPs necessary to repair faults other than image quality faults Section 3 IMAGE QUALITY REPAIR ANALYSIS PROCEDURES RAPs This section contains the Repair Analysis Procedures RAPs necessary to repair image quality faults Section 4 REPAIR ADJUSTMENT PROCEDURES This section contains the Repair and Adjustment procedures for the printer unique procedures will be identified as follows USCO XE Section 5 PARTS LIST This section contains exploded view drawings and referenced replaceable parts lists for the Printer Section 6 GENERAL PROCEDURES This section contains Diagnostic procedures Menus
234. nnectors b Remove the screws and remove the Tray 2 Feeder Assembly Connectors Assembly F2 Figure 1 Removing the Tray 2 Feeder Assembly DocuPrint C55 C55mp NC60 REP 27 3 TRAY 2 CASSETTE PWB PARTS LIST ON PL 27 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Tray 2 Module REP 27 1 2 Figure 1 Remove the Tray 2 Cassette PWB a Remove the Tray 2 Rear Cover b Disconnect the connectors c Remove the screws and remove the Tray 2 Feeder Assembly Cassette PWB Connectors Figure 1 Removing the Tray 2 Cassette PWB 2 99 DocuPrint C55 C55mp NC60 4 53 REP 27 4 TRAY 2 TRAY EMPTY SENSOR PARTS LIST ON PL 27 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Tray 2 Module REP 27 1 2 Figure 1 Remove the screws and remove the Tray 2 Empty Sensor Empty Sensor EZ Figure 1 Removing the Tray 2 Empty Sensor REPAIRS ADJUSTMENTS REP 27 3 27 4 REP 27 5 TRAY 2 FEED SOLENOID AND FEED CLUTCH PARTS LIST ON PL 27 3 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Tray 2 Module REP 27 1 2 Figure 1 Remove the Tray 2 Feed Solenoid 3 Remove the Tray 2 Feed Clutch Feed Solenoid F9 Figure 1 Removing the Tray 2 Feed Solenoid and Feed Clutch REPAIRS ADJUSTMENTS REP 27 5 27 6 REPLACEM
235. nsity from the surrounding area See lines bands streaks Debris Centered Deletion deletion typically in a solid area that contains a dark spot in the center of the deleted area See deletion Deletion The absence of toner from a part of the desired image With multicolored images the result can be white light or colored spots lines streaks bands or untrue colors on the print If all toner is absent the defect is classified as a blank print See Edge Deletion Trail Edge Deletion Debris Centered Deletions Skips Body Deletions Washed Out Image Density high or low High The density of the developed image on the print exceeds the MAX sample on the Density SIR Low The density of the developed image on the print exceeds the MIN sample on the Density SIR Edge Deletion An area of lighter or zero density a missing image at the edge of a desired image See Deletion Fusing marginal the fused image be can easily wiped off of the print Ghosting The reproduction of a previous image usually caused by inadequate erasure of the image on the Drum NOTE This defect ghosting is one of three similar image quality problems listed below 2 99 3 31 Refer to the other defects for additional information Ghosting Drum related Offsetting Fuser related Residual Image Cleaner related Graininess An image defect that causes solid areas to have a sandy looking surface Graininess is mos
236. nt is to switch the density patch toner check on and off When this feature is on the density is checked using development patches before a low toner condition is declared This setting should normally be left OFF if can cause EA Fault codes PROCEDURE 3 2A C55 C55mp IOT FIRMWARE VERSION 75 1 Enter Normal Diagnostics Press Menu amp Enter Power ON 2 If the message display indicates PCU DIAG MODE 75 or higher continue with the adjustment If the display indicates any version lower than 75 exit from diagnostics do not perform the adjustment 3 With PCU DIAG MODE 75 displayed press On Line then Enter Release both keys at the same time DocuPrint C55 C55mp NC60 10 11 12 The message display will indicate PCU DIAG SPECIAL With PCU DIAG SPECIAL displayed press Medial Server then Previous Release both keys at the same time The message display will indicate DIAG BACK GROUND Press Menu to scroll to CONTROL K DVBIAS Use Next Previous to scroll to CONTROL PATCH MD Press Enter The display will indicate OFF ON Use Next Previous to change the setting to ON or OFF To store the change actuate and hold the Bypass switch insert a piece of paper in the bypass slot then press the Form Feed key The ON Line LED will switch on and then off when the change is stored Exit from diagnostics by switching the printer off Wait 10 seconds then switch the printer on 2
237. nta 64 Yellow 62 Toner Concentration Set Point 95 112 Magenta 110 Yellow 102 Control Point Blac 103 Cyan 112 Magenta 103 Yellow 102 Value Blac 103 Cyan 105 Magenta 92 Yellow 103 Delta 0 Magenta 11 Yellow 1 Adjustments Transfer Bias Paper High 1000 Volts 105 volts Normal 1000 Volts 105 volts Low 1200 Volts 105 volts OHP High 2200 Volts 200 volts Normal 2000 Volts 200 volts Low 2200 Volts 105 volts Developer Bias Black 265 Volts Cyan 345 Volts Magenta 345 Volts Yellow 341 Volts THE DOCUMENT COMPANY DocuPrint NC60 2 99 3 25 IMAGE QUALITY SPECIFICATIONS TEST PATTERNS 100 Stripe Test Pattern This test pattern consists of a series of horizontal stripes The pattern includes the basic colors Cyan Magenta Yellow and Black and the process colors Red Blue and Green This test pattern is useful to isolate a problem to one of the basic colors IMAGE QUALITY SPECIFICATIONS TEST PATTERNS 2 99 3 26 100 Color Stripe Pattern DocuPrint C55 C55mp NC60 Step Test Pattern This test pattern consists of a series of steps changes in image density The pattern can be run in any of the four basic colors Cyan Magenta Yellow and Black This test pattern is useful to isolate a problem to a specific color DocuPrint C55 C55mp NC60 Black Step test Pattern 2 99 3 27 IMAGE QUALITY SPECIFICATIONS TEST
238. nter When COLOR ADJUST is displayed press Enter Analyze the test page and choose the number which represents the Black Density the customer desires Keep in mind that this is a 3096 gray Darker is not always better ADJUSTING THE BLACK DENSITY 1 2 Perform the Black Density Check Press Next until BLACK DENSITY is displayed Press Enter When CHOOSE NUMBER is displayed press Enter Use Next Previous to change the numerical setting Press Enter Confirm the change Analyze the test page and determine if additional adjustment is required Press Next 6 until OK ALL CHANGES is displayed then press Enter 7 Press On Line 0 to return the printer to the On Line mode DocuPrint C55 C55mp ADJ 3 1 1C Color Balance C55 C55mp CHECKING THE COLOR BALANCE 1 Press On Line to put the printer in the Off Line mode Press Menu Press Next until SETUP gt is displayed Press Enter When COLOR ADJUST is displayed press Enter Analyze the test page and choose the number which represents the Color Balance the customer desires ADJUSTING THE COLOR BALANCE 1 2 Perform the Color Balance Check Press Next until COLOR BALANCE is displayed Press Enter When CHOOSE NUMBER is displayed press Enter Use Next Previous to change the numerical setting Press Enter Confirm the change Analyze the test page and determine if additional adjustment is required
239. o the Print Drum Check the 96 remaining on the Print Drum Cartridge If the cartridge is at end of life notify the customer and have them install a new Print Drum Cartridge PROCEDURE If the J8 code does not clear when a new Print Drum Cartridge is installed go to BSD 9 2 and check the New Drum Detect signal CN107 15 for an open or short to ground Also check 5 VDC CN107 17 for an open If the J8 code exists even though the Print Drum Cartridge has not reached end of life refer to BSD 9 2 and check the Drum Detect signal CN107 19 If all of the above check OK replace the Print Drum Cartridge If the problem still exists replace the PCU PWB 2 99 2 20 J9 REPLACE FUSER MODULE RAP The Fuser is at end of life NOTE This code is normally preceded by a 4 code INITIAL ACTION Check the Fuser Cartridge life C55 C55mp Press On Line then press Menu use Next to scroll to the MAINTENANCE menu press Enter Use Next to scrol to FUSER MODULE press Enter NC60 Press Menu Up until Service Item Down until CRU Usage Press Value Up to scroll to the Fuser Module Check the 96 remaining on the Fuser Module If the module is at end of life notify the customer and install a new Fuser Module PROCEDURE If the J9 code does not clear when a new Fuser Module is install go to BSD 10 5 and check the New Fuser Detect signal CN103 8 CN306 4 for an open or short to ground Also check 5 VDC CN306 1 f
240. o the Fuser You will b Right and Left Side covers REP 1 3 have to free the harness from the Print Drum 1 standoffs d Color Developer Assembly GP 2 d Ground Wire This wire provides a frame e Black Developer Assembly GP 3 ground to the Transfer Assembly Fuser 5 Remove the Screw securing the wire to the Main Motor frame 2 Figure 1 Remove the two screws and the E Ring and remove the Harness Cover Harness Cover T02 Figure 2 Disconnecting the Oil Sensor Figure 1 Removing the Harness Cover REPAIRS ADJUSTMENTS 2 99 REP 9 9 4 44 DocuPrint C55 C55mp NC60 5 Figure 3 Disconnect the three wire Exit Sensor connector CN308 from the Connector PWB Free the harness from the wiring clips and cut any cable ties TO2A Figure 3 Disconnecting the Exit Sensor DocuPrint C55 C55mp NC60 6 Figure 4 Remove the Right Pivot Arm 7 Figure 5 Disconnect the Left Pivot Arm a Remove the two E Rings a Remove the E Ring b Careful close the Transfer Assembly b Carefully support the bottom of the and remove the spring Transfer Assembly and Disconnect the c Carefully support the bottom of the Left Pivot Arm from the Pin Transfer Assembly and remove the Right Pivot Arm Pivot Arm Figure 4 Removing the Right Pivot Arm Figure 5 Disconnecting the Left Pivot Arm 2 99 REPAIRS ADJUSTMENTS 4 45 REP 9 9 8 Figure 6 Remove the inner an
241. oblem The error occurs if Relative Humidity is less than 10 counts General information on Diagnostic sheet Developer assembly problem e High Voltage Power supply problem Possible causes for Over Limit errors e Very high Relative Humidity The error occurs if Relative Humidity is greater than 35 counts General information on Diagnostic sheet e Dirty white patch on transfer drum The toner concentration in the developer assembly is too high Calibration Errors occur when reading the white patch and the difference between full Gamma voltage and half Gamma voltage is not what was expected Suspect a dirty white patch or bad Gamma Sensor 2 99 3 24 Density Rate Setpoints The default is 90 If the Density and Color Balance has been adjusted these setpoints will change The range is between 80 and 100 If the Density and Color Balance tries to exceed a limit the process control will indicate an over or under error One count is approximately 10 Volts of developer bias Gamma Set Points These are internal setpoints and are the same for all printers Toner Concentration Setpoint The default is 70 When a new developer assembly is installed the toner concentration sensor reads the new housing and the setpoints are entered in NVM These setpoints are critical for proper copy quality and must be re entered if the PCU PWB is replaced or the NVM is initialized If the NVM is accidentally initialized the
242. ok for a small PWB mounted to the left of the hard drive e All Printers check for a good connection between the Hard Disk and the ESS CN101 BSD 13 in Section 7 If the problem still exists replace the Hard Disk before replacing the ESS PWB 2 99 2 13 H2 HARD DISK CONTROLLER ERROR RAP The Hard Disk Controller has failed INITIAL ACTION Switch the power off wait 10 seconds and switch the power on Retry reading the Hard Disk If the Hard Disk still cannot be read check the following for a good connection Between the Hard Disk and the 55 CN101 BSD 13 in Section 7 If the problem still exists replace the ESS PWB STATUS INDICATOR RAPs H1 H2 H3 HARD DISK FULL RAP The Hard Disk is full INITIAL ACTION Switch the power off wait 10 seconds and switch the power on This will force the ESS to retry reading the Hard Disk If the Hard Disk still does not write have the customer remove some of the files from the Hard Disk STATUS INDICATOR RAPs H3 H4 2 99 2 14 H4 REFORMAT HARD DISK RAP The Hard Disk needs to be formatted INITIAL ACTION Switch the power off wait 10 seconds and Switch the power on to retry reading the Hard Disk If the H4 occurs again reformat the hard disk DocuPrint C55 C55mp NC60 J1 ADD YELLOW RAP The yellow toner concentration sensor has detected low yellow toner in the yellow developer assembly When this occurs the Printer will display A
243. oltage Power Supply defective 7 Replace the High Voltage Power Supply 8 Constant Black Data being sent to ROS 8 Refer to Section 7 BSD 6 and check the VIDEO DATA line CN113 8 for a short to ground 9 Constant Black Data being sent to PCU PWB 9 Refer to Section 7 BSD 6 and check the DATA line CN104 11 for a short to ground 10 PCU PWB or ESS PWB defective 10 Replace PCU PWB If problem still exists replace the ESS PWB 11 Laser beam is always on 11 Replace the ROS IMAGE QUALITY RAPs 2 99 IMAGE QUALITY DEFECTS 3 6 DocuPrint C55 C55mp NC60 Defect Name Description Possible Causes Corrective Action 8 BLANK PRINT NO IMAGE IS PRESENT 1 No Developer Drive 1 Developer Drive Belts broken Repair or THE ENTIRE PRINT IS WHITE replace Drive System not camming in when the ROS is closed Check for binding or mechanical interference 2 ESS ESS components not seated 2 Slide ESS out of printer Run IOT Test pattern If OK reseat all plug in components on the ESS reinstall ESS and recheck If prints are blank with ESS removed continue with this procedure 3 Constant Magnetic Roll cleaning 3 Refer to Section 7 BSD 9 6 and check the Magnetic Roll Cleaner Solenoid for an open If the On signal CN115 10 does not go low during print replace the PCU PWB 4 No Horizontal Sync from IOT continuous 4 Refer to Section 7 BSD 6 and check the blank prints when printing HSYNC signal line CN104 9 f
244. or an open 5 No Vertical Sync from IOT continuous blank 5 Refer to Section 7 BSD 6 and check the prints when printing VSYNC signal line CN104 10 for an open 6 No Data signals from ESS 6 Refer to Section 7 BSD 6 and check the DATA signal line CN104 11 for an open 7 PCU PWB defective 7 Replace PCU PWB 9 BLANK PRINT BLACK 1 No Black Developer Clutch No Black 1 Refer to Section 7 BSD 9 7 and check the development Black Developer Clutch for an open If the ON signal 115 2 does not go low during print replace the PCU PWB 2 Constant Black Magnetic Roll cleaning Cleaning Cam timing incorrect refer to the Magnetic Roller Cleaning Cams adjustment ADJ 6 1 and perform the check 2 99 IMAGE QUALITY RAPs DocuPrint C55 C55mp NC60 3 7 IMAGE QUALITY DEFECTS Defect Name Description Possible Causes Corrective Action 10 BLANK PRINT CYAN 1 Cyan Developer Clutch No Cyan development Constant Cyan Magnetic Roll cleaning 11 BLANK PRINT MAGENTA No Magenta Developer Clutch No Magenta development Constant Magenta Magnetic Roll cleaning 12 BLANK PRINT YELLOW No Yellow Developer Clutch No Yellow development Constant Yellow Magnetic Roll cleaning 13 COLOR HALO Most Often A Yellow Halo 2 New Developer Module just installed IMAGE QUALITY RAPs 2 99 IMAGE QUALITY DEFECTS 3 8 1 Very Dry Paper 1 Referto BSD 9 9 and check the Cyan Developer Clutch for
245. or an open If all of the above check OK replace the Fuser Module If the problem still exists replace the PCU PWB DocuPrint C55 C55mp NC60 JA REPLACE OIL PAD RAP The Oil Pad needs to be replaced INITIAL ACTION Check the Oil Bottle and sump If required replace the Wiper Roll and Oil Bottle If this code persists after a new Oil Bottle is installed or the Oil is OK continue with this RAP Paper dust and other contaminants can cause the fuser oil to get cloudy and solidify causing the ball that triggers the Low Oil Sensor to stick When low oil is detected the printer will stop and the fuser will be powered off after 50 prints to prevent Fuser damage If the fuser has the contamination described above the ball could be stuck in a position that will prevent the fuser from warming up Check to ensure the fuser sump has oil in it There have been some reported instances of defective oil bottles failing to dispense oil into the sump Ensure that the valve stem on the oil bottle is not bent or off center A bent stem will not engage the plunger in the sump correctly If the sump is full check to see if the ball is stuck in the bottom of the channel If it is you may be able to correct the problem by removing the rubber stopper in the tank above the ball and using a scribe or screwdriver to loosen the ball NOTE This is only a temporary fix You should have the customer order a new fuser assembly If in your judgment
246. ork or the Printer software Updating the NIC software using CentreWare Open Xerox DocuPrint Open CentreWare Select Tools Upgrade Printer Select Network then select the software It should have an XFN extension Select OK Updating the Printer software using CentreWare Open Xerox DocuPrint Open CentreWare Select Tools Upgrade Printer Select Printer then select the software It should have an XFC extension Select OK Updating the Printer or Optional NIC software using DOS If the NC60 is configured as a parallel printer you can upload printer and Optional NIC software from DOS For Printer upgrade from the DOS prompt type Copy FILENAME XFC LPT For NIC upgrade from the DOS prompt type Copy FILENAME XFN LPT is the printer LPT port The printer will recognize the files as software DocuPrint NC60 ENTERING SERIAL NUMBER SERVICE SUPPLIES DATA USING CENTREWARE NC60 ONLY PURPOSE To enter the printer serial number service phone number and supplies phone number NOTE If the printer is configured as a parallel printer you cannot enter this data using CentreWare Open Xerox DocuPrint Open CentreWare DP Services Select the appropriate Printer Select Printer Properties System In the System Properties window select the Support Tab Enter the required data Select OK 2 99 6 63 ENTERING ALPHANUMERIC DATA USING THE CONTROL PANEL NC60 ONLY PURPOSE
247. ork with lt gt lt gt 0 hOsOb4096T Xerox DocuPrint NC60 More to work with lt lt gt 80 hOsOb4096T Xerox DocuPrint NC60 More to work with lt gt lt gt 50 MEE hOsOb4096T Xerox DocuPrint NC60 More to work with esc L lt gt 0 nosob4096T Xerox DocuPrint NC60 More to work with esc L esc sop 105064096 Xerox DocuPrint NC60 More to work with esc L esc sop nosob4096T DoaPrint C60 M oreto work with lt gt ___1 lt gt 80 nosob4096T Xerox DocuPrint NC60 More to work with esc L esc sop MEE nosob4096T Xerox DocuPrint NC60 More to work with esc L esc sop MEE nos0b4096T Xerox DocuPrint NC60 More to work with lt gt lt 5 gt 50 nos0b4096T X ox DoaPrint C60 M oreto work with lt gt 1 lt 5 gt 50 MEE nosob4096T Xerox DocuPrint NC60 More to work with esc L lt gt 0 MEE nosob4096T Xerox DocuPrint NC60 More to work with lt gt 1 lt gt 60 nosob4096T Xerox DocuPrint NC60 More to work with esc L esc sop WEE nosop4096T Xerox DocuPrint NC60 More to work with esc L esc sop MEE nosob4096T Xerox DocuPrint NC60 More to work with esc L esc sop MEE nosob4096T
248. ors or fans are heard when the printer is switched on INITIAL ACTION Switch the Printer off WARNING Disconnect all network and workstation inputs to the printer PROCEDURE Loosen the two thumb screws on the rear of the ESS and slide the ESS about half way out of the printer Switch the printer on The printer is still dead the display and LEDs are off No motors or fans are heard when the printer is switched on Y N The printer booted when it was switched on The display is now a circling asterisk Switch the printer off If the printer does NOT have a NIC replace the ESS If the printer does have a NIC slide the ESS back into the printer and remove the NIC Switch the Printer on The Printer is still dead the display and LEDs are off No motors or fans are heard when the printer is switched on Y N The printer booted when it was switched on The display is now a circling asterisk Replace the NIC DocuPrint C55 C55mp NC60 A Replace the ESS Switch the printer off Disconnect CN104 from the ESS Interface PWB Switch the printer on The printer is still dead the display and LEDs are off No motors or fans are heard when the printer is switched on Y N The printer booted when it was switched on The display is now a circling asterisk Switch the printer off Reconnect CN104 Disconnect CN102 and CN103 from the Floppy Drive Switch the printer on The printer is still dead the displ
249. oves freely DocuPrint C55 C55mp NC60 REP 8 5 FEED CLUTCH amp SOLENOID PARTS LIST ON PL 8 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Remove the Feed Clutch and Feed Solenoid Feed Clutch Spring Sleeve Feed Solenoid D27 Figure 1 Removing the Feed Solenoid and Feed Clutch DocuPrint C55 C55mp NC60 REPLACEMENT NOTE After assembling the components hand crank the feeder through several cycles Energize the Feed Solenoid several times by hand and check that the Feed Solenoid engages the Feed Clutch and stops the rollers in the flat down position 2 99 4 27 REPAIRS ADJUSTMENTS REP 8 5 REP 8 6 REGISTRATION CLUTCH PARTS LIST ON PL 8 3 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Remove the Grounding Roller Solenoid Lower Registration Roller Gear and the Registration Clutch Lower Registration Roller Gear Roller j Solenoid A D18A Registration Clutch Figure 1 Removing the Registration Clutch REPAIRS ADJUSTMENTS REP 8 6 Grounding REPLACEMENT NOTE After assembling the components hand crank the feeder through several cycles Energize the Grounding Roller Solenoid several times by hand and chec
250. ower Frame NOTE Figure 2 When Reinstalling the Transfer Drum rotate the Transfer Drum Flange until the V Shaped cutouts on the Transfer Drum Flanges are inserted in the V of the Lower Transfer Drum Frame Transfer Drum Flanges do NOT rotate When the Transfer Drum is installed properly the Transfer Drum Gear can be rotated in either direction and the Nip Adjustment Wheels will not rotate 1 Perform the Transfer Drum Nip check ADJ 11 1 V Shaped Cutout Figure 2 Reinstalling the Transfer Drum REPAIRS ADJUSTMENTS REP 9 8 9 9 TRANSFER ASSEMBLY 3 Locate and disconnect the following 4 Figure 2 Disconnect the three wire Oil TRANSFER CLAMSHELL a Fuser Motor Harness This is a five wire Sensor connector GN309 from the harness which connects to the PCU Connector PWB Free the harness from PARTS LIST ON PL 10 PWB CN110 You will have to pry open wiring clips and cut any cable ties REMOVAL the Noise Suppressor around this WARNING harness and free the harness from the a standoffs Switch the Main Power off and disconnect the b Main Connector PWB Harness This is a Power Cord 28 wire harness which connects to the NOTE Be careful not to scratch the Transfer PCU PWB CN103 You will have to Drum free the harness from the standoffs Fuser Connector This is two wire 1 Remove the following J harness White amp Black heavy gauge a Front Cover REP 1 4 which supplies AC t
251. p the Test Prints Switch the Printer off and then on If the Printer Boots without the EA fault continue with step 11 If the printer still has the EA fault repeat steps 3 through 10 and run multiple test prints with the toner off until the toner concentration value in question increases and the EA fault no longer occurs Print a diagnostic sheet a C55 C55mp Off Line Service Test Patterns Diagnostics b NC60 Menu Up to Service Value Up to Diag Summary Enter Compare the Toner Concentration Control Point with the Toner Concentration Value If any of the C M Y Values are 15 points below the Control Point this color is overtoned continue with this procedure Run the color step pattern for the color that is overtoned a C55 C55mp Off Line Service Test Patterns Pattern Type PCL overtoned color Step Run at least 25 prints b NC60 Menu Up to Service Item Up to test Patterns Value Up to overtoned color Step Run at least 25 prints Repeat steps 11 through 13 until the Toner Concentration Value is within 10 to 15 points of the Control Point 2 99 4 67 NOTE This procedure puts the toner concentra tion back within the controlling range If the problem reoccurs refer to GP 3 2 in section 6 to verify that Patch Control is off and the refer to the EA if necessary REPAIRS ADJUSTMENTS ADJ 9 1 ADJ 11 1 TRANSFER DRUM PURPOSE The purpose of this adjustment is to ensure
252. per assembly When this occurs the Printer will display Adjusting Print Quality and attempt to tone up NOTE new color developer housing has been installed make sure the 3 seals have been removed from the left side of the housing INITIAL ACTION Check with the customer to see if they have already added Cyan Dry Ink Add Cyan Dry Ink if required Adding too much toner can cause the toner to cake and not be dispensed C55 C55mp Put the printer in the Off Line mode Select the SERVICE Menu and print a Diagnostic Test Sheet Determine the Engine Software version from the Diagnostic Test Sheet If the Software level is Version 66 replace the PCU PWB All Printers switch the power off wait 10 seconds and switch the power on Allow the Printer to try to tone up to recheck for the fault PROCEDURE Enter IOT normal diagnostics Scroll to the MOTOR TEST program and Press Form Feed 1 to switch on the motors while observing the Color Toner Motor The Color Toner Motor is rotating normally A DocuPrint C55 C55mp NC60 Y N Refer to BSD 9 11 in Section 7 and troubleshoot the Color Toner Motor lines CN116 1 2 for an open or a short to ground If no wiring problem exists replace the PCU PWB f the problem still exists replace the Color Toner Motor Exit from diagnostics Set up the meter to read 24 VDC Measure between 115 12 and ground Switch the power off wait 10 seconds and switch th
253. printer INITIAL ACTION Load paper and insert Cassette 1 into the printer Switch the power off wait 10 seconds and switch the power on Recheck for the fault PROCEDURE Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 01 Press Form Feed 1 Remove Cassette 1 Manually make and break Paper Size Sensor 0 while observing the Cyan LED Sensor 0 is the first one on the left when viewed from the front of the printer The Cyan LED switches on and off Y N Go to BSD 7 2 in Section 7 and trouble shoot the Paper Size 0 Sensor signal CN107 8 for a short to ground If no short is found replace the PCU PWB f the problem still exists replace the Cassette PWB Check for a broken Sensor Flag on the Tray 1 Cassette If the problem still exists replace the PCU PWB If the problem still exists replace the Cassette PWB DocuPrint C55 C55mp NC60 C2 CHECK TRAY 2 RAP Cassette 2 is not in the printer INITIAL ACTION Move the length stop to the 11 inch position Figure 2 2 load paper and insert Cassette 2 into the printer Switch the power off wait 10 seconds and switch the power on Recheck for the fault PROCEDURE Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 03 Press Form Feed 1 Remove Cassette 2 Manually make and break T2 Paper Size Sensor 0 while observing the Cyan LED The Cyan LED switches on and off Y N Refer to B
254. r REP 1 2 2 Remove the Main Drive Motor Belts REP 4 2 D o 3 Figure 1 Remove the Outer Drive Frame a Remove the Pulley b Remove the 4 Clutch Covers Magnetic Roller c Remove the E Rings and Screws and Pulle Cleaning Solenoid then remove the Outer Drive Frame y E10 E21 Figure 1 Removing the Outer Drive Frame Figure 2 Removing the Magnetic Roller Cleaning Solenoid REPAIRS ADJUSTMENTS 2 99 REP 4 8 4 16 DocuPrint C55 C55mp NC60 REP 5 1 M Y TONER CLUTCHES AND MAGNETIC ROLLER CLEANER CLUTCH PARTS LIST ON PL 5 5 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Figure 1 Remove the following Print Drum Module Color Developer Module Right Side Cover REP 1 3 Top Cover REP 1 1 Rear Cover REP 1 2 2 Figure 1 Remove the appropriate Clutch Cover and remove the Clutch a b c Black Developer Module d e f DocuPrint C55 C55mp NC60 Figure 1 Magnetic Roller Cleaner Clutch E14 Removing the Clutches 2 99 4 17 REPLACEMENT NOTE When installing a new clutch put the spring in the center of the 5 notches REPAIRS ADJUSTMENTS REP 5 1 5 2 MAGNETIC ROLLER CLUTCHES PARTS LIST ON PL 5 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following D o f Remove Print Drum Module Color Developer Module Black
255. r Balance Procedure in Section 4 for additional information NOTE It is often difficult to see changes in the color balance You can check the change by running a printer diagnostic sheet before and after the adjustment Changes will show in the values under Density Rate Setpoints and Developer Bias The NC60 includes these values on the Density and Color Balance Test Pattern On the NC60 only you must disconnect all input ports from the ESS before performing this adjustment DocuPrint C55 C55mp NC60 2 99 3 21 Density And Color Balance Adjusment Test Page Adjust Color Density 30 Halftone CYAN MAGENTA YELLOW Decrease Increase Adjust Color Density 30 Halftone BLACK GRAYSCALE i pum EI Decrease Increase gt Adjust Color Balance Choose The circle Which Best Matches The Gray Reference abcdef abcdef abcdef abcdef abcdef abcdef abcdef abcdef Gray Reference Current pr Xerox Corporation 1996 ver 1 2 IMAGE QUALITY SPECIFICATIONS TEST PATTERNS Diagnostic Test Pattern 55 55 This test pattern can be used by the Help Center to determine the status of some of the machine parameters Process Control Status If Black Cyan Magenta or Yellow indicate Under Limit Error Process controls thinks the prints are too light even at the highest bias Over Limit Error Process controls thinks the prints are too dark even at the lowest bias Irregular Error
256. r high humidity bias offset Table 12 Toner Supply Defaults off when the change is stored Bias P P DT N 0 Papernorm humidity bias offset Defaut C Bias P P DT L 0 _ Paper low humidity bias offset C55 C55mp NC60 NC60 C Bias P P BS H 1000 Paper high humidity bias C Bias P P BS 1000 Paper norm humidity bias C Bias P P BS L 1200 Paper low humidity bias P P S Life 5 TC offset black gt 35k S Life 10 gt 35 TC offset black 10 535 S K 2k 10k offset black 2 10k 0 o S Life K 0 2 o o o o C Bias P P DT H 105 high humidity bias offse C Bias P P DT N 105 Paper norm humidity bias offset S Life C35k gt TC offset color gt 35k S Life C10k gt 35k offset color 10 gt 35k S Life C 2k510k offset color 2 10k S Life C 0k 2k The NC60 default values listed above will be NC60 the IOT version 94 defaults Earlier NC60 IOT S Life TS Delta elta for toner override versions should be set to the above values C Bias P P DT L 105 PPaperlow humidity bias offset GENERAL PROCEDURES 2 99 BACKGROUND DIAGNOSTICS 6 14 DocuPrint C55 C55mp NC60 OFF LINE MENUS C55 C55MP ONLY PROCEDURE NOTE Before entering the Off Line Menus ensure that the printer has completed the initialization cycle and the On Line LED is on Press the On Line key The green On Line LED will go out indicating that you are in the Off L
257. r specific subsystems PROCEDURE 1 Open the printer and Clean the Charge Scorotron using the Scorotron cleaner Clean the toner loading area Remove the Following a Print Drum Module GP I b Color Developer Module GP 2 c Black Developer Module GP 3 d Toner Collector GP 4 4 Vacuum the Drum Developer and Toner Collector areas Replace the Toner Collector if required Reinstall the following a Black Developer Module GP 3 b Color Developer Module GP 2 c Print Drum Module GP 1 d Toner Collector GP 4 7 Use Film Remover to clean the Feed Rollers Do not rotate the Feed Rollers more than 270 while cleaning Apply Rubber restore if available 8 Check the Transfer Drum Nip Adjustment ADJ 11 1 9 Wipe the outside of the printer SERVICE CALL PROCEDURES EVERY CALL ACTIVITIES SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE Purpose To check the life remaining on the CRUs PROCEDURE 1 2 Check the life of the Customer Replace able Units CRUS a C55 C55mp Enter the Off Line mode press Menu and scroll to MAINTENANCE NC60 Menu Up until Service Menu Item Up until CRU Usage Value Up to see remaining on the CRUs b Check the life remaining on the following e Black Developer Cartridge Color Developer Cartridge Print Drum e Fuser Module If any of the CRUs are near end of life notify the customer 2 99 1 4 DocuPrint C55 C55mp N
258. r to read 24 VDC Measure between CN107 18 and ground When the fuser is cold the reading should be around 0 VDC When the fuse warms up the reading should switch to approximately 22 VDC The readings are OK Y Go to BSD 10 5 in Section 7 and trouble shoot the Fuser on L signal for a short to ground 107 18 If the wiring is OK replace the PCU PWB If the problem still exists replace the Low Voltage Power Supply Triac shorted replace the Low Voltage Power Supply DocuPrint C55 C55mp NC60 2 99 2 23 UO IOT ROM ERROR RAP A ROM error was detected INITIAL ACTION Switch the power off wait 10 seconds and Switch the power on Recheck for the fault If the problem still exists replace the PCU PWB STATUS INDICATOR RAPs T2 UO U1 IOT RAM ERROR RAP A RAM error was detected INITIAL ACTION Switch the power off wait 10 seconds and switch the power on Recheck for the fault If the problem still exists replace the PCU PWB STATUS INDICATOR RAPs U1 U2 U3 U2 IOT NVM RAM ERROR A NVM error was detected Many xerographic parameters other values are written to the NVM on the PCU PWB every time the machine is powered off These values can be corrupted when the printer is powered off and on too quickly or when there is an irregularity in the power to the printer This can produce a U2 error code If the NVM is initialized without following the proper procedures the toner
259. rallel compatibility with ECP and Nibble Modes Windows 95 Plug and Play Standard C55mp Standard with Ethernet Network Interface Card Optional LocalTalk and Serial Optional Ethernet Token Ring GENERAL PROCEDURES Controller Specifications CONTROLLER SPECIFICATIONS NC60 Intel i960 superscalar processor operating at 66 Mhz Memory 64 MB DRAM 8 MB FLASH ROM Standard on NC60 Upgradable to a maximum of 128 MB Printer Description Languages PDL Adobe PostScript 3 0 and PCL 5C coresident Resident Fonts 35 Type 1 PostScript only 35 Intellifonts PCL 5C 10 TrueType PCL 5C Interfaces P1284 parallel port compatibility with ECP and Nibble Modes Windows 95 Plug and Play Standard Standard with Ethernet 10MB Network Interface Optional Ethernet 100MB Optional Token Ring DocuPrint C55 C55mp NC60 TOOLS Table 1 Standard Tools Basic Tool Kit 600T1835 Multimeter 600T1616 Lead Kit 600T1923 Metric Tool Kit 60071880 Table 2 Unique Tools Description Part Number 5 5 MM Magnetic Socket Driver 600T1123 Mag tip Screw Xcelite Drive 60071989 Insert Optics Blue Cloth lint free 499T90417 cleaning cloth 1 5 MM Hex Key Wrench 600741107 Table 3 Supplies Drop Cloth 35P1737 Clean Ups 43P67 Lint Free Tissues 35P2163 Cotton Swabs 35P2137 2 99 GENERAL PROCEDURES DocuPrint C55 C55mp NC60 6 71 Tools CHANGE INDEX C55 C55mp INTRODUC
260. rom the lower belt idler Slide the lower belt off of the idler 6 The Connector PWB is mounted to a plastic frame This frame has a V shaped extrusion which is mounted over the Cam Shaft Push the V shaped extrusion to the rear pull the Cam Shaft toward the front and to the left and remove the Cam Shaft Assembly 7 Remove the Transfer Drum Cleaning Clutch REPAIRS ADJUSTMENTS REP 9 3 V Shaped Extrusion E Ring amp Bearing Spring Transfer Drum Clip Cleaning Clutch A32 Figure 1 Removing the Transfer Drum Cleaner Clutch REPLACEMENT NOTE Figure 2 When reassembling the clutch position the tab opposite the flat then be sure to engage the spring in the sleeve cutout If you are not sure of how to assemble the clutch or suspect a problem replace the clutch with a new Transfer Drum Cleaner Clutch Assembly NOTE Observe the Cleaner Assembly during the copy quality setup When the Cleaning Solenoid is energized the Cleaning Assembly should be cammed forward and the high point of the cam shaft should be pressing on the cleaner assembly When the Solenoid is deenergized the Cleaning Assembly should be cammed away and the low point of the cam shaft should be pressing on the cleaner assembly 2 99 4 38 Sleeve A42 Figure 2 Assembling the Clutch DocuPrint C55 C55mp NC60 REP 9 4 TRANSFER DRUM CLEANER ASSEMBLY PARTS LIST ON PL 9 4 REMOVAL WARNING Switch the Main Power off and d
261. rom 24 VDC to 0 Y N Go to BSD 9 10 in Section 7 and trouble shoot the Yellow Toner Solenoid signal and 24 VDC Interlocked 115 16 15 for an open If no open exists replace the PCU PWB If the problem still exists replace the Yellow Toner Solenoid Check the Yellow Dispense Shaft to see if it rotates when the Solenoid energizes not look fora mechanical problem gears etc Check the ground to the Yellow Toner Concentration Sensor CN118 4 to CN1009 7 BSD 9 10 If the ground is OK replace the PCU PWB 2 99 2 15 STATUS INDICATOR RAPs 92 ADD MAGENTA TONER RAP The magenta toner concentration sensor has detected low magenta toner in the magenta developer assembly When this occurs the Printer will display Adjusting Print Quality and attempt to tone up NOTE If a new color developer housing has been installed make sure the 3 seals have been removed from the left side of the housing INITIAL ACTION Check with the customer to see if they have already added Magenta Dry Ink Add Magenta Dry Ink if required Adding too much toner can cause the toner to cake and not be dispensed C55 C55mp Put the printer in the Off Line mode Select the SERVICE Menu and print a Diagnostic Test Sheet Determine the Engine Software version from the Diagnostic Test Sheet If the Software level is Version 66 replace the PCU PWB All Printers switch the power off wait 10 seconds and switch the power on
262. rom Background diagnostics to Normal diagnostics 2 Press Form Feed 1 again to exit from Normal Diagnostics 3 Or switch the power off wait 10 seconds and then switch the power on 2 99 6 11 INITIAL This Diagnostic routine is used to initialize the following printer parameters Gamma Sensor A adjust density Gamma Sensor calibrate sensor e Gamma Sensor C calculate sensor correction Black Developer set current black TC as Black toner setpoint Color Developer set current color TC as Color toner setpoint Both Developers set current TC as toner setpoint for all four colors e Drum reset drum counter e Fuser reset fuser counter 1 Enter Background diagnostics and press the Menu 3 key until INITIAL GAMMA_A is displayed on the Message Display 2 Use the Previous 5 Next 6 keys to select the parameter to be initialized 3 initialize the item Insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored 4 When the initialization routine is compete press Previous 5 Next 6 key to select the next parameter to be initialized GENERAL PROCEDURES BACKGROUND DIAGNOSTICS CONTROL This Diagnostic routine is used to set the control points for the following printer parameters K Developer Bias C Developer Bias M Developer Bias Y Developer Bias G
263. round distributed toner particles in the non image areas Background can be uniformly distributed over the entire surface of the print or only in localized areas The density of the background can vary from barely visible to extremely dark Bad text black Text that is fuzzy broken up is too wide or fat or contains hollow characters Bad text color Colored text that has poor color fidelity or text that is fuzzy broken up is too wide or fat or contains hollow characters Bands Bands are wider than lines See lines bands streaks Banding Repeating bands Blank print a print with no image Blurred or fuzzy images Images that are not clear appear out of focus or are broken up The defect can affect the entire print or parts of the print Body deletion a deletion on the print other than on an edge or a corner Color incorrect bad poor colors on the print that are not acceptable reproductions of the desired image Color Banding Repeating color bands See lines bands streaks DocuPrint C55 C55mp NC60 Color Contamination Impure colors that is desired colors that contain toner that is not required For example yellow that may have some black toner mixed in or red that has some cyan toner or other contaminate Color misregistration color images that are not superimposed and should be Colored streaks a colored strip on the print that differs in color or de
264. rum 3 Replace the Print Drum Module 4 Grounding Roller always raised 4 Check the Grounding Roller for binding If OK refer to BSD 8 3 and check the Grounding Roller Solenoid On Signal CN101 6 for a short to ground Foreign particles under the Print Drum 5 Remove the Cleaning Blade 3 screws and Cleaning Blade clean the blade Reinstall and make several prints to verify cleaning If problem still exists replace the Print Drum Module Low or Fuser Wiper Roll failure 6 If Oil is low refer to the W5 RAP and check the operation of the Oil Sensor Add Oil or replace the Fuser Wiper Roll Developer being pulled from housing by high 7 Charge Scorotron contaminated by fuser oil Check fuser for leaks Replace Print Drum Module Replace Fuser if required 8 Stripper Finger marks 8 If marks line up with Stripper fingers clean Stripper Fingers replace paper 9 OilLeakage 9 Replace all oil contaminated parts Clean as required pay special attention to the Transfer Drum Cleaning Brush Oil on the brush will re contaminate the Print Drum IMAGE QUALITY RAPs 2 99 IMAGE QUALITY DEFECTS 3 10 DocuPrint C55 C55mp NC60 4 Spots on Print Drum 4 Check for Oil leaks Replace Print Drum Module 18 DELETIONS COMET 1 High Volume operation more that 500 prints 1 Switch on Cleaning Cycles Small white deletions app 1mm wide X 1 per day Refer to GP 3 4 5mm long 19 DELETIONS HOLLOW CHARACTERS 1
265. s Toner Concentration Setpoint The default is 70 When a new developer assembly is installed the toner concentration sensor reads the new housing and the setpoints are entered in NVM These setpoints are critical for proper copy quality and must be re entered if the PCU PWB is replaced or the NVM is initialized If the NVM is accidentally initialized the setpoints can be obtained from the Diagnostic sheet and re entered into NVM Control Point This is the value that the toner concentration sensor in the developer assembly tries to maintain The control point uses the setpoint as a starting point and then varies depending on the temperature and relative humidity In high humidity conditions the value is increased and in low humidity conditions the value is decreased The Black value varies between 20 to 27 The Color value varies between 28 to 22 2 99 3 22 Value The values are measured by the toner concentration sensors during the print cycle and determine when toner needs to be added to the developer assembly The value usually does not equal the control point exactly but is generally within 5 counts Process Voltage Transfer Bias This is the voltage applied to the transfer drum The Paper default is 1305V and varies depending on the temperature and relative humidity In high humidity conditions the value is decreased and in low humidity conditions the value is increased The Paper bias vari
266. s the Form Feed 1 key The On Line LED will switch on and then off when the change is stored 3 The following Tables 2 through 6 will be initialized Table 2 COUNTER SET Consumable Usage Counters COUNTER SET YDEV COUNTER SET MDEV COUNTER SET CDEV COUNTER SET KDEV COUNTER SET PRNT COUNTER SET FSU Fuser Usage COUNTER SET YTON COUNTER SET MTON COUNTER SET CTON COUNTER SET KTON Black Toner On time sec COUNTER SET OIL Oil Usage DocuPrint C55 C55mp NC60 Table 3 4 5 and 6 are in Special Diagnostics Table 3 COUNTER SET2 Print Error Counters COUNTER SET2 YPR Yellow Print Images COUNTER SET2 MPR Magenta Print Images P Table 4 TONER LEVEL Toner Concentration in developer assembly K Toner concentration default 70 Table 5 ID LEVEL Density Rate Setpoint Y Density Rate default 90 M Density Rate default 90 ID LEVEL CYAN C Density Rate default 90 ID LEVEL BLACK K Density Rate default 90 Table 6 TIMEOUT SET Sets the Power Save and Polygon Motor time out TIMEOUT SET SLP Sleep Power Save default 30 min TIMEOUT SET PLM Polygon time out default 180 sec 2 99 6 7 COUNTER SET This Diagnostic routine is used to preset the consumable counters to a desired value 1 Enter Normal diagnostics and press the Menu 3 key until COUNTER SET DRUM is displayed on the Message Display 2 Press the Next 6 Previous 5 keys until the Me
267. s while observing the Fuser Drive Motor The Fuser Drive Motor is rotating normally Y N Go to BSD 10 1 in Section 7 and trouble shoot the Fuser Drive Motor clock lines If the lines are OK replace the PCU PWB If the problem still exists replace the Fuser Drive Motor e Make sure Fuser Cover fits correctly e Check for a Mechanical problem 2 99 2 7 STATUS INDICATOR RAPs E5 E6 DRUM JAM RAP Paper is jammed on the Transfer Drum and could be caused by one of the following e Transfer Drum Cleaner not cleaning the Transfer Drum or resting on the Transfer Drum during the Print cycle e Paper did not reach the Gamma Sensor e Paper did not tack to the Transfer Drum and actuated the Transparency Jam Sensor e Paper did not tack to the Transfer Drum and actuated the Cleaner Jam Switch e Arcing between the Charge Scorotron connectors and the Print Drum INITIAL ACTION Open the Printer and check for torn paper or an obstruction in the paper path Check for a sheet of paper or a transparency actuating the Transparency Jam Sensor or the Cleaner Jam Switch Check the Toner Collector for layered toner sand art effect If layered toner is present refer to OF8 Arcing RAP If the problem only occurs when running color prints check the Stripper Fingers for binding or interference Open the Printer and position the Transfer Drum Home Position Sensor flag at the 3 o clock position The Lead edge of the wh
268. s Current paee these values on the Density and Color Balance Test Pattern On the NC60 only you must disconnect all input ports on the ESS Xerox Corporation GENERAL PROCEDURES 2 99 DENSITY AND COLOR BALANCE 6 38 DocuPrint C55 C55mp NC60 BOOT SEQUENCE C55 C55MP The following is the boot sequence for the C55 C55mp printers ESS also boots while the printer is booting IOT BOOT SEQUENCE ROM Checksum RAM Checksum NVM Checksum All Sensors Checked for Paper Main Motor On Process Control Setup Begins Message Display indicates moving during ESS Boot sequence When ESS Boot is complete Message display indicates INITIALIZING and all message display LEDs come on ESS BOOT SEQUENCE ROM Checksum NVM Test Dram Test TIFF PWB Test Local Serial SLIC PWB Tested Font SIMM Test Network Interface Card Tested Floppy Test Hard Disk Test ESS PWB Communicates with PCU PWB Message display indicates INITIALIZING and all message display LEDs come on DocuPrint C55 C55mp IOT COPY QUALITY SETUP Main Motor and Fuser Motor on Cleaner Solenoid energizes Cleaner Assembly moves against Transfer Drum Black Developer Clutch energizes and Black toner concentration is checked If necessary the Black Toner Motor switches on and tones the black developer Cyan Developer Clutch energizes and Cyan toner concentration is check
269. s changed when setting the color density and color balance DocuPrint C55 C55mp NC60 TIMEOUT SET This Diagnostic routine is used to set when the printer enters the Power Saver Sleep mode It is also used to set when the Polygon motor shuts off 1 Enter Special diagnostics and press the Menu 3 key until TIMEOUT SET SLP is displayed on the Message Display 2 Press the Next 6 Previous 5 keys until the Message Display steps to the timeout to be changed Table 6 3 Press the Enter 7 key the display will indicate XXX XXX is the timeout feature to be changed is the current timeout value 4 Press the Next 6 Previous 5 keys to change the timeout value 5 store the change insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored 6 Press the Media Server 2 key to return to the TIMEOUT SET list Repeat steps 2 through 5 to change the other timeout value 2 99 6 9 PANEL KEY TEST This Diagnostic routine is check the operation of the switches on the control panel 1 Enter Special diagnostics and press the Menu 3 key until PANEL KEY TEST is displayed on the Message Display 2 Actuate the Bypass Switch then press the Form Feed 1 key The display will indicate 1222374752627 28 3 Refer to Table 7 for the number assigned to the key When the key is
270. screws and slide the cover forward slightly 3 Disconnect CN305 4 Remove the Front Cover Screws D2 Figure 1 Removing the Front Cover DocuPrint C55 C55mp NC60 2 1 TOP FRONT COVER PARTS LIST ON PL 2 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Open the Transfer Drum Assembly 2 Release and open the Fuser Cover 3 Figure 1 Remove five screws and remove the Top Front Cover Top Front D28 Figure 1 Removing the Top Front Cover 2 99 DocuPrint C55 C55mp NC60 4 5 REPAIRS ADJUSTMENTS REP 2 1 REP 3 1 LOW VOLTAGE POWER SUPPLY ASSEMBLY PARTS LIST ON PL 3 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following Top Rear Cover REP 1 1 Rear Cover REP 1 2 Right Side Cover REP 1 3 Paper Cassette Photoreceptor Module Color Developer Module Black Developer Module REPAIRS ADJUSTMENTS REP 3 1 Figure 1 Remove screws and remove the Black Developer Connector Cover Disconnect CN201 CN702 CN703 CN704 CN707 and FT701 from the Low voltage Power Supply Connector D4 Figure 1 Removing the Connector Cover 2 99 4 6 D Figure 2 Disconnect CN1004 AC connec tor next to PCU PWB Remove the wiring from the harness Disconnect CN202 from the Cassette PWB Remove screws and remove the Low Voltage Power Supply If you are installing a new Lo
271. setpoints can be obtained from the Diagnostic sheet and re entered into NVM Control Point This is the value that the toner concentration sensor in the developer assembly tries to maintain The control point uses the setpoint as a starting point and then varies depending on the temperature and relative humidity In high humidity conditions the value is increased and in low humidity conditions the value is decreased The Black value varies between 20 to 27 The Color value varies between 28 to 22 Value The values are measured by the toner concentration sensors during the print cycle and determine when toner needs to be added to the developer assembly The value usually does not equal the control point exactly but is generally within 5 counts DocuPrint NC60 Delta this is the difference between the Control Point and the Value measured The delta will vary but rarely exceeds 20 Process Voltage Transfer Bias This is the voltage applied to the Transfer Drum The Paper default is 1305V and varies depending on the temperature and relative humidity In high humidity conditions the value is decreased and in low humidity conditions the value is increased The Paper bias varies between 1000 1200V The Transparency default is 2000V varies depending on the temperature and relative humidity The voltage varies for each of the 4 colors when running transparencies Black default is 2000V Cyan default is 2
272. ssage Display steps to the counter to be changed Table 2 3 Press the Enter 7 key the display will indicate XXXX is the consumable name THHHHHHHE is the current counter value 4 Press the Menu 3 key to select the digit to be changed 5 Press the Next 6 Previous 5 keys to change the counter value 6 To store the counter change insert a sheet of paper into the bypass slot to actuate the Bypass Switch then press the Form Feed 1 key The On Line LED will switch on and then off when the change is stored 7 Press the Media Server 2 key to return the COUNTER SET list Repeat steps 2 through 6 to change additional counters GENERAL PROCEDURES NORMAL DIAGNOSTICS SPECIAL DIAGNOSTICS The Special mode is used to e Change the Counter Set2 values Change the Toner Concentration values Change the Print Density values e Change the Power Saver values Test the Operation of the Control Panel keys ENTERING THE SPECIAL DIAGNOSTIC MODE 1 First enter the Normal Diagnostic mode 2 While PCU DIAG MODE XX is displayed press On Line 0 then press Enter 7 Release both keys at the same time 3 The Message Display will indicate PCU DIAG SPECIAL 4 Press the Menu 3 key to step through the diagnostic routines EXITING FROM THE SPECIAL DIAGNOSTIC MODE 1 When PCU DIAG SPECIAL is displayed on the Message Display press the Form Feed 1 key to exit from Special diagnostics
273. ssible Causes Corrective Action 41 TRANSPARENCY PROBLEMS 1 Jamming mottle type deletions Oil offsetting 1 Adjust Transparency Mode GP 3 3 2 Hollow characters 2 Try Printing on other side of Transparency Adjust Transfer Drum Nip ADJ 11 1 Try different transparency material 3 Low density Deletions 3 Adjust Transfer Drum Nip ADJ 11 1 4 Oily Transparencies 4 Try GP 3 3 Interleaf transparencies and paper after printing Paper will absorb the oil 42 WRINKLED PAPER 1 Paper is less than 16 lb 1 Use heavier paper from 20 to 24 Ib 2 Feed rolls drive rolls dirty 2 Clean the feed rolls and drive rolls 3 Paper not installed correctly or in poor 3 Check the following condition Fan the paper e Change the paper e Turn the paper over in the cassette 4 Transfer Drum to Print Drum nip incorrect 4 Perform the Transfer Drum Nip adjustment uneven side to side ADJ 11 1 5 Paper feed problem wrinkle occurs before 5 Check the following Replace paper feed transfer observe print on transfer drum assembly if required e Tabs broke on large springs loading the lower registration roller e Defective lower registration roller 6 Fuser Module failure wrinkle occurs after 6 Replace Fuser Module transfer observe print on transfer drum 7 Exit roller skewed wrinkle occurs after 7 Check for broken or missing bearings fusing Replace output shaft if required 2 99 IMAGE QUALITY RAPs DocuPr
274. t C55 C55mp NC60 2 2 Paper fed from Tray 2 did not reach the Registration Sensor INITIAL ACTION Remove the cassette and check that the paper is loaded correctly and is in good condition Check the position of the rear stop Make sure that Tray 1 is pushed all the way in Switch the power off wait 10 seconds and Switch the power on Recheck for the fault PROCEDURE Try to run a print from Tray 1 The print feeds OK from Tray 1 Y N Go to E1 TRAY 1 JAM RAP Check the following e Obstructions in the paper path Dirty Feed Rolls e Dirty Drive Rollers e Mechanical drive problem Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 03 Press Form Feed 1 Remove cassette 2 Actuate and deactuate the Tray 2 Empty Sensor while observing the Black LED The Black LED switches on and off Y N Go to BSD T2 7 1 in Section 7 and troubleshoot the T2 Tray Empty Sensor signal CN109 4 for a short to ground If no short exists replace the PCU PWB If the problem still exists replace the Tray 2 Empty Sensor DocuPrint C55 C55mp NC60 A Exit from diagnostics Set up the meter to read 24 VDC Measure between CN109 8 and ground Make one print while monitoring the meter The meter swings from 24 VDC to 0 and back to 24 Y N Go to BSD T2 7 3 in Section 7 and troubleshoot the T2 Feed Solenoid signal and 24 VDC Interlocked CN109 8 7
275. t noticeable in mid density solid areas Gray balance incorrect Grays are produced with a color tint Halo colored or shadows around text A colored ring shadow or fringe that appears around text or lines Halo white A white ring or fringe that appears around text of lines that are on a colored background Hollow Characters Small circular shaped deletions in image characters The characters are not completely filled in with toner Job to job variability Image quality variations between prints of the same or similar image from different jobs during the same day A job includes all the prints resulting from a single selection of the start print process Lead edge to trail edge streaks s A streak is a mark comprised of many small lines of varying length width giving the appearance of a brush stroke See lines bands streaks IMAGE QUALITY RAPs IMAGE QUALITY DEFECTS Light Streaks or Bands Lower than desired density image areas in the shape of streaks or bands Lines bands streaks a strip on the print that differs in color or density from the surrounding area A line is typically narrow in width and can be any length A band is wider than a line A streak is comprised of many small lines of varying length and width giving the appearance of a brush stroke Microdarks Dark spots of any color easiest seen in non image areas The spots are much larger than the toner particle size spo
276. t the Paper Feed Motor clock lines If the lines are OK replace the PCU PWB If the problem still exists replace the Paper Feed Motor Exit from diagnostics Set up the meter to read 24 VDC Measure between 103 4 and ground Make one print while monitoring the meter The meter swings from 24 VDC to 0 and back to 24 Y N Go to BSD 9 16 in Section 7 and trouble shoot the Stripper Solenoid signal and 24 VDC Interlocked CN103 4 CN303 2 1 for an open If no open exists replace the PCU If the problem still exists replace the Stripper Solenoid 2 99 2 6 B Set up the meter to read 24 VDC Measure between CN101 5 and ground Make one print while monitoring the meter The meter swings from 24 VDC to 0 and back to 24 Y N Go to BSD 7 4 in Section 7 and trouble shoot the Feed Solenoid signal CN101 5 for a short to ground If no short exists replace the PCU PWB If the problem still exists replace the Feed Solenoid Set up the meter to read 24 VDC Measure between CN101 4 and ground Make one print while monitoring the meter The meter swings from 24 VDC to 0 and back to 24 Y N Go to BSD 8 2 in Section 7 and trouble shoot the Registration Clutch signal and 24 VDC Interlocked CN101 4 1 for an open If no open exists replace the PCU If the problem still exists replace the Registration Clutch Check the following e Obstructions torn
277. tab which actuates the sensors is not broken Carefully load the paper size which is not being detected correctly Switch the power off wait 10 seconds and Switch the power on Make a print of the paper size which is loaded to recheck for the fault PROCEDURE Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 01 Press Form Feed 1 Remove Cassette 1 Observe the LED s The Cyan Magenta and Yellow LEDs are all off Y N Refer to BSD 7 2 and check the following e f all three LEDs are on check the 5 CN107 7 for an open Cyan LED on check Paper size 0 CN107 8 for an open e Magenta LED on check Paper Size 1 CN107 9 for an open e Yellow LED on check Paper Size 2 CN107 10 for an open If wiring is OK replace the PCU PWB If the problem stil exists replace the Cassette PWB DocuPrint C55 C55mp NC60 A Press Media Server 2 select Scan Row 02 Press Form Feed 1 Observe the LED s The Black and Cyan LEDs are off Y N Refer to BSD 7 2 and check the following Black LED on check Paper size 3 CN107 11 for an open e Cyan LED on check Paper Size 4 CN107 12 for an open If wiring is OK replace the PCU PWB If the problem stil exists replace the Cassette PWB With Scan Row 02 still selected move the length stop to the Legal 14 position Figure 2 3 Insert the cassette Observe the LED s The Cyan LED goes on when the cassette
278. ter color laser printers require extra care and preparation before and while moving them It is very important to remove the fuser first and hand carry it to the new location to prevent spilling oil in the machine Do not tilt the fuser If the fuser has spilled oil do not reinstall as damage to the machine could occur Once the fuser is removed two people should move the printer also taking care not to tilt the printer If you must ship your printer and it will possibly NOT be kept level more preparation is needed Complete moving instructions can be obtained from the CD ROM that accompanies your printer under Technical Information Guide TIG Chapter 12 Alternately contact your reseller or the Xerox web site Monthly Print Volume The DocuPrint NC60 is carefully designed to run reliably at typical office print volumes of 3 000 color prints per month If you regularly produce considerably higher print volumes you should consider additional printer s to handle peak workloads quickly and maximize uptime Two sided Duplex Printing The DocuPrint NC60 is not designed for duplex printing Using paper that has already been printed on one side may damage the printer Driver Configuration Be sure to set the device options in the driver to correctly reflect your printer configuration Connectivity The NC60 comes standard with 10 Ethernet on board with the option to upgrade to 10 100MB Ethernet or TokenRing via
279. that the nip between the Transfer Drum and Print Drum is within specification Too large a nip may cause paper jams or registration problems Too small a nip may cause copy quality problems CHECK 1 Run an IOT Test Pattern and panic stop the printer with the Cyan strip on the drum a Enter Normal diagnostics Menu 3 Enter 7 Power On b Use Menu 3 to scroll to TEST PRINT c Press Form Feed 1 and observe the toner concentration T2 indication on the Message Display d Wait until the paper feeds then be prepared to switch the printer off e ObDserve the Message Display When the display indicates wait approximately 2 seconds then switch the power off 2 Open the printer and remove the Print Drum module REPAIRS ADJUSTMENTS ADJ 11 1 3 Figure 1 Rotate the Print Drum up until there is a Cyan color bar in the position shown NOTE sure to rotate the gear in the direction shown If the drum is rotated in the reverse direction the Cleaning blade or Drum may be damaged Print Drum Color Bar Figure 1 Rotating the Print Drum 2 99 4 68 Reinstall the Print Drum Module Figure 2 Rotate the Transfer drum until the paper is positioned with a blank area opposite the Print Drum as shown Transfer Drum Blank TDO4A Area Figure 2 Positioning the Transfer Drum DocuPrint C55 C55mp NC60 Close then open the Transfer Assembly This will transfer the Cyan im
280. the Grounding LEAD TO TRAIL EDGE Roller Solenoid circuit for an open 30 MULTISHEET FEED 1 Paper is less than 20 Ib 1 Use heavier paper from 20 to 24 Ib 2 Paper not installed correctly or in poor 2 Check the following condition Fan the paper Change the paper Turn the paper over in the cassette e Snubber alignment 31 OIL SPOTS 1 Fuser leaks 1 Check for any spills from bottle replacement These may appear as background or black If OK check for fuser oil leaks Replace the spots on the print Fuser if required IMAGE QUALITY RAPs 2 99 IMAGE QUALITY DEFECTS 3 14 DocuPrint C55 C55mp NC60 Defect Name Description Possible Causes Corrective Action 32 REPEATING PRINT DEFECTS EVERY 220 1 Defective damaged Print Drum 1 Clean the Print drum with film remover Be MM 8 66 sure to let the drum dry before rotating it If the defect persists replace the Print Drum Module 33 REPEATING PRINT DEFECTS EVERY 93 1 Out of Oil 1 If Oil is low refer to the W5 RAP and check MM 3 66 the operation of the Oil Sensor Add Oil Run 20 blank prints to clean the fuser roll 2 Damaged Fuser Roll 2 Replace the Fuser Module 34 REPEATING PRINT DEFECTS EVERY 63 5 Grounding Roller always raised 1 Check the Grounding Roller for binding If MM 2 5 OK refer to BSD 8 3 and check the Grounding Roller Solenoid On Signal CN101 6 for a short to ground 35 PRINT DEFECT 63 5 MM 2 5 FROM 1
281. the Photoreceptor module is near the end of life 10 remaining When a J8 occurs the customer should install a new Print Drum Module When a new Print Drum Module is installed the J8 and W3 codes will no longer appear If the J8 code still exists refer to the J8 RAP DocuPrint C55 C55mp NC60 W4 FUSER MOD RAP This code indicates that the Fuser module is near the end of life 1096 remaining When a J9 occurs the customer should install a new Fuser Module When the new Fuser Module is installed the J9 and W4 codes will no longer appear If the J9 code still exists refer to the J9 RAP DocuPrint C55 C55mp NC60 W5 FUSER OIL BOTTLE PAD RAP This code indicates that the Oil Bottle and Pad are near the end of use When a JA occurs the customer should install a new Fuser Bottle and Pad When a new Oil Bottle is installed the JA and W5 codes should no longer appear If the JA code still exists refer to the JA RAP 2 99 2 29 STATUS INDICATOR RAPs WA W5 OF1 DEAD PRINTER RAP This RAP is used when the Printer is dead There is no display no Control Panel LEDs are on and no motors or fans are heard when the printer is switched on NOTE A description of the C55 and NC60 IOT and ESS boot routines can be found in Section 6 of this manual Refer to the Section 6 Table of Contents INITIAL ACTION Remove the power cord and check for AC power at the wall outlet If there is no power at the wall o
282. the optional NIC slot If you experience connectivity problems when connecting a 3 party connectivity box to the printer parallel port you may have to set the printer parallel port bi directional setting to off If you have any questions please call us Toll Free USA 1 800 TeamXRX Canada 1 800 93XEROX Visit our Web site at hitp xerox networkprinters com DocuPrint NC60 2 99 6 37 GENERAL PROCEDURES TIPS amp TRICKS DENSITY AND COLOR BALANCE TEST PATTERN Density And Color Balance Adjusment Decrease Increase C55 C55mp Entry Test Page Next until SETUP gt Enter lt PROCESSING gt 2 Adjust Color Density 30 Halftone BLACK GRAYSCALE 7 8 9 10 Menu Up until Menus Color Adjust 3 Adjust Color Balance Choose The circle Which Best Matches The Gray Reference This test pattern is used to set the density and to abcdef abcdef abcdef abcdef abcdef abcdef abcdef abedef determine if the printer color is balanced properly It will allow the customer to judge the color balance and correct the color balance if necessary Refer to ADJ 3 1 Density and Color Balance Procedure in Section 4 for additional information NOTE It is often difficult to see changes in the color balance You can check the change by running a printer diagnostic sheet before and after the adjustment Changes will show in the values under Density Rate Setpoints and Developer Bias The 60 include
283. till exists replace the ROS STATUS INDICATOR RAPs U4 U5 06 MOTOR FAULT DEVELOPER RAP The Developer Drive motor is not running NOTE This problem can be caused by arcing at the Print Drum Module spring contacts If the 06 code is intermittent and occasionally accompanied by a high pitch squeal clean and reform the spring contacts It the problem persists replace the Print Drum Module INITIAL ACTION Remove and inspect both developer modules Check to ensure no foreign material is wedged in the drive gears and the gears on both modules rotate freely Reinstall both developer modules Check the Toner Collector for layered toner sand art effect If layered toner is present refer to OF8 Arcing RAP Switch the power off wait 10 seconds and switch the power on Recheck for the fault PROCEDURE Set up the meter to read 5 VDC Connect the meter to CN117 2 and ground Enter IOT normal diagnostics Scroll to the MOTOR TEST program and press Form Feed 1 to switch on the motors while observing the meter The meter reads 5 VDC before the motor program starts and 0 VDC when the motor program is running Y Set up the meter to read 24 VDC Connect the meter to CN117 3 and ground gt STATUS INDICATOR RAPs U6 A B The meter reads 24 VDC Y N Go to BSD 9 5 in Section 7 and troubleshoot the 24 VDC CN117 3 for an open no open exists replace the PCU PWB Go to BSD 9 5 in
284. ts in background Misregistered image See the Image Registration Specification Mottle Small areas of low or light densities within a darker solid area that makes the overall solid area look measled grainy or sandy The low density areas are random in shape and size The size typically is between 0 1MM to 1 0MM Mottle is most noticeable in high density solid areas Offsetting fuser The removal of toner from the print by the fuser and the redeposition of that toner on another area of the same print or another print Removing toner from the image leaves the image rough and without gloss The redeposited toner may appear as a duplicate image partially shifted image or lines and streaks IMAGE QUALITY RAPs IMAGE QUALITY DEFECTS NOTE This defect fuser offsetting is one of three similar image quality problems see list below Refer to the other defects for additional information Ghosting Drum related Offsetting Fuser related Residual Image Cleaner related Oil Marks Dark round or irregularly shaped marks caused by an oil leak or drips Print A machine produced reproduction of an electronic original store in memory Residual Image A toner image that remains on the Drum after cleaning The next image is placed on top of the residual image and both images are transferred to the next print NOTE This defect residual image is one of three similar image quality problems see list below Refer to the
285. ttp xerox networkprinters com products NC60 THE DOCUMENT COMPANY 4 Xerox The Document Company the stylized X DocuPrint and all Xerox product names are trademarks of XEROX CORPORATION Adobe Postscript and the Postscript logo are trademarks of Adobe Systems Incorporated which may be registered certain jurisdictions Adobe PostScript 2 abd PANTONE CALIBRATED are trademarks of Pantone Inc Adobe PostScript 3 2 99 GENERAL PROCEDURES DocuPrint NC60 6 21 STARTUP SETTINGS C55 C55mp On Line Next until Next until This page lists the printer configuration and network settings customer should retain a copy of this page If you replace the ESS PWB all of these setting will be lost OFF LINE gt CONTROL PRINT GENERAL PROCEDURES SETTINGS Xerox DocuPrint C55mp Color Laser Printer Current Settings General Information Serial Number D3V 030361 Startup Page Enabled Yes AppleTalk Name DocuPrint C55 Software and Memory Total RAM Installed 24 MB Software Version 3 3 4 Software Part Number 537E56350 Engine Software Version 66 Interpreters Postscript and PCL 5C Adobe Postscript Version 2016 105 Print Counts Total Pages 2404 Fuser 1634 Prints Print Drum 3523 Images Black Developer 2373 Images Color Developer 1074 Images Timing Wait Timeout 60 Seconds Manual Feed Timeout 2 Minutes Hold Job Timeout 60 Seconds PowerSa
286. ur print driver This selection will produce an ultra smooth image without visible dots in the print Note that with complex documents the first print might be delayed a few seconds Refer to the user s guide for additional color settings Special Purpose Printing Fax Friendly Black Fax Friendly Black converts colors into different patterns of black and white so you can fax or copy your document without losing any information The document remains clear readable and informative Fast Blue Do you need faster output but want to keep the impact of color Fast Blue mode converts your images to shades of black and cyan blue while doubling the print speed to 6 ppm ZipColor When full color images with little text are needed quickly ZipColor increases color print speed by 3396 to 4 pages per minute This feature will also eliminate differential gloss sometimes seen on prints containing dark graphics or photos For the best black text quality choose either the Intelligent Color or Vivid Color mode Expert Color Control If you want to adjust the color of your prints to better match those from another printer Xerox provides Expert Color Controls These controls enable you to fine tune the colors on your printed document Color Adjustment Choose color adjustment from the print driver to make changes for lightness and saturation on individual print jobs Color Balance With Color Balance you can adjust the contrast ran
287. ur printer b Follow the next three steps completely to remove the developer packing e Remove the two plastic strips by pulling them as shown Remove the foam sheet c Rotate the lever on the cardboard roller from the bottom of the printer as shown as shown until it releases DO NOT remove any of the tape holding the roller to the foam GENERAL PROCEDURES 2 99 GP 15 1 INSTALL 6 56 DocuPrint C55 C55mp NC60 4 Loadthe Toner a IMPORTANT Shake the black toner bottle vigorously There is an internal paddle to aid in mixing the toner b Place the base of the toner bottle on the matching color coded platform fitting the hooks into the slots 10 DocuPrint C55 C55mp NC60 c Grasp the base of the toner bottle and e Allow the toner to flow out of the bottle pull it to the end of the slide then tap the bottle gently DO NOT SQUEEZE f When the bottle is empty slide it back to the original insertion point and remove it 2 99 GENERAL PROCEDURES 6 57 GP 15 1 INSTALL 0 Place the bottle into a supplied plastic bag and dispose of it properly GENERAL PROCEDURES GP 15 1 INSTALL Repeat steps a through g for each of the 3 color toner bottles Remember to shake vigorously and remove the tape as shown as soon the bottle is in place CN 17 2 99 6 58 DocuPrint C55 C55mp NC60 e Remove the roller from th
288. ure 2 Remove the Transfer Drum Cleaning Brush Cleaning Brush A37 Figure 2 Removing the Transfer Drum Cleaning Brush 2 99 4 41 REPAIRS ADJUSTMENTS REP 9 7 NOTES REPAIRS ADJUSTMENTS 2 99 NOTES 4 42 DocuPrint C55 C55mp NC60 REP 9 8 TRANSFER DRUM PARTS LIST ON PL 11 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord NOTE You must replace the Transfer Drum Cleaning Blade when installing a new Transfer Drum The blade can be easily accessed when the Transfer Drum is removed 1 Remove the Front Cover REP 1 4 2 Remove the Drum Module 3 Place several sheets of paper over the Paper Feeder 4 Remove the Stripper Finger Assembly REP 9 1 5 Figure 1 Remove the left side Arm and Spring 6 Remove the Transfer Drum Mounting Plates NOTE The left plate is spring loaded 7 Slide the Transfer Drum Bearings out and remove the Transfer Drum 8 Remove the Flanges and disassemble the Transfer Drum as required NOTE When reinstalling the transfer drum be sure to reinstall the washer between the spring and on the left side DocuPrint C55 C55mp NC60 RH Mounting LH Mounting Right Bearing cf Left qu PRU p Bearing LH Flange A30 Figure 1 Removing the Transfer Drum 2 99 4 43 REPLACEMENT NOTE Before replacement locate the V Shaped cutouts on the transfer drum flanges and the V in the Transfer Drum L
289. ure 2 Removing the Paper Feed Motor 2 99 4 25 4 Figure 3 Remove the four screws and disconnect the connectors CN101 102 105 5 Pull the printer forward until it is resting on the edge of the work surface Note During the removal of the Paper Feeder Assembly it will be necessary to pivot the Transfer Drum Assembly 6 While feeding the wires through the hole remove the Paper Feed Assembly Paper Feed Assembly A46B Figure 3 Removing the Paper Feed Assembly REPAIRS ADJUSTMENTS REP 8 2 8 3 TRAY EMPTY SENSOR PARTS LIST ON PL 8 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 2 Figure 1 Unclip and carefully remove the Tray Empty Sensor in the direction shown D12 Figure 1 Removing the Tray Empty Sensor REPAIRS ADJUSTMENTS REP 8 3 8 4 REP 8 4 REGISTRATION SENSOR PARTS LIST ON PL 8 2 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Paper Guide REP 8 1 b Paper Feed Assembly REP 8 2 c Tray Empty Sensor REP 8 3 2 Figure 1 Unclip and carefully remove the Registration Sensor D11 Figure 1 Removing the Registration Sensor 2 99 4 26 REPLACEMENT NOTE When replacing the Registration Sensor make sure that it is snapped securely in place and the actuator m
290. utlet ask the customer to call an electrician to restore the AC power If power is available at the wall outlet disconnect the power cord from the printer Plug the cord into the wall and check for AC power at the printer end of the power cord If power is available at the wall outlet but not available at the printer end replace the power cord PROCEDURE WARNING Disconnect all network and workstation inputs to the printer OTHER FAULTS RAP s OF1 A Switch the printer off wait 10 seconds and switch the printer on while listening to the IOT and observing the Message Display The IOT runs when the printer is switched on Y N Set up the meter to measure 5 VDC Measure between 108 1 and CN108 2 The meter indicates 5 VDC Y N Go to OF1 1 5 RAP Set up the meter to measure 5 VDC Measure between CN310 11 and CN310 10 The meter indicates 5 VDC Y N Replace the Connector PWB Go to OF2 CONTROL PANEL RAP Switch the printer off wait 10 seconds and Switch the power on while observing the LEDs on the ESS PWB The ESS appears to boot normally and the Control Panel is blank Y N Check CN104 the ESS to IOT connector If OK go to OF6A C55 C55mp or OF6B NC60 Go to OF2 CONTROL PANEL RAP 2 99 2 30 DocuPrint C55 C55mp NC60 OF1 1 5 VDC RAP This RAP is used when the 5 VDC is not present at the PCU PWB The printer is dead the display and LEDs are off No mot
291. ve from the harness Remove the screws and remove the Main Drive Motor Assembly Main Drive DN Motor Assembly E8 Figure 2 Removing the Main Drive Motor Assembly 2 99 4 8 Figure 3 Remove the Main Drive Motor and Motor Spacers Main Drive Motor E19 Figure 3 Removing the Main Drive Motor DocuPrint C55 C55mp NC60 REP 42 MAIN DRIVE MOTOR BELTS PARTS LIST ON PL 4 4 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following a Right Side Cover REP 1 3 b Top Cover REP 1 1 c Rear Cover REP 1 2 Figure 1 Loosen the Idler if required Disconnect CN112 and remove from the harness Remove the screws and remove the Main Drive Motor Assembly DocuPrint C55 C55mp NC60 Main Drive Motor Assembly E8 Figure 1 Removing the Main Drive Motor Assembly 2 99 4 9 Figure 2 Remove the Main Drive Motor Belts Belt B E9 Figure 2 Removing the Main Drive Belts REPAIRS ADJUSTMENTS REP 4 2 REP 4 3 DEVELOPER DRIVE MOTOR BELTS PARTS LIST ON PL 4 5 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the following D o f Print Drum Module Color Developer Module Black Developer Module Right Side Cover REP 1 3 Top Cover REP 1 1 Rear Cover REP 1 2 2 Remove the Main Drive Motor Belts REP 4 2 3 Qo m Figure
292. ver part is appropriate for the configuration of the machine on which the part is to be installed the machine does have a particular Tag and the only replacement part available is listed as W Tag install the Tag kit or all of the piece parts The Change Tag Index tells you which kit or piece parts you need Whenever you install a Tag kit or all the piece parts that make up a Tag mark the appropriate number on the Tag matrix DocuPrint C55 C55mp NC60 SYMBOLOGY A tag number within a circle and pointing to an item number shows that the part has been changed by the tag number within the circle Figure 1 Information on the modification is in the Change Tag Index Figure 1 With Tag Symbol DocuPrint C55 C55mp NC60 A tag number within a circle having a shaded bar and pointing to an item number shows that the configuration of the part shown is the configuration before the part was changed by the tag number within the circle Figure 2 Figure 2 Without Tag Symbol 2 99 5 3 A tag number within a circle with no apex shows that the entire drawing has been changed by the tag number within the circle Figure 3 Information on the modification is in the Change Tag Index Figure 3 Entire Drawing With Tag Symbol A tag number within a circle with no apex and having a shaded bar shows that the entire drawing was the configuration before being changed by the tag number within the circle Figure 4
293. verDelay 10 Minutes Hard Disk Installed No Print Media Tray I Paper Size Letter 81 2x I I in Tray 2 Paper Size Not Installed Custom Paper Size 81 2 x 13 in Support and Supplies Xerox Supplies Phone Number Dealer Supplies Phone Number Xerox Service Phone Number Dealer Service Phone Number Media Server Enabled Not Installed Parallel Settings Enabled Yes Mode AutoSelect Handshake Bi Directional Serial Settings Enabled Not Installed LocalTalk Settings Enabled Not Installed Network Settings Network Card Type Ethernet Network Card S W Rev 4 02 3 21 1997 10 57 Card Address 00 00 55 2 4 Connector Type BNC EtherTalk Enabled Yes Mode AutoSelect Zone Phase 2 Type LaserWriter Novell IPX Type Bindery Print Server Mode AutoSelect IPX Encapsule Adaptive Primary Server Print Server Name 552 4 Queue Scan Rate 2 TCP IP IP Address Resolution Static CurrentIPAddress 13 139 1 10 Subnet Mask 255 255 0 0 Default Gateway 152 51 1 222 TFTP Enabled Yes LPR Enabled Yes Mode AutoSelect Print Host Banner Page No Appsocket Enabled Yes Mode AutoSelect Telnet Status Enabled Yes Menu Enabled Yes NetBEUI Enabled Yes Group ENGINE Name XEROX 55 2a c4 Remark Service XeroxColor SNMP System Contact System Name Xerox Color Laser System Location HTTP PrinterURLAddress http HI3 139 1 10 Printing Enabled Yes THE DOCUMENT COMPANY Visit our web site at Http xero
294. w Voltage Power Supply Assembly remove the Cassette PWB and install it on the new Power Supply CN1004 vt Low Voltage Power Supply D5 Figure 2 Removing the Low Voltage Power Supply DocuPrint C55 C55mp NC60 REP 3 2 CASSETTE PWB PARTS LIST ON PL 3 1 REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the Low Voltage Power Supply REP 3 1 2 Figure 1 Remove screws and remove cassette PWB Cassette PWB D6 Figure 1 Removing the Cassette PWB DocuPrint C55 C55mp NC60 REP 3 3 PCU PWB PARTS LIST ON PL 4 2 NOTE Before removing the PCU PWB you must obtain some of the old NVM values These values will then be entered in the new PWB NVM Refer to ADJ 3 3A and perform the following DETERMINING THE CONSUMABLE USAGE AND TONER CONCENTRATION VALUES steps 1 through 6 NOTE If these steps cannot be performed because of a PCU PWB problem use the values from the Diagnostic Test Pattern REMOVAL WARNING Switch the Main Power off and disconnect the Power Cord 1 Remove the PCU PWB Cover 2 Disconnect all of the Connectors 3 Remove 4 screws and remove the PCU PWB REPLACEMENT 1 Install the new PWB 2 Reconnect the Connectors 3 Refer to ADJ 3 3B and perform the following INITIALIZING THE NVM steps 1 through 7 4 Reinstall the PCU PWB Cover 2 99 4 7 REP 3 4 ESS PWB PAR
295. when de energized and stops the outer tab when energized Check for flashing on the plastic assembly a bent solenoid actuator or other things that could interfere with proper operation Clean the cams and the cam followers with film remover to minimize friction not attempt to lubricate these cams Observe the op eration several times and look for smooth consistent operation Do not attempt to disassemble and adjust the clutch If the clutch is defective order the new Cleaner Clutch Shaft Assembly A B 2 99 2 8 A B Set up the meter to read 24 VDC Measure between CN103 3 and ground Switch the power off wait 10 seconds and switch the power on while monitoring the meter The meter swings from 24 VDC to 0 and back to 24 Y N Go to BSD 9 14 in Section 7 and troubleshoot the Transfer Drum Cleaning Solenoid signal 24 VDC Interlocked CN103 3 CN316 2 1 for an open or a short If 24 VDC is not available at 316 1 on the Connector PWB go to BSD 1 and troubleshoot the 24 VDC Interlocked 114 1 103 1 Check the Transfer Drum Cleaning Solenoid and the cleaner assembly for binding If the sheet appears to be stopping at the Transfer Drum to Print Drum Nip check the Transfer Drum Nip Adjustment ADJ 11 1 Enter IOT normal diagnostics Scroll to the SWITCH SCAN program and select Scan Row 05 Press Form Feed 1 Open the Printer Actuate and deactuate the Transparency Jam Sensor w
296. when the Control Panel Message Display LEDs or Buttons do not work INITIAL ACTION Switch the power off wait 10 seconds and Switch the power on and recheck for the fault Enter IOT normal diagnostics Menu 3 Enter 7 Power On and check the operation of the Control Panel If the Control Panel works OK in diagnostics refer to BSD 6 and check the PCU to ESS connectors CN104 If the connections OK replace the ESS PWB PROCEDURE Classify the problem into one of the following categories then 00 to the appropriate subsection of the RAP OF2 1 The Message Display top row consists of m s The bottom row is blank OF2 2 The Message Display is blank no during IOT Boot OF2 3 The message display is flickering off and displaying random characters OF2 4 Message display works OK LEDs do not work correctly OF2 5 Message display works OK Switches do not work correctly OF2 6 Circles Continuously OF2 7 Rebooting message never clears OTHER FAULTS RAPs OF2 OF2 1 The Message Display top row consists of 5 The bottom row 15 blank PROCEDURE Switch the power off wait 10 seconds and switch the power on while listening to the IOT The IOT runs boots up when the printer is switched on Y N Refer to BSD 6 and check the RES signal CN104 8 for a short to ground Refer to BSD 2 1 and check the D3 signal CN103 25 for a short to ground It the wiring is OK replace the PCU
297. wing areas Transfer Drum Cleaner Print Drum Black Developer Housing Color Developer Housing Fuser Paper Feed Assembly Replace any contaminated components 25 MISREGISTRATION BLACK Fuser Speed incorrect V66 IOT Firmware Perform Fuser Speed check GP 3 1 2 Transfer Drum to Print Drum Nip to large 2 Perform the Transfer Drum Nip check ADJ 11 1 26 MISREGISTRATION YELLOW Fuser Speed incorrect V66 IOT Firmware Perform Fuser Speed check GP 3 1 2 Transfer Drum to Print Drum Nip to large 2 Perform the Transfer Drum Nip check ADJ 11 1 2 99 IMAGE QUALITY RAPs DocuPrint C55 C55mp NC60 3 13 IMAGE QUALITY DEFECTS Defect Name Description Possible Causes Corrective Action 27 MISREGISTRATION SIDE TO SIDE 1 Registration adjustment incorrect 1 Perform Margins adjustment ADJ 3 2 2 Constant HSYNC from IOT 2 Refer to BSD 6 and check the HSYNC signal CN104 9 for a short to ground 28 MISREGISTRATION LEAD TO TRAIL 1 Registration adjustment incorrect 1 Perform Margins adjustment ADJ 3 2 EDGE 2 Registration clutch always energized 2 Refer to BSD 8 2 and check the Registration Clutch CN101 4 for a short to ground 3 Transfer to Print drum gear mesh incorrect 3 If prints are OK when using enhanced alignment refer to Transfer Drum Nip adjust ment ADJ 11 1 and perform the check 29 MISREGISTRATION HEAVIER STOCK 1 Grounding roller not being raised 1 Refer to BSD 8 3 and check
298. x Yellow Black 0 Adjustments Cyan Top Margin 0 0 Magenta 11 Left Margin 0 0 Yellow 1 Cleaning Cycle Never Adjustments TC Patch Control Off Transfer Bias Fast Black On Paper Extra Toner On High 1000 Volts 105 volts Cyclic toneup On Normal 1000 Volts 105 volts Mode None Low 1200 Volts 105 volts Process Control Status OHP Black OK High 2200 Volts 200 volts Cyan OK Normal 2000 Volts 200 volts Magenta OK Low 2200 Volts 105 volts Yellow OK Developer Bias Calibration OK Black 265 Volts Cyan 345 Volts Magen 345 Volts Yellow 341 Volts lt 0 0 E B a e 103 105 92 ow 103 sss THE DOCUMENT COMPANY 2 99 GENERAL PROCEDURES DocuPrint NC60 6 25 DIAGNOSTICS PCL FONT 55 55 Xerox DocuPrint C55mp Color Laser Printer Next until PRINT gt PCL 5C Resident Fonts Enter STARTUP gt Internal Scalable Typefaces and Bitmapped Fonts Typeface Pitch Point Font Next until PCL FONT Line Printer 16 67 8 5 000 Courier Scale 10 5 76 001 Courier Scaled 10 5 76 002 Courier Bd Scaled 10 576 1004 Enter lt PROCESSING gt LetterGothic Scaled 10 576 1005 LetterGothiclt Scaled 10 576 006 LetterGothicBd Scaled 10 576 007 This page lists the PCL Fonts which are resident on the ESS This will vary somewhat from printer to printer CG Times It Scaled 25 999 75 1010 CG Times Bd S
299. x networkprinters com products c55 2 99 6 22 DocuPrint C55 C55mp CONFIGURATION NC60 Menus Print Menu Up until Item Down until Print Config Sheet Processing Config Sheet Xerox DocuPrint NC60 Color Laser Printer Configuration Sheet General Serial Number Total Prints Total System Memory Software Version 9886 64 MB 1 80 47 Engine Software Version 94 PCL Emulation version Postscript version Installed options Printer Counts Total Fuser Print Drum Black Developer Color Developer PCL5C 19971007 Level 3 3010 106 None 9886 9114 17090 9780 3330 Ethernet HW address Printer URL AppSocket Ports EtherTalk Name Type Zone NetBEUI Group Machine Name Service Remarks 00 00 AA 79 00 7B http 0 0 0 0 2000 2501 9100 XRX 0000AA790054 LaserWriter WORKGROUP XEROX 79 0 7B XEROXPRINTER Netware Network Number 000000000 Netware Frame Type SNAP Support and Supplies Xerox Supplies Phone Number Dealer Supplies Phone Number Xerox Service Phone Number Dealer Service Phone Number This is the configuration page it lists the printer configuration and network settings The customer should retain a copy of this page If you replace the ESS PWB all of these setting will be lost DocuPrint NC60 L rrt E Ethernet Menu LPR Enable LPR Banner LPR PDL LPR Binary PS DLC LLC Enable DLC LLC PDL DLC LLC Bin PS NetBEUI Enable NetBEUI PDL NetBEUI Bin PS
300. xxx Engine software Version xx Serial Number xxx xxx xxx Total Ram Installed 24 Yellow Okay J10 J11 0 MB This is the DRAM in the lower two slots Calibration Okay Binary Contone Lossy Counters The C55 printer uses compression and decompression to save memory However if the job is very complex lossy compression may be used The printer will still try to print the job however data may be lost If this occurs the Lossy Counters will increment Add more memory to fix this problem Humidity Temperature counts These readings are used to adjust the copy quality to the environment If these readings extreme 0 or 255 the Temperature Humidity sensor is not working properly Density Rate Setpoints Bla ck 90 Cyan 90 Magenta 90 Yel ow 90 Toner Concentration Setpoint B ack 91 Cyan 94 Magenta 102 Base 8 Mb J8 J9 16 Mb J10 J11 0 Mb Total Pages Binary Lossy Counter 0 Prints Contone Lossy Counter 0 Prints Relative Humidity 20 Counts Temperature 107 Counts Fuser Temperature 157 Counts Consumable Usage Status Fuser xxx Prints Print Drum 939 Images Fuser Oil Okay Black Developer xxx Images Color Developers Cyan xx Images Magenta xx Images Yellow xx Images Fuser Temp This count represents fuser temperature The Val following values are normal Cyan Print Counts 1 Magenta Total Pages xxxxx Transparencies 160 Yellow 84 Black xxxxx

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