Beruflich Dokumente
Kultur Dokumente
5
July 2013
P Preparation
Service Training Student Sign Off Sheet ...........................................................................................................P-1
2 Product Overview
Module Overview.........................................................................................................................................................2-1
Module Objectives ......................................................................................................................................................2-1
Configurations..............................................................................................................................................................2-1
Machine Overview.......................................................................................................................................................2-2
General ..................................................................................................................................................................2-2
Control Panel.......................................................................................................................................................2-3
DADH .....................................................................................................................................................................2-3
Options ..................................................................................................................................................................2-4
Finishing Options.........................................................................................................................................................2-5
Installation.....................................................................................................................................................................2-5
Work Projects ................................................................................................................................................................2-6
Work Project 1 - User Interface Screens ..................................................................................................2-6
Work Project 2 - Copy ......................................................................................................................................2-6
Work Project 3 - Print .......................................................................................................................................2-7
6 Scanning
Module Overview.........................................................................................................................................................6-1
Module Objectives ......................................................................................................................................................6-1
Scanning Overview .....................................................................................................................................................6-2
Document Glass...........................................................................................................................................................6-3
General ..................................................................................................................................................................6-3
Document Size Sensing ..................................................................................................................................6-4
Scanner Module ...........................................................................................................................................................6-4
Scan Carriage Assembly .................................................................................................................................6-5
Imaging and Control .................................................................................................................................................6-7
Initialisation ..................................................................................................................................................................6-9
Work Projects .............................................................................................................................................................6-11
Work Project 1 - Scanner Module ............................................................................................................6-11
Work Project 2 - dc604.................................................................................................................................6-11
Sign Off ..............................................................................................................................................................6-12
Module 6 Quiz............................................................................................................................................................6-13
Module Summary.....................................................................................................................................................6-14
7 DADH
Module Overview.........................................................................................................................................................7-1
Module Objectives ......................................................................................................................................................7-1
DADH Overview............................................................................................................................................................7-1
Document Sensing......................................................................................................................................................7-1
Jam Clearance ..............................................................................................................................................................7-4
Drives and Interlocks .................................................................................................................................................7-5
Power and Control ......................................................................................................................................................7-7
Feed Assembly..............................................................................................................................................................7-8
Post Feed Transportation and Scanning ........................................................................................................7-11
8 Xerographics
Module Overview.........................................................................................................................................................8-1
Module Objectives ......................................................................................................................................................8-1
Technical Overview.....................................................................................................................................................8-1
Toner Save ...........................................................................................................................................................8-1
Magnetic Seal.....................................................................................................................................................8-1
Toner ......................................................................................................................................................................8-2
Module 8 Quiz...............................................................................................................................................................8-2
Module Summary........................................................................................................................................................8-3
Course Assessment .....................................................................................................................................................8-3
9 Quiz Answers
Module 2.........................................................................................................................................................................9-1
Module 3.........................................................................................................................................................................9-2
Module 4.........................................................................................................................................................................9-3
Module 5.........................................................................................................................................................................9-3
Module 6.........................................................................................................................................................................9-4
Module 7.........................................................................................................................................................................9-5
Module 8.........................................................................................................................................................................9-6
Student Name:
Location:
Class Date:
Instructor:
You will be introduced to the differences between the WorkCentre 58xx and the WorkCentre 57xx over
the the duration of the course as you complete the different portions of this training.
This course was designed to provide you with all the necessary knowledge to diagnose and service the
WorkCentre 57xx family of machines.
Course Objectives 0
When you have successfully completed this course, you will be able to:
• Describe the available configurations for the WorkCentre 57xx family of machines.
• Describe the differences in technology (both mechanical and electrical) between the WorkCentre
58xx and the WorkCentre 57xx families.
• Understand the sequence of operation of each sub-system of the machine.
• Be familiar with the Service Documentation and the resources available to you to diagnose and
service the WorkCentre 57xx.
• Diagnose and service the WorkCentre 57xx family of machines.
You are required to have the following hardware and software in addition to the course prerequisites, in
order to service this product:
• Xerox approved PWS
• The cables and tools listed below are also required to service this product. If you do not have any
of the following, contact your training administrator for guidance.
- Serial cable (600T2058) - used to connect the Xerox approved PWS to the machine while
performing a PWS Altboot procedure.
- Null Modem Adapter (113E40060) - used with the Serial Cable when connecting a PWS while
performing a PWS Altboot procedure.
- USB Memory Device (702P00614) - used to perform Altboot system installations and
upgrades. This must be a USB memory device approved by Xerox for 5790 Family use.
- Micro-probe Tool (600T2177) - used as an extension of the standard meter probes in order to
probe very small connectors in the machine without damaging them.
- Finisher Bypass Connector (600T02261) - fitted to the machine in place of a connector from
any optional finisher. When fitted, the machine remains operational.
- ESD Kit (600T42001)
- Brush Mag Tool (600T91952)
- WorkCentre 5790 family PWS Tools
Course Structure 0
This Xerox® WorkCentre® 5790 from 5890 Differences Service Training is presented in a modular
format, with each module covering specific aspects of the machine. The information contained in this
Workbook is supplemented with an e-learning element, allowing content to be conveyed using a variety
of media including animations. You will be directed by the Workbook to review this content when it is
appropriate.
Work Projects are provided for the majority of modules to facilitate hands-on training for those
undertaking the course in a training centre with access to a WorkCentre 57xx family machine. If you do
not have access to the machine, skip these elements of the course and continue with the module quiz.
Introduction 0
This provides an overview of the course, the pre-requisites and the course objectives. It will also provide
information on laser safety and electrostatic discharge precautions.
Product Overview 0
This describes the main features and functionality of the machine while providing a high level overview
of the differences between the WorkCentre 58xx and the WorkCentre 57xx family of machines. This will
give you a basic understanding of the machine.
Scanning 0
You will learn which key mechanical, electrical and optical components are different in this Scanner
Module and how they operate to scan a document.
Document Handler 0
The WorkCentre 57xx utilises a Duplexing Automatic Document Handler (DADH) in place of the SPDH.
This module will describe the key mechanical and electrical components and how documents are fed
during scanning.
Xerographics 0
This details the minor differences in the xerographic process between the WorkCentres.
If you have not been provided with or cannot gain access to any of these resources, contact your
training administrator for guidance.
Course Guidelines 0
To complete this course as quickly and effectively as possible, please follow the guidelines below:
• Take the modules in the order they are presented and do not skip a module.
• Do not skip any sub-modules or fail to take the module quiz. They are here to enable you to check
your understanding of the material and to prepare you for the final Certification Test.
• If you are unable to answer some of the questions correctly in the quiz, review the appropriate
material again.
And finally
• Take periodic breaks to maintain your concentration.
This product uses an invisible laser beam to expose the Photoreceptor. It is important that all safety
precautions be followed during Service Procedures. The product is certified to comply with Laser
Product Performance Standards as a Class I product. This means that it is a laser product that does not
emit dangerous laser radiation during any mode of customer operation. However, incorrect or careless
service techniques could expose the service technician to damaging levels of infra-red radiation.
WARNING: The laser beam can cause eye damage if directed into your eye. Service procedures
must be followed exactly as written, without change. The Service Representative must observe the
established local laser safety precautions when servicing the product.
Do not:
• Place tools with a reflective surface in the area of the LSU window
• Bypass any laser interlocks for any reason
Permanent eye damage can result if the laser is directed into your eye. The use of controls or
adjustments other than those specified in the Laser Safety Training Program may result in an exposure
to dangerous laser radiation.
Electrostatic Discharge 0
All standard field Electrostatic Discharge (ESD) precautions should be followed whenever servicing this
product. The electronics in Xerox products are advanced and have become very sophisticated to meet
the needs of customers for additional features and increased speed. These advances have increased
performance and reduced costs by packing more electronic circuits in ever smaller areas. In the past,
many electronic components could withstand ESD voltages as high as several thousand volts. However,
due to today's extreme miniaturisation and high sensitivity, an ESD as low as 25 volts can cause
damage.
The sophisticated electronics in this product require the use of all standard ESD procedures to ensure
increased customer satisfaction and reduced service costs.
If you are not familiar with the ESD procedures, or do not possess an ESD kit, you must inform your
Training Administrator before proceeding.
LE Lead Edge
LEF Long Edge Feed
LVPS Low Voltage Power Supply
NVM Non-Volatile Memory
OCT Offsetting Catch Tray
OS Operating System
PC Personal Computer
PFM Paper Feed Module
PFP Paper Feed Platform
PPI Post Process Inserter
PWB Printed Wiring Board
PWS Portable Work Station
SAR Semi Active Retard
SBC Single Board Controller
SEF Short Edge Feed
SPDH Single Pass Document Handler
SWAP Software Activation Portal
TCP/IP Transmission Control Protocol / Internet Protocol
TE Trail Edge
UI User Interface
USB Universal Serial Bus
Module Summary 0
During this module you have been made aware of the course objectives, course overview and the
relevant resources needed for successful course completion. Laser Safety and Electrostatic Discharge
warnings have also been outlined. Follow these guidelines and you will successfully complete the
course.
Have your Instructor sign you off on Module 1.
______________________________ Instructor
Module Objectives 0
On completion of this module, you will be able to describe the available configurations, machine
features, functions and the available options.
Configurations 0
The WorkCentre 57xx family of machines are black and white multi-function devices enabling digital
copying, printing, faxing and scanning. The machines are available in three standard configurations.
These are:
• A Speed - WorkCentre 5735 (35 ppm)
• B Speed - WorkCentre 5740 (40 ppm), 5745 (45 ppm) and 5755 (55 ppm)
• C speed - WorkCentre 5765 (65 ppm), 5775 (75 ppm) and 5790 (90 ppm)
All of these can be configured with a number of finishing and productivity options. For more
information, refer to the WorkCentre 57xx Customer Documentation available to download from
Xerox.com/support.
NOTE: A ‘Copier’ only configuration is available in the United States of America. Use GP30 to help
identify these types of machine.
NOTE: The Faxing and Scanning features are optional and must be purchased and enabled by the User.
The Faxing feature requires an Embedded Fax Module to be installed.
The next few sections introduce the major components of the WorkCentre 57xx.
Machine Overview 0
General 0
The appearance of the WorkCentre 57xx is shown in Figure 1.
The major difference between the WorkCentre 57xx and the WorkCentre 58xx is the Image Input
Terminal. The WorkCentre 57xx has a Duplex Automatic Document Handler (DADH) in place of a SPDH
and different type of Scanner Module.
It is important to note that the Tray numbers differ to the WorkCentre 58xx.
Control Panel 0
The Control Panel is the User Interface to the machine through a LCD Touch Display. Access is provided
to all the features as well as providing control of diagnostic routines.
The layout and appearance of the WorkCentre 57xx Control Panel shown in Figure 2. differs to the
WorkCentre 58xx. Important points to note include:
• USB Port - the Control Panel does not have a USB Port.
• The machine cannot be turned On/Off from the Control Panel. This functionality is achieved with a
On/Off Switch located on the left hand side of the machine.
• A Power Save button is situated on the top right hand side of the Control Panel to place the
machine into and wake it from a power save mode.
DADH 0
The DADH will handle mixed originals up to A3 or 11 x 17” SEF with paper weights between 50 and 160
gsm.
Unlike the SPDH fitted to the WorkCentre 58xx, the DADH scans each side of a document separately in
two passes. Prior to the second pass, the document is inverted in the paper path, presenting side 2 to
the Scanner Module.
There are two types of DADH fitted to WorkCentre 57xx machines. These are:
• 75 sheet capacity - fitted to the WorkCentre 5735 only
• 100 sheet capacity - fitted to the WorkCentre 5740, 5745, 5755, 5765, 5775, 5790
NOTE: The DADH is covered in detail in Section 8 of this course.
Figure 3. DADH
Options 0
The following options are available with the WorkCentre 57xx family of machines.
• Platen Cover - Only available on the WorkCentre 5735 in place of the DADH.
• Stand - Available on the WorkCentre 5740, 5745 and 5755 in place of the Trays 3 and 4 (HCF)
• Embedded Fax Kit - this kit comes in a number of region specific variants offering single or two line
fax connections to the machine.
The following options are NOT available with the WorkCentre 57xx family of machines;
• Wireless Print Kit
• McAfee Enhanced Security
• McAfee Integrity Kit
All customer purchased options are enabled through the UI using an Enablement PIN supplied with the
option kit. The WorkCentre 57xx family of machines is not supported by the Software Activation Portal
(SWAP) system.
Finishing Options 0
The following finishing options are available with the WorkCentre 57xx family of machines.
• OCT
• 1KLCSS
• 2KLCSS
• HVF
• HVF-BM
• Tri-folder
• Post Process Inserter (PPI)
NOTE: The LVF-BM is not available with the WorkCentre 57xx family of machines.
Installation 0
The WorkCentre 57xx family of machines does not support installation using a SIM Card.
Activation Codes are used in place of SIM Cards. These are printed on a label, located at the rear of the
machine.
During installation, the Activation Code will be requested by the Installation Wizard. This will configure
the machine speed.
If a ‘Machine Speed Configuration Error’ occurs, the machine speed can be reset using the procedures
detailed in GP 15.
Work Projects 0
These work projects are provided to facilitate hands-on training in facilities where a machine is
available. If you are undertaking this course remotely, you may skip this section and continue to the
Module Quiz.
Ask your Instructor for some A4/ 8.5x11 inch and A3/ 11x17 inch Demonstration Originals, or make
some using a marker pen and paper.
Sign Off 0
Ask your Instructor to sign off these work projects. If you have any questions ask your Instructor
now.
______________________________ Instructor
Module 2 Quiz 0
Complete the Module 2 Quiz below, indicating a correct answer by ticking the box. You may use the
machine (if available) or any of the documentation to assist with your answers.
Module Summary 3
In this module, you have been made aware of the available machine configurations, features and
options.
Review the objectives at the beginning of the module. If you do not feel comfortable with your
ability to perform any objective, review the materials for that objective. If you are in a training
facility, then discuss the information with your Instructor.
If you are comfortable with your understanding of the information presented, proceed to the next
module.
If you are in a training facility, have your Instructor sign off Module 2.
______________________________ Instructor
Module Objectives 0
On completion of this module, you will be able to identify the service documentation and support
available to you and how it differs from the WorkCentre 58xx equivalents.
Documentation 0
Available Documentation 0
To assist you in servicing the WorkCentre 57xx machines and to assist the customer during a Service
Call, you will be provided with the following documentation:
• WorkCentre 5790 Service Manual including Wiring Diagrams
• WorkCentre 5790 Principles of Operation
• WorkCentre 5790 System Administrator Guide
• WorkCentre 5790 User Guide
XX-YYY
Where:
These sub-sections detail the procedure to adopt during a service call and are used to identify and
rectify an issue with the machine.
SCP 2 - Call Actions, as used in the WorkCentre 5890 Service Manual is separated into two individual
Service Call Procedures, namely SCP 2 - First Call Actions and SCP 3 - Normal Call Actions. SCP 2 - First
Call Actions should only be used for the first service call to the machine. Any subsequent service calls to
a machine should use SCP 3 - Normal Call Actions.
Work Projects 0
These work projects are provided to facilitate hands-on training in facilities where a machine is
available. If you are undertaking this course remotely, you may skip this section and continue to the
Module Quiz.
Sign Off 0
Ask your Instructor to sign off these work projects. If you have any questions ask your Instructor
now.
______________________________ Instructor
Module 3 Quiz 0
Complete the Module 3 Quiz below, indicating a correct answer by ticking the box. You may use the
machine (if available) or any of the documentation to assist with your answers.
2. What fault and service code format is used on the WorkCentre 57xx family of machine?
XXX-YYY-ZZ
XXX-YYY
X-YYY
XX-YYY
Module Summary 3
In this module, you have been made aware of the differences in the service manual and supporting
documents.
Review the objectives at the beginning of the module. If you do not feel comfortable with your
ability to perform any objective, review the materials for that objective. If you are in a training
facility, then discuss the information with your Instructor.
If you are comfortable with your understanding of the information presented, proceed to the next
module.
If you are in a training facility, have your Instructor sign off Module 3.
______________________________ Instructor
Module Objectives 0
On completion of this module, you will be able to identify the power generation, distribution and
control assemblies that have changed. You will also be able to describe the purpose and function of
these assemblies.
Standby Power 0
The 3.3VDC standby (SB) voltage is generated by the Low Voltage Power Supply (LVPS) whenever the
machine is connected to an AC mains supply. This SB voltage is distributed to the IOT PWB and
onwards to the On/Off Switch located on the left hand side of the machine (refer to Figure 1.).
1 On/Off Switch
When the On/Off Switch is depressed, the 3.3VDC SB is momentarily grounded initiating the machine
start-up sequence.
Alternatively, follow the link below to access this content, and then return to this Workbook.
http://xerox.ravnur.com/video/2517/Machine-Startup-Sequence.aspx
NOTE: Figure 2. shows a W/TAG 150 SBC Module fitted with a Embedded Fax Module and a Daughter
PWB. These non standard options are detailed later.
The SBC PWB Module is housed below the Scanner and can be easily withdrawn by a Service Technician
for service and upgrades. It contains the SBC PWB that interfaces with all the previously identified
modules and devices through various harnesses and cables. As standard the SBC PWB Module is fitted
with the components detailed below and shown in Figure 3.
• Hard Disk Drive (HDD) - this is used to store data from Scan to Export jobs and incoming network
data.
• 1 Gb Memory Module - this is used to store shared image data.
• Software Module - this is used to store the Boot ROM, NVM and MFD Feature Key
• Power Distribution PWB - this distributes power to the various machine modules under the control
of the SBC PWB.
The rear panel of the SBC PWB Module (shown in Figure 4.) has five connectors for connection of
external devices. These are:
• Three USB 2.0 Connectors - these host connectors are for USB memory devices to provision
printing and software upgrades.
• RS-232 Serial Connector - used to connect a PWS to the machine.
• 10/100/1000 Mbit/s Ethernet Connector - used to connect the machine to a client’s Local Area
Network (LAN) and a PWS during Service Calls.
1 USB 2.0
2 10/100/1000 Mbit/s Ethernet
3 RS-232
Colour Scanning 0
To enable processing of colour images for all machines fitted with the 600 dpi colour scanner (TAG
150), a Scanner Daughter PWB is fitted to the SBC PWB during manufacturing as shown in Figure 6.
NOTE: The Scanner Daughter PWB cannot be fitted to a mono SBC PWB designated W/O TAG150.
Embedded Fax 0
The optional Embedded Fax Module provides connectivity for one or two lines. It is installed in the SBC
PWB module on the left hand side of the Riser PWB. The integral PCI connector slots into the Riser PWB
for power and data communication.
Figure 7. shows the Embedded Fax Module fitted to the SBC PWB Module.
Figure 8. and Figure 9. show each of these cables connected between the PWS and machine.
Figure 8. Serial Cable, Null Modem Adapter and Ethernet Crossover Cable
1 USB Cable
For more information on the PWS Diagnostic Tools, refer to GP5 in the Service Manual.
Work Projects 0
These work projects are provided to facilitate hands-on training in facilities where a machine is
available. If you are undertaking this course remotely, you may skip this section and continue to the
Module Quiz.
Sign Off 0
Ask your Instructor to sign off these work projects. If you have any questions ask your Instructor
now.
______________________________ Instructor
Module 4 Quiz 0
Complete the Module 4 Quiz below, indicating a correct answer by ticking the box. You may use the
machine (if available) or any of the documentation to assist with your answers.
1. Which of the following sends the power on signal to the LVPS once the 3.3 VDC SB voltage is
grounded?
On/Off Switch
IOT PWB
Power Save Button
The Riser PWB provides additional PCI slots for connecting the _________.
FDI PWB
Embedded Fax Module
Memory Module
Software Module
3. What should be used to connect the PWS to the machine while performing an Altboot?
Serial Cable
USB Cable
Serial Cable and Null Modem Adapter
Ethernet Crossover Cable 3
Module Summary 3
In this module, you have been made aware of the differences in power generation, distribution and
control.
Review the objectives at the beginning of the module. If you do not feel comfortable with your
ability to perform any objective, review the materials for that objective. If you are in a training
facility, then discuss the information with your Instructor.
If you are comfortable with your understanding of the information presented, proceed to the next
module.
If you are in a training facility, have your Instructor sign off Module 4.
______________________________ Instructor
Module Objectives 0
On completion of this module, you will be able to identify the mechanical and electrical paper feed and
registration assemblies that have changed. You will also be able to describe the purpose and function
of these assemblies and their sequence of operation.
TAG 151 indicates which Paper Feed Assemblies are fitted to the machine.
• W/TAG 151 - the machine is fitted with the FAR Paper Feed Assemblies
• W/O TAG 151 - the machine is fitted with the BDT Paper Feed Assemblies
The FAR Paper Feed Assemblies were introduced with TAG 151 to replace the BDT Paper Feed
Assemblies. They are interchangeable, but the FAR Paper Feed Assemblies require SMP1 Software
(061.131.221.10401) or later to operate.
Before servicing a machine, check the TAG/Machine Plate fitted to the machine to identify which Paper
Feed Assemblies are fitted.
NOTE: For the remainder of this Workbook, the BDT Paper Feed Assemblies will be referred to as W/O
TAG 151 Paper Feed Assemblies.
NOTE: The FAR Paper Feed Assemblies fitted to the WorkCentre 57xx are identical to those fitted to the
WorkCentre 58xx and are not detailed in this Service Training.
Tray Elevation 0
Paper Trays 3 and 4 each have their own Tray Elevation Mechanisms that are an integral part of the
tray. Each Tray Elevation Mechanism consists of:
• Paper Lift Plate
• Front and Rear Elevator Cable Systems
• Elevator Drive Gear Coupling
• Tray Elevator Motor and Encoder
• Tray Home Sensor
Although the visual appearance and location of these components differs to the WorkCentre 58xx, they
function in exactly the same manner.
Two devices prevent over-elevation of a tray in the event of a Stack Height Sensor failure. These are:
• Stack Limit Switch - this switch is actuated when the Stack Height Sensor Actuator exceeds its
normal range of movement. Once actuated, all drive to the Tray Elevation Mechanism is removed
and a fault is declared.
• Stack Limiter - this is a mechanical fail-safe the physically prevents over-elevation of the tray.
Figure 1., Figure 2. and Figure 3. show the location of these key components on the WorkCentre 57xx.
The position of the Feed Roll is controlled by a Lever that connects to the pivoting Housing. When the
tray is closed, a prong on the rear of the tray actuates the Lever, lowering the Housing and thus the
Feed Roll to the feed position. When the tray is opened, the Lever returns to its ‘home’ position under
spring pressure allowing the Housing to raise.
• Tray Empty Sensor - when all the sheets in the tray have been fed, the Tray Empty Sensor actuator
falls into a cut-out in the Paper Lift Plate, triggering the sensor. Then a message will appear on the
UI instructing the user to load the tray.
When the signal is received to feed sheets, the Feed Motor is energised and drive is provided to the
Feed Rolls through a Worm Gear and Two-way Clutch. As the Feed Roll begins to rotate, it moves
backwards in the Housing due to the friction level between the Feed Roll and the top sheet. This action
forms a feed arc that will be stock dependent. As the Feed Roll continues to rotate, the inter-sheet
friction is overcome and the now stationary Feed Roll drives sheets into the paper transport. As the trail
edge of the sheet passes the Feed Roll, it returns to its initial position under spring pressure.
The W/O TAG 151 Paper Feed Assembly components are shown in Figure 4.
Tray 3 Transport 0
Tray 3 has a Transport Assembly to feed sheets from the Tray 3 Paper Feed Assembly to the Tray 3 and
4 Transport Roll located on the left hand side of the machine prior to the Pre-registration Roll.
The Transport Assembly is fixed to Tray 3 and sits above Tray 4. It consists of a single Transport Roll and
Takeaway Roll mounted between the Tray Base and the Jam Clearance Cover. Drive to these rolls is
provided by the HCF Transport Motor through a drive belt.
Sheets moving through the Transport Assembly are monitored by the Tray 3 Feed Sensor. This provides
timing and jam clearance information to the IOT PWB.
Alternatively, follow the link below to access this content, and then return to this Workbook.
http://xerox.ravnur.com/video/2538/W-O-TAG-151-Paper-Feed-Assembly.aspx
The Short Paper Path Assembly with the vacuum fan and Transport rollers (designated as W/O TAG114)
is shown in Figure 7.
Figure 8. Inverter/Decurler
All other WorkCentre 57xx machines are fitted with a Inverter Assembly as shown in Figure 9. It is an
option, designated as W/TAG 148, to install the Inverter/Decurler Assembly on ‘A’ and ‘B’ machines.
This can be installed to rectify sub-standard stacking performance when the machine has an OCT
fitted.
Figure 9. Inverter
It is recommended that this tool is used with the WorkCentre 57xx machines fitted with a Tray 5 (PFP).
There are no procedures detailing its use in the Service Manual, instead Service Technicians should refer
to Service Bulletin T8071-03-23 for the appropriate procedures to follow.
1 Stack Height Sensor and Retard Shield Dual Purpose Tool - 600T0232
Figure 10. Stack Height Sensor and Retard Shield Dual Purpose Tool
Work Projects 0
These work projects are provided to facilitate hands-on training in facilities where a machine is
available. If you are undertaking this course remotely, you may skip this section and continue to the
Module Quiz.
Sign Off 0
Ask your Instructor to sign off this work project. If you have any questions ask your Instructor now.
______________________________ Instructor
Module 5 Quiz 0
Complete the Module 5 Quiz below, indicating a correct answer by ticking the box. You may use the
machine (if available) or any of the documentation to assist with your answers.
1. What W/TAG number indicates a machine is fitted with FAR Paper Feed Assemblies?
004
046
148
151
154
The position of the Feed Roll in a W/O TAG 151 Paper Feed Assembly is controlled by the _________.
Housing and Lever
Housing
Lever
Feed Motor
Module Summary 3
In this module, you have been made aware of the differences in paper feed and registration
assemblies, particularly Paper Tray 3 and 4 Paper Feed.
Review the objectives at the beginning of the module. If you do not feel comfortable with your
ability to perform any objective, review the materials for that objective. If you are in a training
facility, then discuss the information with your Instructor.
If you are comfortable with your understanding of the information presented, proceed to the next
module.
If you are in a training facility, have your Instructor sign off Module 5.
______________________________ Instructor
Module Objectives 0
On completion of this module, you will be able to identify the Scanner Module, describe its
components and detail how they are sequenced. In addition you will be able to describe the Document
Glass and the CVT glass and their purpose.
Scanning Overview 0
Documents can be copied manually from the Document Glass or automatically using the DADH. The
Scanner Module, mounted below the DADH, makes a digitised image of the document which is sent to
the SBC PWB for post processing e.g. reduction/enlargement. When multiple copies are selected, the
document is only scanned once and stored in the system memory.
The Scanner Module has a Scan Carriage Assembly to scan and expose the documents. This operates in
one of two modes:
• Fixed Mode - the Scan Carriage Assembly is positioned below the Constant Velocity Transport
(CVT) Glass. Documents are transported over the CVT Glass by the DADH where they are scanned.
• Document Glass Mode - the document remains stationary on the Document Glass while the Scan
Carriage Assembly is moved beneath it.
The Scanner Module, CVT Glass and Document Glass are shown in Figure 1.
The following sections will provide a detailed overview of the Scanner Module components and how
they are sequenced.
NOTE: The DADH is described in Section 7.
Document Glass 0
General 0
The Document Glass is generally used to make copies of single or bound documents that can be
scanned with the DADH open or closed. The design of the DADH hinges allow for documents up to
25mm (1”) in thickness to be copied with the DADH in the closed position. The document is registered
to the right hand side of the Document Glass (indicated by the green arrow). Document sizes up to A3
or 11 x 17” can be scanned.
1 Registration Arrow
When the DADH is closed, a pre-scan of the document is performed and the data received by the CCD is
used to determine document width.
Scanner Module 0
The Scanner Module contains a Scan Carriage Assembly, Lens and Charge Coupled Device (CCD).
These assemblies operate together to expose and scan the document placed into the DADH or onto
the Document Glass.
There are two types of Scanner Module that can be fitted to the WorkCentre 57xx; these being
monochrome and colour.
TAG 150 is fitted as standard to WorkCentre 5765, 5775 and 5790 machines but is an option on
WorkCentre 5735, 5740, 5745 and 5755 machines. Before servicing a machine, check the TAG/
Machine Plate fitted to the machine to identify which Scanner Module is fitted.
The colour and monochrome Scanner Modules function in exactly the same way, but the location of
components differs. For the remainder of this section, the W/TAG 150 colour Scanner Module is
described.
An Exposure Lamp controlled by the Exposure Lamp Inverter PWB is fitted to the Full Rate Carriage to
illuminate the document. The reflected image is directed towards the CCD by a system of mirrors
mounted on each carriage. The Half Rate Carriage moves at 50% of the Full Rate Carriage to maintain
a constant optical path length.
The position of the Scan Carriage Assembly is monitored by the Scan Carriage Home Sensor. This is
used as a known point from which all movements of the Scan Carriage Assembly are calculated.
Now access Learning @ Xerox to review the . When you have accessed the programme, click the
Scan Carriage Assembly button. This demonstrates the movement of the Scan Carriage Assembly.
Alternatively, follow the link below to access this content, and then return to this Workbook.
http://xerox.ravnur.com/video/2230/Scan-Carriage-Assembly.aspx
The Scanner Module is controlled by the Scanner PWB as shown in Figure 6. This supplies both power
and control signals to the CCD PWB and the Exposure Lamp Inverter PWB during operation through
ribbon cables and harnesses.
1 Scanner PWB
Initialisation 0
Whenever the machine is switched on or woken from power save mode, the machine initialises and
performs calibration routines. During these routines, the Scan Carriage Assembly is parked in the Home
position and the Exposure Lamp is turned on for a pre-determined interval. This is to ensure the lamp is
sufficiently warmed-up prior to calibration providing consistent results.
Once the Exposure Lamp is warm, the Calibrate Auto, Calibrate Black and Calibrate White routines are
completed. White strips at the front edge of the CVT Glass and Document Glass are used as a reference
during calibration.
Once the calibration routines are complete, a countdown timer is started at a pre-set duration. Once
the time duration has elapsed, the calibration routines are performed again. This process is repeated
until the machine is switched off or it enters power-save mode. The duration between calibration
routines will be dependent on the temperature of the Exposure Lamp.
Transportation
During transit, the Scan Carriage Assembly must be secured to prevent damage using the Transit
Screw. This can be fitted as shown in Figure 7. whenever the Scan Carriage Assembly is in the home
position.
1 Transit Screw
Registration Routines
Whenever the Scanner Module and/or the DADH is removed or replaced, it is essential that dc604 is
performed. This measures and adjusts paper registration using the four routines detailed below:
• Image Output Terminal Registration Side 1 - this sets the simplex lead and top edge registration.
• Image Output Terminal Registration Side 2 - this sets the duplex lead and top edge registration.
• Scanner Registration - this sets the Document Glass lead and top edge registration.
• DADH Registration - this sets the CVT lead edge and centre registration.
To ensure correct registration of the Scanner Module and the DADH, the Image Output Terminal (IOT)
must first be registered before the Image Input Terminal (IIT). The routines must be carried out as
directed by the Service Manual in the required order. DO NOT perform these routines out of sequence.
Work Projects 0
These work projects are provided to facilitate hands-on training in facilities where a machine is
available. If you are undertaking this course remotely, you may skip this section and continue to the
Module Quiz.
Sign Off 0
Ask your Instructor to sign off this work project. If you have any questions ask your Instructor now.
______________________________ Instructor
Module 6 Quiz 0
Complete the Module 6 Quiz below, indicating a correct answer by ticking the box. You may use the
machine (if available) or any of the documentation to assist with your answers.
1. What W/TAG number indicates a machine is fitted with a colour Scanner Module?
004
046
148
150
151
Module Summary 3
In this module, you have been made aware of the location of the Scanner Module components, their
purpose and how they are sequenced to scan and expose a document. You have also been made aware
of the different types of Scanner Module and when they are fitted.
Review the objectives at the beginning of the module. If you do not feel comfortable with your
ability to perform any objective, review the materials for that objective. If you are in a training
facility, then discuss the information with your Instructor.
If you are comfortable with your understanding of the information presented, proceed to the next
module.
If you are in a training facility, have your Instructor sign off Module 6.
______________________________ Instructor
Module Objectives 0
On completion of this module, you will be able to identify and describe the DADH components and
detail how they are sequenced during simplex and duplex copy jobs.
DADH Overview 0
The DADH will handle a maximum of 100 sheets (80 gsm) mixed originals up to A3 or 11 x 17” SEF
with paper weights between 50 and 160 gsm. The DADH transports documents over the CVT Glass
during scanning for both simplex and duplex copy jobs. During duplex copy jobs, the DADH performs
an additional inversion operation / re-stack operation. This allows side 2 of the document to be
scanned and the document to be re-stacked in its original orientation.
NOTE: The DADH fitted to the WorkCentre 5735 has a maximum capacity of 75 sheets.
Document Sensing 0
When documents are placed into the Input Tray, the User adjusts the Document Guides to match the
width of the documents. The Document Guides are connected to the Document Width Sensor which is
a variable linear potentiometer. This provides an output to the IOT PWB which is used to determine the
width of common document sizes.
The document length can be determined in static or dynamic conditions. The DADH utilises two
Document Length Sensors to determine document length in the static condition: these are DADH
Length Sensor 1 and DADH Length Sensor 2. Both are a reflective type and are mounted on the right
hand side of the Input Tray.
The presence of documents in the Input Tray is monitored by the Document Present Sensor.
If the document length cannot be determined using the DADH Length Sensors, dynamic length sensing
is used.
Dynamic length sensing is achieved by checking if the Post Feed Sensor is actuated as the first
document passes the Registration Sensor. If actuated, then A4 or 8.5 x 11” size is indicated. If the Post
Feed Sensor is not actuated then A5 or 5.5 x 8.5” size is indicated. This type of document sensing is
used to determine the difference between 8.5 x 11” SEF and A5/8.5 x 5.5” LEF documents.
Dynamic length detection is also used to ensure documents meet the minimum feed length. If the
documents are below 110 mm long, a fault is declared and the user is advised to copy documents using
the Document Glass.
Jam Clearance 0
Raising the Top Cover provides access for jam clearance for the upper paper path of the DADH
including the feed and takeaway regions as shown in Figure 3.
Jam clearance access is also provided at the underside of the DADH as shown in Figure 4. for clearing
jams in the CVT Roll and Duplex Gate regions. This can be accessed by raising the DADH and lowering
the Document Pad.
1 Document Pad
Two interlocks protect the DADH when the machine is powered. These are:
• Top Cover Interlock Switch - this isolates all +24V supplies whenever the Top Cover is opened.
• DADH Closed Switch - this prevents the DADH operating when open. The switch is mounted in the
Scanner Module and is actuated by a magnet in the DADH.
1 DADH PWB
Feed Assembly 0
The Feed Assembly uses a Feed, Nudger and Retard Roll to feed documents from the Input Tray into
the DADH paper path. These rolls are packaged as a Customer Replaceable Unit (CRU) for easy
replacement by the User.
The Feed and Nudger Rolls are driven by the Feed Motor via the Feed Clutch. The Feed Motor also
provides drive for the Takeaway Roll and the Exit Roll.
A Nudger Motor, when energised, simultaneously lowers the Nudger Roll onto the top of the document
stack while raising the Input Gates to allows documents to be fed. The Input Gates remain in the raised
position until all documents have been fed. At this point, the Nudger Motor is de-energised, raising the
Nudger Roll and lowering the Input Gates.
Figure 8., Figure 9. and Figure 10. show the feed components.
1 Retard Roll
The action of the Nudger Roll is to feed the top document of the stack into the nip between the Feed
and Retard Rolls. The Retard Roll is a semi-active type, featuring a stationary inner wrap spring
connected to an outer friction material. During feed, the Retard Roll is rotated by the Feed Roll due to
friction. Eventually, the wrap spring torque is exceeded and the Retard Roll will overrun in the Feed
Direction.
If two sheets are fed simultaneously, the low levels of friction between sheets allow the Retard Roll to
rotate in the reverse direction driven by the torque of the wrap spring. This action drives the unwanted
sheet back into the document stack.
Document feed skew is controlled by correctly positioned Document Guides. Additional skew correction
is achieved by driving the sheet into the Takeaway Roll, which rotates at a slower speed. This difference
in speed causes the lead edge of the sheet to momentarily buckle, correcting any skew.
Sheets exiting the Takeaway Roll are transported toward, over and away from the CVT Glass by the CVT
Roll in conjunction with three idler rolls as shown in Figure 12. and Figure 13. These are:
• CVT Idler Roll - located on the upper left hand side of the CVT Roll, immediately after the
Takeaway Roll.
• Pre-Scan Idler Roll - located on the lower left hand side of the CVT Roll, immediately before the
CVT Glass.
• Post Scan Idler Roll - located on the lower right hand side of the CVT Roll, immediately after the
CVT Glass.
At all times while the sheet is fed over the CVT Glass, it will remain in contact with at least two of the
Idler Rolls. This ensures the sheet is not de-skewed during feeding.
Three sensors, shown in Figure 14. and Figure 15. monitor the sheet during post feed transportation.
These are:
• Takeaway Sensor - this sensor, when actuated, causes the Feed Clutch to be de-energised between
feeds.
• CVT Sensor - this sensor is used to provide timing information to maintain a suitable inter-sheet
gap during feeding.
• Registration Sensor - this sensor is used to start a scan of the document as it passes over the CVT
Glass.
All three sensors also provide jam clearance information for their respective areas.
1 Registration Sensor
After sheets have exited the Post Scan Idler Roll they are transported under the passive Duplex Gate
and into the Output Tray by the Exit Roll. As sheets are outputted, they are monitored by the Exit
Sensor.
Alternatively, follow the link below to access this content, and then return to this Workbook.
http://xerox.ravnur.com/video/2402/DADH-Simplex.aspx
Duplex Mode
Duplex Mode is used to scan the second side of a document. After the first side of a document has
been scanned as described in the previous sections, the sheet passes the Exit Sensor causing the Feed
Motor to stop. The Feed Motor is energised in the reverse direction to drive sheets over the passive
Diverter Gate, back into the paper path.
As the lead edge of the sheet enters the paper path, the CVT Sensor is actuated. This signals causes the
Duplex Solenoid to be energised opening the nip between the Exit Roll and its idler. This nip must open
momentarily to allow sheets to be fed by the CVT Roll, which rotates faster than the Exit Roll.Once the
sheet has been scanned, the Diverter Solenoid is de-energised and the Feed Motor is energised in the
forward direction.
Sheets are passed through the duplex paper path a second time WITHOUT scanning to invert the
sheet to its original orientation.
The duplex paper path components are shown in Figure 17. and Figure 18.
1 Diverter Gate
Alternatively, follow the link below to access this content, and then return to this Workbook.
http://xerox.ravnur.com/video/2226/DADH-Duplex.aspx
Work Projects 0
These work projects are provided to facilitate hands-on training in facilities where a machine is
available. If you are undertaking this course remotely, you may skip this section and continue to the
Module Quiz.
Sign Off 0
Ask your Instructor to sign off this work project. If you have any questions ask your Instructor now.
______________________________ Instructor
Module 7 Quiz 0
Complete the Module 7 Quiz below, indicating a correct answer by ticking the box. You may use the
machine (if available) or any of the documentation to assist with your answers.
The action of the ________ is to feed the top document of the stack into the nip between the Feed and
Retard Rolls.
Nudger Roll
Feed Roll
Retard roll
Module Summary 3
In this module, you have been made aware of the location of the DADH components, their purpose and
how they are sequenced to sense, size and scan a document.
Review the objectives at the beginning of the module. If you do not feel comfortable with your
ability to perform any objective, review the materials for that objective. If you are in a training
facility, then discuss the information with your Instructor.
If you are comfortable with your understanding of the information presented, proceed to the next
module.
If you are in a training facility, have your Instructor sign off Module 7.
______________________________ Instructor
Module Objectives 0
On completion of this module, you will be able to identify and describe how the Xerographic process
components and assemblies differ to the WorkCentre 58xx.
Technical Overview 0
The Xerographic process components and assemblies remain virtually unchanged from the WorkCentre
58xx in terms of fit, form and function. Minor differences are described in the following section relating
to product specific toner and configurations relating to machine speed.
Differences
Toner Save 0
The Toner Save feature on the WorkCentre 58xx is not available on the WorkCentre 57xx.
Magnetic Seal 0
All WorkCentre 58xx machines have a magnetic strip on the Developer Module to attract small
amounts of toner particles to form a seal. On the WorkCentre 57xx, this is only fitted to the ‘C’ speed
machines.
Toner 0
The toner used in the WorkCentre 57xx is not as fine as the MRC Toner used in the WorkCentre 58xx.
This produces a difference in image quality. The Toner Cartridges are product specific and are NOT
interchangeable.
Module 8 Quiz 0
Complete the Module 8 Quiz below, indicating a correct answer by ticking the box. You may use the
machine (if available) or any of the documentation to assist with your answers.
2. On the WorkCentre 57xx, what speed machines feature the magnetic strip on the Developer Module?
A
B
C
Module Summary 2
In this module, you have been made aware of the differences in the Xerographic process components
and assemblies.
Review the objectives at the beginning of the module. If you do not feel comfortable with your
ability to perform any objective, review the materials for that objective. If you are in a training
facility, then discuss the information with your Instructor.
If you are in a training facility, have your Instructor sign off Module 8.
______________________________ Instructor
Course Assessment 2
Congratulations, you have now completed the . Now access Learning @ Xerox and click the assessment
link to complete the Course Assessment. The course code is WC57XTB.
Module 2 0
1. What types of machine are classified as B speed configurations?
5735
5740
5745
5755
5765
5775
5790
50 sheets
75 sheets
100 sheets
125 sheets
OCT
1KLCSS
2KLCSS
LVF-BM
HCSS
HCSS-BM
HVF
HVF-BM
Tri-Folder
PPI
Module 3 3
1. Under what circumstances should SCP 2 be used?
2. What fault and service code format is used on the WorkCentre 57xx family of machine?
XXX-YYY-ZZ
XXX-YYY
X-YYY
XX-YYY
IQ1
IQ5
IQ6
IQ13
Module 4 3
1. Which of the following sends the power on signal to the LVPS once the 3.3 VDC SB voltage is
grounded?
On/Off Switch
IOT PWB
The Riser PWB provides additional PCI slots for connecting the _________.
FDI PWB
Memory Module
Software Module
3. What should be used to connect the PWS to the machine while performing an Altboot?
Serial Cable
USB Cable
Module 5 3
1. What W/TAG number indicates a machine is fitted with FAR Paper Feed Assemblies?
004
046
148
151
154
The position of the Feed Roll in a W/O TAG 151 Paper Feed Assembly is controlled by the _________.
Housing
Lever
Feed Motor
Feed Roll
Transport Roll
Takeaway Roll
Pre-registration Roll
Module 6 3
1. What W/TAG number indicates a machine is fitted with a colour Scanner Module?
004
046
148
150
151
Scanner PWB
SBC PWB
CCD PWB
True
False
Module 7 3
1. How is the size of documents in the DADH detected?
Using DADH Length Sensors, setting of Document Guides and active length sensing
Takeaway Sensor
CVT Sensor
Registration Sensor
Exit Sensor
Feed Sensor
The action of the ________ is to feed the top document of the stack into the nip between the Feed and
Retard Rolls.
Nudger Roll
Feed Roll
Retard roll
Module 8 3
1. Is the Toner Save feature available on the WorkCentre 57xx?
Yes
No
2. On the WorkCentre 57xx, what speed machines feature the magnetic strip on the Developer Module?