Xerox 4118 Service manual

Name: Xerox 4118
Brand: Xerox
SKU: 5055066
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Product

WorkCentre M20, 4118 Family

Title

Service Manual

Part Number

708P88419

Supersedes

708P87563

Date

April 2006

Service Manual binder inserts

Front pocket insert

Spine insert

Xerox

WorkCentre

M20, 4118 Family

Service Manual

Xerox

WorkCentre M20, 4118 Family

Service Manual

April 2006

Xerox WorkCentre M20, 4118 Family

Service Manual

WorkCentre M20, 4118 Family

Service Documentation

WorkCentre M20, 4118 Service Manual

708P88419

April 2006

Prepared by:

The Document Company, Xerox

Global Knowledge & Language Services

Enterprise Centre

P.O. Box 17

Bessemer Road

Welwyn Garden City

Hertfordshire AL7 1BU

England.

***Xerox Private Data***

All service documentation is supplied to Xerox external customers for informational purposes

only. Xerox service documentation is intended for use by certified, product trained service per-

sonnel only. Xerox does not warrant or represent that it will notify or provide to such customer

any future change to this documentation. Customer performed service of equipment, or modules,

components or parts of such equipment may affect whether Xerox is responsible to fix machine

defects under 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.

While every care has been taken in the preparation of this manual, no liability will be accepted by

Xerox Europe arising out of any inaccuracies or omissions.

Xerox Europe, Xerox ® and all identifying numbers used in connection with the Xerox products

mentioned in this publication are trademarks of Xerox. Other company trademarks are also

acknowledged.

Printed in the United Kingdom.

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Revision Control List

Product:

WorkCentre M20, 4118

Family

Title:

Service Manual

Part Number:

708P88419

Revision:

April 2006

Documentation compatible with this revision.

EDOC (Compact Disc) . . . . . . . . . . . . . . . . . . . . . . . . . . 708P88418

PDF on CD-Rom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708P88420

EDOC Supplement (hard copy wiring diagrams) . . . . . . 708P88421

April 2006

WorkCentre M20, 4118 Family

Introduction

About This Manual ............................................. .... .... .... ........... .... .... .... ......... .... .... .... ..... iii

Change History ............................................................................................................... iv

Warnings, Cautions And Notes....................................................................................... v

Safety Precautions........................................................................ ................... ............... vi

Health and Safety Incident reporting............................................................................... vii

Translation of Warnings .................................................................................................. viii

April 2006

WorkCentre M20, 4118 Family

Introduction

April 2006

iii

WorkCentre M20, 4118 Family

About This Manual

Introduction

About This Manual

This manual is part of a multinational service documentation system that is structured in the

standard Xerox service manual format.

This manual is based on a Korean original. The part names used throughout do not comply

with the standard Xerox part naming convention. Because part names have been molded on to

some plastic components and may also be embedded in the software, the part names have not

been changed.

To aid part identification, an acronym list and cross reference lists of more commonly recogn-

ised part names have been included in the manual. Refer to GP 20, Acronyms and Parts

Description List.

Organization

The service manual is the document used as the primary information source for repairing and

maintaining this family of products and is available as EDOC on a CDROM, or in printed for-

mat. The information within the manual is divided into an introduction and eight other sections.

Section 1 Service Call Procedures

This section is used to start and complete a service call. The procedures in this section will

either direct you to a Repair Analysis Procedure (RAP), or identify a faulty component or sub-

assembly.

Section 2 Status Indicator Repair Analysis Procedures

This section contains the Repair Analysis Procedures (RAPs) and checkouts necessary to

diagnose, isolate and repair faults other than image quality faults.

Section 3 Image Quality

This section contains the Image Quality Repair Analysis Procedures (IQ RAPs), checkouts and

setup procedures necessary to diagnose, isolate and repair image quality faults.

Section 4 Repairs/Adjustments

This section contains the instructions for removal, replacement, and adjus tm ent of parts within

the machine.

Section 5 Parts List

This section contains the detailed and illustrated spare parts list. Any part that is spared or that

must be removed to access a spared part is illustrated.

Section 6 General Procedures / Information

This section contains all other procedures, product specifications and general information.

Section 7 Wiring Data

This section contains the wiring diagrams.

Section 8 Accessories

This section contains details of any accessories that the machine may have.

Publication Comments Sheet

A Publication Comment Sheet is provided at the rear of the hardcopy manual.

April 2006

WorkCentre M20, 4118 Family

Introduction

Change History

These are the changes made to this issue of the service documentation.

The WorkCentre 4118P and WorkCentre 4118X have been introduced. These are variations of

the WorkCentre M20. Throughout this manual, procedures and parts that are unique to either

the WorkCentre M20 family or the WorkCentre 4118 family will be designated M20F or 4118.

This issue of the service manual was updated at a time when the introduction of RoHS

(Restriction of Hazardous Substances) compliant parts was initiated. Due to these factors,

extensive changes have occurred to the part numbering within the parts lists.

The following procedures are updated

• SCP 7 Machine Configurations and Options.

• 1.1 Power Failure RAP

• 5.1 Load Document RAP

• 5.2 Document Jam RAP

• 6.1 LSU Error RAP

• 8.1 Door Open RAP

• 8.2 Bypass Lam RAP

• 8.3 Duplex Jam RAP

• 8.4 Paper Jam 0 Open/Close Door RAP

• 8.5 Paper Jam 1 Open/Close Door RAP

• 8.6 Paper Jam 2 Check Inside RAP

• 8.7 No Paper Add Paper RAP

• 9.1 Install Cartridge RAP

• 9.2 Non-Xerox Toner Cartridge RAP

• 9.4 Replace Drum RAP

• 9.5 Toner Empty RAP

• 10.1 Low Heat Error RAP

• 10.2 Open Heat Error RAP

• 10.3 Over Heat Error RAP

• 20.1 Fax Error Messages RAP

• 20.3 Fax Faults Without a Message RAP

• OF3 Use Auxiliary Access RAP

• OF4 Audible Noise RAP

• IQ1 Blank Copies RAP

• IQ2 Black Copies From the Scanner RAP

• IQ3 Blurred Image From the Scanner RAP

• IQ4 Vertical Black Lines or Bands RAP

• IQ6 Light Image RAP

• IQ7 Dark Image RAP

• IQ8 Background RAP

• IQ9 Ghost Images RAP

• IQ11 Poor Fusing RAP

• IQ14 Different Image Density (Left and Right) RAP

• IQ15 Horizontal Bands RAP

• IQ16 Periodic Printing Defects RAP

• REP 1.2 PBA Main (M20F)

• REP 2.1 ELA HOU OPE Assembly (M20F)

• REP 4.1 ELA HOU - Drive Assembly

• GP 1 Engine Test Mode Entry

• GP 2 User Mode Entry

• GP 3 Service Mode Entry

• GP 5 Memory Clear

• GP 6 Maintenance

• GP 7 Reports

• GP 11 Machine Specifications

• GP 12 Circuit Description

• GP 13 Circuit Operation

• GP 15 Host Interface

• GP 20 Acronyms and Parts Description List

• GP 21 DADF/ADF Document Feeding Specifications

• Wiring Diagram 1 (M20F)

• Wiring Diagram 2 (M20F)

• Wiring Diagram 3 (M20F)

• Wiring Diagram 4 (M20F)

• Wiring Diagram 5 (M20F)

• Wiring Diagram 6

The following procedures are new.

• IQ17 Print Damage RAP

• IQ18 DADF Lead Edge Offset RAP (M20F)

• IQ19 Poor Side Edge Registration RAP

• IQ20 Spots or Marks RAP

• REP 1.3 PBA Main (4118)

• REP 1.4 SMPS (4118)

• REP 1.5 SMPS (4118)

• REP 2.2 ELA HOU OPE Assembly (4118)

• REP 5.2 ELA HOU - ADF (4118)

• ADJ 5.1 DADF Side Edge Registration Adjustment (M20F)

• ADJ 5.2 ADF Side Edge Registration Adjustment (4118)

• GP 24 ADF Test (4118)

• Wiring Diagram 7 (4118)

• Wiring Diagram 8 (4118)

• Wiring Diagram 9 (4118)

• Wiring Diagram 10 (4118)

• Wiring Diagram 11 (4118)

• Wiring Diagram 12 (4118)

April 2006

WorkCentre M20, 4118 Family

Warnings, Cautions And Notes

Introduction

• PWB Connector Locations

• Change Tags

• ACC 2 Foreign Device Interface Installation

The following bulletins, ETI and TIPs are included.

• ETI 189796 C20 techmode flowchart

• ETI 208283 Faint or blank copies / DADF pause 10 sec. before feeding

• ETI 208756 Paper jam 2 message

• ETI 208972 Paper jam 0 paper does not feed from tray

• ETI 214834 Noise and toner spill

• ETI 234008 Duplex jams and grinding noise

• ETI 240382 Tray 2 module will not feed paper

• ETI 243009 Side edge registration adjustment from DADF only

• ETI 260720 DADF lead edge offset

• ETI 284873 Copy output ‘indentation’ damage

• ETI 285328 Dead machine F1 blown

• ETI 322931 Noise that is hard to pin down / noisy ROS (LSU)

• ETI 332890 Bands or streaks across copies / Internal prints OK

Warnings, Cautions And Notes

A translated version of all warnings is in Translation of Warnings.

WARNING

A warning is used whenever an operating or main tenance procedure, practice, condi-

tion or statement, if not strictly observed, could result in personal injury.

CAUTION

A caution is used whenever an operation or maintenance procedure, practice, condition or

statement, if not strictly observed, could result in damage to the equipment.

NOTE: A note is used where it is essential to highlight a procedure, practice, condition or state-

ment.

The following are examples of the symbols that are used in this m anual for an electrostatic

damage caution and laser radiation warning.

ESD caution symbol

CAUTION

Certain components in this product are susceptible to damage from electr ostatic discharge.

Observe all ESD procedures to avoid component damage.

Laser radiation warning symbol.

WARNING

Follow the service procedure exactly as written. Use of controls or adjustments other

than those specified in this manual, may result in an exposure to invisible laser radia-

tion. During servicing, the invisible laser radiation can cause eye damage if looked at

directly.

April 2006

WorkCentre M20, 4118 Family

Safety Precautions

Introduction

Safety Precautions

Follow these safety, ESD, and servicing precautions to prevent personal injury and equipment

damage.

1. Ensure that all built in protective devices are in place. Restore any missing protect ive

shields.

2. Make sure there are no cabinet openings through which people, particularly children,

might insert fingers or objects and contact dangerous voltages.

3. When re-installing chassis and assemblies, be sure to restore all protective devices,

including control knobs and compartment covers.

4. Design alteration warning; never alter or add to the mechanical or electrical design of this

equipment, such as auxiliary connectors, etc. Such alterations and modifications will void

the manufacturers warranty.

5. Components, parts, and wiring that appear to have overheated or are otherwise damaged

should be replaced with parts which meet the original specifications. Always determine

the cause of damage or overheating, and correct any potential hazards.

6. Observe the original harness routing, especially near sharp edges, AC, and high voltage

power supplies. Always inspect for pinched, out of place, or frayed wiring. Do not change

the spacing between components and the printed circuit board.

7. Product safety notice; some electrical and mecha nical parts have special safety related

characteristics which might not be obvious from visual inspection. These safety features

and the protection they provide could be lost if a replacement component differs from the

original. This holds true, even though the replacement may be rated for higher voltage,

wattage, etc.

8. Use only replacement components that have the same ratings, especially for flame resis-

tance and dielectric specifications. A replacement part that does not have the same safety

characteristics as the original may create shock, fire, or other safety hazards.

ESD Precautions

1. Certain semiconductor devices can be easily damaged by static electricity. Such compo-

nents are commonly called ‘Electrostatically Sensitive (ES) Devices’, or ESDs. Examples

of typical ESDs are: integrated circuits, some field effect transistors, and semiconductor

‘chip’ components.

The techniques outlined below should be followed to help reduce the incidence of compo-

nent damage caused by static electricity.

CAUTION

Ensure no power is applied to the chassis or circuit, and observe all other safety precautions.

2. Immediately before handling a semiconductor component or semiconductor equipped

assembly, discharge any electrostatic charge on your body by touching a known earth

ground. Alternatively, employ a commercially available wrist strap device, which should

be removed for your personal safety reasons prior to applying power to the unit under

test.

3. After removing an electrical assembly equipped with ESDs, place the assembly on a con-

ductive surface, such as aluminum or copper foil, or conductive foam , to prev ent electro-

static charge buildup in the vicinity of the assembly.

4. Use only a grounded tip soldering iron to solder or desolder ESDs.

Use only an ‘antistatic’ solder removal device. Some solder removal devices not classified

as ‘antistatic’ can generate electrical charges sufficient to damage ESDs.

5. Do not use freon propelled chemicals. When sprayed, these can generate electrical

charges sufficient to damage ESDs.

6. Do not remove a replacement ESD from its protective packaging until immediately before

installing it. Most replacement ESDs are packaged with all leads shorted together by con-

ductive foam, aluminum foil, or a comparable conductive material.

7. Immediately before removing the protective shorting material from the leads of a replace-

ment ESD, touch the protective material to the chassis or circ uit assemb ly into which the

device will be installed.

8. Maintain continuous electrical contact between the ESD and the assembly into which it

will be installed, until completely plugged or soldered into the circuit.

9. Minimize body motion when handling unpacked replacement ESDs. Normal motions,

such as the brushing together of clothing fabric and lifting a foot from a carpeted floor , can

generate static electricity sufficient to damage an ESD.

Lithium Battery Precautions

1. Exercise caution when replacing a lithium battery. There could be a danger of explosion

and subsequent operator injury and/or equipment damage if incorrectly installed.

2. Be sure to replace the battery with the same or equivalent type recommended by the

manufacturer.

3. Lithium batteries contain toxic substances and should not be opened, crushed, or burned

for disposal.

4. Dispose of used batteries according to the manufacture’s instructions.

April 2006

vii

WorkCentre M20, 4118 Family

Health and Safety Incident reporting

Introduction

Health and Safety Incident reporting

I. Summary

This section defines requirements for notification of health and safety incidents involving Xerox

products (equipment and materials) at customer locations.

II. Scope

Xerox Corporation and subsidiaries worldwide.

III. Objective

To enable prompt resolution of health and safety incidents involving Xerox products and to

ensure Xerox regulatory compliance.

IV. Definitions

Incident:

An event or condition occurring in a customer accoun t that has resulted in injury, illness or

property damage. Examples of incidents include machine fires, sm oke generation, physical

injury to an operator or service representative. Alleged events and product conditions are

included in this definition.

V. Requirements

Initial Report:

1. Xerox organisations shall establish a process for individuals to report product incidents to

Xerox Environment Health & Safety within 24 hours of becoming aware of the event.

2. The information to be provided at the time of reporting is contained in Appendix A (Health

and Safety Incident Report involving a Xerox product).

3. The initial notification may be made by any of the following methods:

• For incidents in North America and Developing Markets West (Brazil, Mexico, Latin

American North and Latin American South):

– Phone* Xerox EH&S at: 1-800-828-6571.

– Electronic mail Xerox EH&S at: Doris.Bush@xerox.com.

– Fax Xerox EH&S at: 1-585-422-6449 [intelnet 8*222 6449].

• For incidents in Europe and Developing Markets East (Middle East, Af rica, India,

China and Hong Kong):

– Phone* Xerox EH&S at: +44 (0) 1707 353434.

– Electronic mail Xerox EH&S at: Elaine.Grange@xerox.com .

– Fax Xerox EH&S at: +44 (0) 1707 353914 [intelnet 8*668 3914].

*Initial notification made by phone must be followed within 24 hours by a completed inci-

dent report and sent to the indicated electronic mail address or fax number.

NOTE: If sending a fax, please also send the original via internal mail.

Responsibilities for resolution:

1. Business Groups/Product Design Teams responsible for the product involved in the inci-

dent shall:

a. Manage field bulletins, customer correspondence, product recalls, safety retrofits.

b. Fund all field retrofits.

2. Field Service Operations shall:

a. Preserve the Xerox product involved and the scene of the incident inclusive of any

associated equipment located in the vicinity of the incident.

b. Return any affected equipment/part(s) to the location designated by Xerox EH&S

and/or the Business Division.

c. Implement all safety retrofits.

3. Xerox EH&S shall:

a. Manage and report all incident investigation activities.

b. Review and approve proposed product corrective actions and retrofits, if necessary.

c. Manage all communications and correspondence with government agencies.

d. Define actions to correct confirmed incidents.

VI. Appendices

The Health and Safety Incident Report involving a Xerox Product (Form # EH&S-700) is avail-

able in the following locations:

• On electronic documentation (EDOC), located in the folder \safety.

• In the hardcopy, located at the end of the manual.

April 2006

viii

WorkCentre M20, 4118 Family

Translation of Warnings

Introduction

Translation of Warnings

Introduction

Warnings, Cautions And Notes

WARNING

A warning is used whenever an operating or maintena nce procedure, practice, condi-

tion or statement, if not strictly observed, could result in personal injury.

DANGER: Une note Danger est utilisée chaque fois qu'une procédure d'utilisation ou de

maintenance peut être cause de blessure si elle n'est pas strictement respectée.

AVVERTENZA: Un segnale di avvertenza è utilizzato ogni volta che una procedura oper-

ativa o di manutenzione, una pratica, una condizione o un'istruzione, se non stretta-

mente osservata, potrebbe causare lesioni personali.

VORSICHT: Weist darauf hin, dass ein Abweichen von den angeführten Arbeits- und

Wartungsanweisungen gesundheitliche Schäden, möglicherweise sogar schwere Ver-

letzungen zur Folge haben kann.

AVISO:Un aviso se uti liza siempre que un procedimiento de operación o mantenimiento,

práctica o condición puede causar daños personales si no se respetan estrictamente.

WARNING

Follow the service procedure exactly as written. Use of controls or adjustments other

than those specified in this manual, may result in an exposure to invisible laser radia-

tion. During servicing, the invisible laser radiation can cause eye damage if looked at

directly.

DANGER : Les procédures de dépannage doivent être suivies à la lettre. Si les réglages

ou vérifications ne sont pas effectués suivant les instructions de ce manuel, il peut y

avoir un risque d'exposition dangereuse au faisceau laser. Celui-ci peut provoquer des

lésions oculaires s'il est observé directement.

AVVERTENZA: Eseguire le procedure di servizio esattamente come descritto. L'utilizzo

di dispositivi di controllo o di registrazione diversi da quelli riportati in questo manuale

potrebbe comportare un'esposizione a radiazioni laser invisibili. Tali radiazioni possono

danneggiare gli occhi se si guarda direttamente il fascio laser durante gli interventi di

servizio.

VORSICHT: Die Wartungsarbeiten genau den Anweisungen entsprechend durchführen.

Der Umgang mit Steuer- oder Bedienelementen, deren Verwendung nicht ausdrücklich

in diesem Handbuch angewiesen wurde, kann dazu führen, dass unsichtbare Laser-

strahlung frei gesetzt wird. Direkter Blickkontakt mit dem Laserstrahl kann bleibende

Augenschäden verursachen.

AVISO: Siga los procedimientos de mantenimiento tal como están descritos. El uso de

controles o ajustes no especificados en este manual puede tener como resultado la

exposición a radiación láser invisible. Durante las operaciones de mantenimiento, la

radiación de láser invisible puede causar daños en los ojos si se mira directamente a

ella.

1 Service Call Procedures

SCP 1 Initial Actions

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the cus-

tomer’s supply while performing tasks that do not need electricity. Electricity can cause

death or injury. Moving parts can cause injury.

DANGER : Couper l'alimentation électrique de la machine. Déconnecter le cordon d'ali-

mentation de la prise pendant les activités de dépannage ne nécessitant pas d'aliment a-

tion électrique. L'électricité peut entraîner des blessures graves voire mortelles. Les

pièces mobiles peuvent également présenter un danger.

AVVERTENZA: Spegnere la macchina. Scollegare il cavo elettrico dalla presa durante gli

interventi che non richiedono elettric ità. L'elettricità può ca us a r e infortuni o morte e azi-

onare parti della macchina che possono causare lesioni personali.

VORSICHT: Gerät ausschalten. Bei Wartungsarbeiten, die keine Stromzufuhr erfordern,

Netzstecker ziehen! Bei Kontakt mit der Netzspannung besteht Verletzungs- und Leb-

ensgefahr. Bei beweglichen Teilen besteht Verletzungsgefahr.

AVISO: Ap ague la máquina. Desconecte el cable de alimentación de la toma de corriente

mientras efectúa tareas que no necesitan energía eléctrica. La electricidad puede

causar lesiones e incluso la muerte. Las piezas móviles pueden causar lesiones.

WARNING

Do not work in a confined space. 1m (39 inches) space is needed for safe working.

DANGER : Ne pas travailler dans un espace restreint. 1 mètre d'espace est nécessaire

pour un dépannage en toute sécurité.

AVVERTENZA: Non lavorare in uno spazio limitato; è necessario uno spazio di almeno

un metro attorno alla macch ina per la sicurezza dell'operatore .

VORSICHT: Nur mit ausreichendem Bewegungsspielraum (1 m) arbeiten.

AVISO: No trabaje en un espacio reducido. Se necesita 1 metro de espacio para trabajar

con seguridad.

SCP 5 Subsystem Maintenance