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.
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 perÂsonnel 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 modÂules, 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.
About This Manual .............................................................................. ......... .... .... .... .......iii
How To Use This Manual................................................................................................iii
Change History ...............................................................................................................iv
Service Safety Summary...... .......................... ......................... ......................... ...............v
Symbols Used on the Product.........................................................................................vii
Voltage Measurement and Specifications.......................................................................viii
Health and Safety Incident Reporting .............................................................................viii
Translation of Warnings..................................................................................................x
Technical Support Information ................................................................... .... .... .. .... .. .....xiii
Introduction
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Introduction
Introduction
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About This Manual
The Phaser 6510 Printer (SFP) and WorkCentre 6515 Multifunction Printer (MFP) Service
Manual is part of a multinational service documentation system delivered in the standard Xerox
EDOC service manual format. This manual is the primary document used for diagnosing,
repairing, maintaining, and troubleshooting these systems. The Service Manual is the control
ling publication for a service call. To ensure product understanding, complete the Xerox SerÂvice Training Program for this printer.
How To Use This Manual
Always start with the Service Call Procedures, Section 1. Perform Initial Actions and verify the
problem, then follow the directions given.
-
How to Differentiate Between Machine Variants
The machines will be identified in this manual by the model identifier 6510N/DN/DNI or 6515N/
DN/DNI.
Organization
Section titles and the information contained in each is presented in the following paragraphs:
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 adjustment of parts.
Section 5 Parts List
This section contains the 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.
When a procedure, parts list description or other reference is unique amongst different models
of machine, the appropriate model designator is indicated. Any artwork is also specific. The
Phaser 6510 and WorkCentre 6515 models may also be referred to as SFP and MFP respec
tively.
NOTE: This manual services all configurations of the machine. Ignore references to options
-
not installed on the machine.
Warnings, Cautions and Notes
WARNING
A warning is used whenever an operating or main tenance procedure, practice, condiÂtion or statement, if not strictly observed, could result in personal injury.
A translated version of all warnings is in Tr anslation of Warnings.
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 appears to highlight a procedure, practice, condition or statement.
Service Acronyms
While using this service documentation, you may encounter acronyms that are unfamiliar.
To find definitions for Xerox acronyms, go to the following page in your web browser, then enter
the acronym and click Search:
https://open.xerox.com/Services/acronym
-
Section 8 Principles of Operation
This section contains details of printer operation and component locations.
Component Names
Names of parts that appear in the disassembly procedures may not be exactly the same as the
names that appear on the part or listed in the Parts List. For example; a part called the Regis
tration Chute Assembly may appear on the Parts List as Assembly, Chute REGI.
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iii
Introduction
About This Manual, How To Use This Manual
Change History
This page gives information on major changes to the service manual. Go to the relevant
update.
•BUS Update June 2018
•BUS Update July 2019
•BUS Update July 2020
BUS Update June 2018
The following procedures are updated:
•SCP 7 Configurations and Options
•024-933, 940, 941 Drum Cartridge Y Life End RAP
•124-315, 317, 355 DC132 Error 02, 04 and 14 RAP
•REP 18.3 ESS PWB (MFP)
•REP 18.21 ESS PWB (SFP )
•GP 15 Special Boot Modes
•061-362 to 061-393 LPH Fault RAP
•PL 18.1 Electrical WC6515 (1/4)
•PL 1.1 UI (WC6515)
•PL 1.2 UI (P6510)
•PL 2.1 LPH
•PL 3.1 Drive
•PL 6.1 Transfer
•PL 7.1 Fuser
•PL 10.1 Option Feeder (1/3)
•PL 10.2 Option Feeder (2/3)
•PL 15.2 Registration (2/2)
•PL 18.5 Electrical P6510 (1/4)
•PL 19.2 Cover WC6515 (2/2)
•PL 19.4 Cover P6510 (2/2)
•PL 50.1 Scanner
Introduction
Change History
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Service Safety Summary
General Guidelines
For qualified service personnel only: Refer also to the section Electrical Safety.
Avoid servicing alone: Do not perform internal service or adjustment of this product unless
another person capable of rendering first aid or resuscitation is present.
WARNING
Take care, a hazardous voltage is present at the C inlet, LVPS PWB (PL 18.1 Item 16/PL
18.5 Item 16), and ESS MFP/ES S SFP PWBs (P L 18.1 Item 5/PL 18.5 Item 5). Electricity
can cause death or injury.
Use care when servicing with power applied: Dangerous voltages may exist at several points in
this product. To avoid personal injury, do not touch exposed connections and components
while power is on. Disconnect power before removing the power supply shield or replacing
components.
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and other metallic
objects could come into contact with dangerous voltages and currents.
Electrical Safety
•Use the Power Cord supplied with the printer.
•Plug the Power Cord directly into a properly grounded electrical outlet.
•Do not use a ground adapter plug to connect the printer to an electrical outlet that does
not have a ground connection terminal.
•Do not use an extension cord or power strip.
•Do not place the system in an area where people might step on the power cord.
•Do not place objects on the power cord.
•Do not block ventilation openings. These openings prevent printer overheating.
•Do not drop paper clips or staples into the printer.
Operational Safety
The printer and supplies were designed and tested to meet strict safety requirements. These
include safety agency examination, approval, and compliance with established environmental
standards.
•Do not use aerosol cleaners. The use of supplies that are not approved may cause poor
performance and could create a hazardous condition.
•Do not burn any consumables or routine maintenanc e items. For information on Xerox
supplies recycling programs, go to www.xerox.com/gwa.
Safety Labels
Read and obey all posted caution, warning, and danger labels. Throughout the printer, these
safety labels are displayed on potentially dangerous components. As you service the printer,
check to make certain that all safety labels remain in place.
•Caution: An unapparent hazard exists that may cause personal injury or damage to the
equipment. For example, a panel may cover the hazardous area.
•Warning: An unapparent hazard exists that may cause serious personal injury.
•Danger: An unapparent hazard exists that may cause serious personal injury or death.
Safety Interlocks
Use caution so that the safety devices for preventing accidents (interlocks switches, fuses,
thermostats, etc.) and the protective parts for users (covers, control panel, etc.) can function as
intended. Make sure all covers are in place and all interlock switches are functioning correctly
after you have completed a service call. If you bypass an interlock switch, use extreme caution
when working on or around the printer. Figure 1 and Figure 2 show the interl ock switch loca
tions and circuitry.
-
Pay attention to these safety guidelines to ensure the continued, safe operation of the printer.
•Use the supplies specifically designed for your system. The use of unsuitable materials
may cause poor performance and a possible safety hazard.
•Follow all warnings and instructions marked on, or supplied with, the system, options and
supplies.
NOTE: The Total Satisfaction Guarantee is available in the United States and Canada. CoverÂage may vary outside these areas; please contact your local representative for details.
Maintenance Safety
•Do not attempt maintenance not specifically described in the printer documentation.
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Figure 1 Safety Interlock Switch Locations
Introduction
v
Service Safety Summary
Drive Units
When servicing gears or other driving units, be sure to Switch off the machine, switch and
unplug the power cord. Drive them manually when required.
High-Temperature Units
When servicing high-temperature units (securing unit, etc.), be sure to turn them off to prevent
burns, injuries and other troubles. Remove the power plug and wait 40 minutes before starting
service processes so they have cooled down sufficiently.
Routing Wire Harnesses
Before starting the service operation, carefully check how the harness wires are routed. When
routing them, check that they are routed in the same way as they were before the servicing,
and that they are not pinched or do not interfere with the corners or edges of any operating
components.
Battery
A lithium battery is used on the ESS PWB.
WARNING
To avoid the possibility of fire or explosion, always replace the battery with the same
type, and dispose of old batteries as required by local regulations.
Figure 2 Safety System Schematic
Introduction
Service Safety Summary
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Symbols Used on the Product
The following precautionary symbols may appear on the machine.
Figure 1 indicates Danger High Voltage.
Figure 1 High Voltage symbol
Figure 2 is the Protective Ground (Earth) symbol.
Figure 2 Protective Ground (Earth) symbol
Figure 3 is the symbol indicating a hot surface. Use caution to avoid personal injury.
Figure 3 Hot Surface symbol
Figure 5 Pinch Injury symbol
Figure 6 is the symbol to use caution (or draws attention to a particular component). Refer to
the manual(s) for information.
Figure 6 Use Caution symbol
Figure 7 is the symbol indicating that the item is sensitive and should not be touched.
Figure 7 Do Not Touch symbol
Figure 8 is the symbol indicating the item is sensitive to sunlight, and exposure to it will reduce
its life span.
Figure 4 is the symbol indicating that the surface is hot while the printer is running. After turning
off the power, wait 30 minutes.
Figure 4 Wait 30 Minutes symbol
Figure 5 is the symbol indicating where to avoid pinching fingers in the printer. Use caution to
avoid personal injury.
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Figure 8 No Sunlight symbol
Figure 9 is the symbol indicating the item is sensitive to any light, and exposure to it will reduce
its life span.
Figure 9 No Light symbol
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Symbols Used on the Product
Introduction
Volt age Me as ureme n t and S pec if ica t ions
Table 1 shows the voltages present in the WorkCentre 6515. Measurements of DC voltage
must be made with reference to the specified DC Com mon, unless some other point is refer
enced in a diagnostic procedure. All measurements of AC voltage should be made with respect
to the adjacent return or ACN wire.
Table 1 Voltage Measurement and Specifications
VoltageSpecification
Input Power 220V198VAC to 254VAC
Input Power 100V 90VAC to 135VAC
Input Power 120V 90VAC to 135VAC
+5VDC+4.75VDC to +5.25VDC
+24VDC+23.37VDC to +27.06VDC
Logic Voltage Levels
Table 2 show the logic levels present in the WorkCentre 6515. Measurements of logic levels
must be made with reference to the specified DC Com mon, unless some other point is refer
enced in a diagnostic procedure.
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 acco unt that has resulted in injury, illness or
property damage. Examples of incidents include machine fires, smoke generation, physical
-
injury to an operator or service representative. Alleged events and product conditions are
included in this definition.
Table 2 Logic Levels
VoltageH/L Specification
+5VDCH = +3.00VDC or greater
L = below 0 .8VDC
+3.3VDCH = +2VDC or greater
L =below 0.8VDC
DC Voltage Measurement in RAPs
The RAPs have been designed so that when it is required to use the DMM to measure a DC
voltage, the first test point listed is the location for the red (+) meter lead and the second test
point is the location for the black meter lead. For example, the following statement may be
found in a RAP.
There is +5VDC from P/J7 to P/J68.
In this example, the red meter lead would be placed on P/J7 and the black lead on P/J68.
If a second test point is not given, it is assumed that the black meter lead may be attached to
chassis ground.
V. Requirements
Initial Report:
1.Xerox organizations 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:
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 inciÂdent 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.
Introduction
Voltage Measurement and Spec ifications, Health and
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d.Define actions to correct confirmed incidents.
VI. Appendices
The Health and Safety Incident Report involving a Xerox Product (Form # E H &S -700) is availÂable in the location that follows:
•GSN Library 1789
Regulatory Specifications
Xerox has tested this product to elec tromagnetic emission and immunity standards. These
standards are designed to mitigate interference caused or receiv ed by this product in a typical
office environment.
United States (FCC Regulations)
The WorkCentre 6515 has been tested and found to comply with the limits for a Class A digital
device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference in a commercial installation. This equipment generates,
uses, and can radiate radio frequency energy. If it is not installed and used in accordance with
these instructions, it may cause harmful interference to radio communications. Operation of
Class A equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his/her own expense. There is no guarantee
that interference will not occur in a particular installation.
If this equipment does cause harmful interference to radio or television reception, which can be
determined by turning the equipment Off and O n, the user is encou raged to try to correct the
interference by one or more of the following measures:
•Reorient or relocate the receiver.
•Increase the separation between the equipment and receiver.
•Connect the equipment to a different electrical circuit.
•Consult the dealer or an experienced radio/ television technician for help.
Any modifications not expressly approved by Xerox could void the user's authority to operate
the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interf ace
cables.
Canada (Regulations)
This Class A digital apparatus complies with Canadian ICES-003.
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la sortie de l'inverseur de la lampe d'exposition.
AVVERTENZA: fare attenzione alla carica elettrica di uscita dell'invertitore della lampada
di esposizione. L'el e ttricità può causare infor tuni o morte.
VORSICHT: Achtung: Spannung am Ausgang des Belichtungslampeninverters.
AVISO: Tenga cuidado; hay tensión peligrosa en la salida del inversor de la lámpara de
exposición. La electricidad puede causar lesiones e incluso la muerte.
WARNING
Isolate the machine from the electrical supply whi le performing tasks that do not need
electricity. Refer to GP 4. Electricity can cause death or injury. Moving parts can cause
injury.
AVVERTENZA: Isolare la macchina dall’alimentazione elettrica quando si eseguono
attività che non richiedono elettricità . Vedere GP 4. L’elettricità può causare morte o
lesioni personali. Le parti in movimento possono causare lesioni personali.
VORSICHT: Gerät bei Arbeiten, die keinen Strom erfordern, von der Stromversorgung
trennen. Andernfalls besteht Stromschlaggefahr und Verletzungsgefahr durch bew egli
che Teile. Siehe auch GP 4.
Regulatory Specifications, Translation of Warnings
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WARNING
Switch off the electricity to the machine. Refer to GP 4. Disconnect the power cord from
the customer supply while performing tasks that do not need electricity. Electricity can
cause death or injury. Moving parts can cause injury.
AVVERTENZA: Spegnere la macchina. Vedere GP 4. Scollegare il cavo di alimentazione
dall'alimentatore quando si eseguono attività che non richiedono elettricità . L'elettricitÃ
può causare morte o lesioni personali. Le parti in movimento possono causare lesioni
personali.
VORSICHT: Schalten Sie die Stromversorgung der Maschine ab. Siehe auch GP 4. Zie Âhen Sie das Stromkabel ab, wenn Sie Aufg aben ausführen, für die keine StromversorÂgung benötigt wird. Stromschläge können Todesfällen oder Verletzungen verursachen.
Bewegliche Teile können zu Verletzungen führen.
un metro attorno alla macchina 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.
WARNING
Perform the steps in the following procedure carefully. Failure to follow this procedure
carefully could result in electrical shock and personal injury.
AVVERTENZA: Si prega eseguire attentamente la seguente procedura. Omettere di
eseguire attentamente la procedura indicata può provocare forti scosse e gravi ferite.
VORSICHT: Befolgen Sie die Schritte der folgenden Anleitung genau. Die NichtbefolÂgung dieser Anweisungen kann elektrischen Schlag oder andere Körperverletzungen
zur Folge haben.
Use extreme care when working in the following area. Some of the components are elecÂtrically energized and could cause electrical shock and personal injury if touched.
AVVERTENZA: Maneggiare la seguente area con la massima precauzione. Alcuni comÂponenti sono carici di corrente elettrica e se toccati possono provocare scosse
elettriche e lesioni.
VORSICHT: Bei Arbeiten in folgenden Bereichen besondere Vorsicht walten lassen.
Einige der Komponenten sind elektrisch aufgeladen und können bei Berührung einen
Stromschlag und körperliche Verletzung verursachen
Use high voltage probes when testing high voltage. Electricity can cause death or injury.
DANGER: Utilisez des sondes haute tension lorsque vous testez les hautes tensions.
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.
Introduction
xi
Translation of Warnings
WARNING
Use safe handling procedures when removing the module. Refer to GP 16. The module
is heavy.
AVVERTENZA: Utilizzare procedure di gestione sicure durante la rimozione del modulo.
Vedere GP 16. Il modulo è pesante.
VORSICHT: Verwenden Sie sichere Vorgehensweisen zum Entfernen des Moduls. Siehe
auch GP 16. Das Modul ist sehr schwer.
AVISO: Utilice los procedimientos de seguridad cuando elimine el módulo. Consulte el
GP 16. El módulo es pesado.
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.
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.
WARNING
USA and Canada. Do not install this machine in a hallway or exit route that does not
have 1.12 m (44 inches) of space additional to the normal space requirements in front of
the machine. To conform with fire regulations this additional 1.12 m (44 inches) of space
is needed in front of the machine in hallway and exit routes.
AVVERTENZA: N/A
VORSICHT: N/A
AVISO: Estado s Unidos y Canadá. No instale esta máquina en un corredor o ruta de sal-
ida que no tenga 1.12 m (44 pulgadas) de ancho delante de la máquina, sin incluir el
espacio que ocupe la máquina. Este espacio adicional de 1.12 m (44 pulgadas) delante
de la máquina en corredores y rutas de salida es necesario para cumplir los requisitos
de las normas sobre incendios.
-
WARNING
Use only Xerox materials and components. This product is safety certified using Xerox
materials and components. The use of non Xerox materials and components may invali
date the safety certificate.
AVVERTENZA: Utilizzare solo materiali e componenti Xerox per avvalersi della certificaÂzione di protezione. L'utilizzo di materiali e componenti non Xerox può rendere nulla la
certificazione di protezione.
VORSICHT: Verwenden Sie nur Materialien und Komponenten von Xerox. Dieses
-
Produkt besitzt die Sicherheitszertifizierung bei Verwendung von Xerox-Materialien und
-Komponenten. Die Verwendung von Materialien und Komponenten anderer Hersteller
setzt möglicherweise das Sicherheitszertifikat außer Kraft.
AVISO: Utilice solo los materiales y componentes Xerox. Este producto dispone de un
certificado de seguridad si se utilizan los materiales y componentes Xerox. Este certifi
cado de seguridad no será válido si se utilizan materiales y componentes que no sean
de Xerox.
-
-
Introduction
Translation of Warnings
WARNING
Do not touch the Fuser while it is hot.
DANGER: Ne pas toucher au four pendant qu'il est encore chaud.
AVVERTENZA: Non toccare il fonditore quando è caldo.
VORSICHT: Fixierbereich erst berühren, wenn dieser abgekühlt ist.
AVISO: No toque el fusor mientras está caliente.
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Revised BUS Update: July 2020
WARNING
Do not handle the Fuser components until they have cooled. Some Fuser components
operate at hot temperatures and can produce serious personal injury if touched.
VORSICHT: Die Fixieranlage sollte erst gehandhabt werden, wenn diese genügend
abgekühlt ist. Einige Teile der Fixieranlage erzeugen übermäßige Hitze und führen bei
der Berührung zu schweren Verbrennungen.
AVISO: No manipule los componentes del fusor antes de que se enfrà e n. Algunos de los
componentes del fusor funcionan a altas temperaturas y pueden ocasionar daños per
sonales graves si se los toca.
WARNING
Do not attempt to remove or lift the following component with less than 2 people. The
component is very heavy and requires at least 2 people to lift or remove it. Any attempt
to remove or lift the component with less than 2 people could result in serious personal
injury.
AVVERTENZA: Non tentare di togliere o sollevare il componente seguente con meno di
2 persone. Il componente è molto pesante e richiede almeno 2 persone per sollevarlo o
rimuoverlo. Tentare di rimuovere o sollevare questo componente con meno di 2 persone
può provocare gravi fer ite.
VORSICHT: Versuchen Sie keinesfalls, die folgende Komponente mit weniger als 2 PerÂsonen zu entfernen oder zu heben. Die Komponente ist sehr schwer, daher werden
mindestens 2 Personen benötigt, um sie zu heben oder zu entfernen. Der Versuch, die
Komponente mit weniger als 2 Personen zu entfernen oder zu heben, kann schwere Kör
perverletzung zur Folge habe n.
AV IS O: No intente levantar o retirar el componente siguiente usando menos de 2 persoÂnas. El componente es muy pesado, y se necesitan por lo menos 2 personas para levanÂtarlo o retirarlo. Intentar retirar o levantar el componente usando menos de 2 personas
puede resultar en lesionales personales serias.
Technical Support Information
The Xerox Service Manual is the primary document used for repairing, maintaining, and trouÂbleshooting the Phaser 6510 and WorkCentre 6515. To ensure complete understanding of
these products, participation in Xerox Service Training is strongly recommended. To service
these products, certification for these products is required.
For updates to the Service Manual, Service Bulletins, knowledge base, etc., go to:
•Xerox Global Service Net - https://www.xrxgsn.com/secure/main.
For further technical support, contact your assigned Xerox Technical Support representative.
-
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Introduction
Translation of Warnings,
Introduction
Translation of Warnings,
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SCP 6 Final Actions........................................................................................................1-9
1 Service Call Proced ur es
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1-1
Service Call Procedures
Service Call Procedures
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SCP 1 Initial Actions
Initial Actions are used to gather information on printer performance
Start a service call with SCP 1 and end with SCP 6 Final Actions.
Also refer to Machine Specifications, GP 7.
Procedure
WARNING
solate the machine from the electrical supply while performing tasks that do not need
electricity. Refer to GP 4. Electricity can cause death or injury. Moving parts can cause
injury.
WARNING
Do not work in a confined space. 1 m (39 inches) space is needed for safe working.
NOTE: Ignore references to options not installed on the printer.
1.Identify the problem.
•Verify the reported problem does exist.
•Ask the operator to describe or demonstrate the problem.
•Print normal customer prints and service test prints.
•Make note of any print-quality problems in the test prints.
•Print a Usage Profile, if the printer is able to print.
2.Make note of any mechanical or electrical abnormalities present.
3.Make note of any unusual noise or smell coming from the printer.
4.To view engine error and jam histories, perform Diagnostic s dC118, dC120, dC122, and
dC125.
5.Take note of symptoms or error messages.
6.Make su re:
a.The power cord is connected to the wall outlet and to the machine.
b.The AC input from the wall outlet is within specifications.
c.Paper is loaded correctly and all paper trays and covers are closed
d.If installed, the USB cable or network connection is installed correctly.
7.If available, check the service log book for any previous actions that may be relevant to
the call.
8.If this is the f irst service call to th is printer, perform SCP 2 First Call Actions, otherwise go
to SCP 3 Normal Call Actions.
Accessing Engine Fault History
Listed below are three ways in which you can access fault history. Additional fault history inforÂmation appears in GP 2.
3.If the printer is connected to a network and has a TCP/IP address, view the printer’s web
page using a web browser.
a.Open a web browser.
b.Enter the printer’s IP address as the URL.
c.Select > > and the fault history displays.
NOTE: Error and fault code definitions appear in Section 2.
1.Read (if possible) fault history from Device -> Support -> Support Pages -> Err or Histor y
Report on the control panel. The error history is listed on screen.
2.Accessing fault history in Service Diagnostics
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Service Call Procedures
SCP 1
SCP 2 First Call Actions
First Call Actions are used for the first service call.
SCP 3 Normal Call Actions
Normal Call Actions are used to determine the reason for the service call.
Procedure
1.Check the machine configuration with the customer, refer to Machine Specifications, GP
7. Check that all required hardware and software is installed and/or enabled.
2.Check that all the relevant machine settings are correctly entered, refer to GP 4 System
Administration T ools.
3.If a fault is present, go to SCP 3 Normal Call Actions. If there is no fault present, go to
SCP 6 Final Actions.
4.Enter the printer and customer details in the service log.
Procedure
NOTE: If a fault message appears at any time. Refer directly to the RAP for the fault mes sage
and perform the procedure.
If possible, perform the following:
1.Review any defective print samples.
2.Determine that the user accessible settings are correct. If necessary refer to the user docÂumentation.
3.Check all job queues and verify with the customer any requirement to print the documents
in memory, before switching off the power or clearing memory.
4.Print the Customer Assistance Report (Call for Assistance), then record the total print
count.
5.Go to SCP 4 Fault Analysis.
Service Call Procedures
SCP 2, SCP 3
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SCP 4 Fault Analysis
Fault Analysis is used to identify a fault.
Procedure
When diagnosing or repairing a fault in a particular subsystem, exercise the machine in all
modes until the fault is determined. In the instance of finding more than one fault or failure, cor
rect one fault before going to the next fault. If no fault is found, go to SCP 5 Subsystem MainteÂnance.
Fault Codes
If a fault code is displayed, go to the relevant RAP. Also refer to Unresolved Faults.
Control Panel Faults
If the power is on but the Control Panel is blank, test the Control Panel with dc305.
Image Quality Defects
If the image quality is defective, go to the IQ1 Image Quality Entry RAP.
Unresolved Faults
If a fault cannot be resolved using the appropriate RAP, and only if instructed by 2nd level supÂport, obtain a device log. Refer to GP 38 Obtaining Audit and Device Logs. Escalate the probÂlem to 2nd level support.
Additional Information
If necessary, refer to the following general procedures and information:
•GP 1 Using the Service Diagnostics
•GP 2 Fault Codes and History Logs
•GP 3 Device In formation
•GP 4 How to Switch Off or Sw i t c h On the Printer
•GP 6 Electrostatic Discharge Prevention
•GP 7 Machine Specifications
•GP 8 General Disassembly Precautions
•GP 9 Firmware Version Upgrade
•GP 10 How to Check a Motor
•GP 11 How to Check a Sensor
•GP 12 How to Check a Solenoid or Clutch
•GP 13 How to Check a Switch
•GP 14 How to Clone Device Settings
•GP 15 Special Boot Modes
•GP 16 Separate System Modules
•GP 17 External FAX Line Test
•GP 18 Printing Reports
•GP 19 Intermittent or Noise Problem
•GP 20 How to Safely Lift or Move the Printer
•GP 21 Machine Lubrication
•GP 22 Installation Space Requirements
•GP 23 First Print Output Time
•GP 24 Restriction of Hazardous Substances (RoHS)
•GP 26 Media Specifications
•GP 27 Environmental Data
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•GP 28 Supplies Plan Conversion
•GP 29 How to Check a Dispenser Motor
•GP 30 IP (ESS) Specifications
•GP 31 IIT Specifications
•GP 32 FAX Specifications
•GP 33 Interior and Exterior Cleaning
•GP 34 Cleaning the Scanner and DADF
•GP 35 Setting Up an Ethernet Connection
•GP 36 How to Manually Configure an IP Address
•GP 37 Reset Administrato r Password
•GP 38 Obtaining Audit and Device Logs
•GP 39 FFC Cables
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Service Call Procedures
SCP 4
SCP 5 Subsystem Maintenance
Subsystem Maintenance contains information regarding the component life of the machine.
Procedure
WARNING
Isolate the machine from the electrical supply w hile performing tasks that do not need
electricity. Refer to GP 4. Electricity can cause death or injury. Moving parts can cause
injury.
1.Clean the Pick Rollers on every call.
2.Use the Control Panel to check maintenance item counters.
3.Compare the counter values to those listed in Table 1.
4.Advise the customer of any routine maintenance items that are approaching or over the
service limit.
Inspection
Lubrication
CAUTION
Plastic parts deteriorate when unspecified lubricants or chemicals are used. To avoid damage,
use only approved lubricant.
The printer is lubricated during assembly at the factory and does not require periodic lubricaÂtion. Some parts require lubrication following replacement. These parts are identified in the
replacement procedures. When lubricating during replacement, use approved grease.
Component Life
The design life of the major components are shown in Table 1. Environmental conditions and
actual use will vary these factors. The component life shown in Table 1 is for reference only.
Dimensions and Mass of Consumables
The WC6515 and P6510 contain the consumables shown in Table 1:
Table 2 Dimensions and Mass of Consumables
ConsumableWidth (mm) Depth (mm) Height (mm) Mass (g)
Toner Cartridges C, M, Y,
K
(Figure 1)
Drum Cartridges C, M, Y,
K
(Figure 2)
Waste Cartridge
(Figure 3)
61.318057.3K: 100/120/140
C,M,Y: 90/110/120
(STD / HI / EX-HI)
77.3335.478.5720
357176.333250
Figure 1 Toner Cartridge
Table 1 Design Life of Major Components
1.Pick and Nudger Rollers100,000 pages
2.Separator Roller100,000 pages
3.Transfer Unit / Transfer Roller100,000 images
4.Fuser100,000 images
5.Feed Rollers100,000 pages
6.Waste Cartridge3 0,000 pages
7.Drum Cartridge48,000 pages
Consumables and Maintenance
Consumables consist of C, M, Y, and K Toner Cartridges, C, M, Y , and K Drum Cartridges, and
the Waste Cartridge.
Service Call Procedures
SCP 5
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Figure 2 Drum Cartridge
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Xerox P6510 Color Printer/WC6515 Color MFP Service Manual
Figure 3 Waste Cartridge
Consumables Life Expectancies
Each Toner Cartridge (except s tarter cartridges) has a CRUM (Customer Replaceable Unit
Monitor) to record regional and toner usage information. The CRUM maintains a count of the
amount of toner consumed. When the count reaches set values, warning and error messages
appear to notify the user when near and end of life status is reached.
Like the Toner Cartridges, each Drum Cartridge has a CR UM to maintain a page count. When
the count reaches a set value, warning and error m essages a ppear to notify the user that the
Drum Cartridge has reached near or end of life status.
NOTE: The specifications showing life ratings are correct at the time of product release. For
the most current values, go to www.xerox.com.
Life ratings are shown in Table 3.
•Transfer Belt unit + Transfer Roller unit: 100 kPV (life of machine)
CMYK Standard Capacity Toner Cartridges starter cartridgescolor: 1,000
black: 1,500
sold cartridgescolor: 1,000
CMYK High Capacity/Extra High Capacity
Toner Cartridges
Drum Cartridge (C, M, Y, K)48,000
Waste Cartridge30,000
Routine Maintenance Items
Figure 4 and Figure 5 show the routine maintenance items which are service parts:
•Fuser (110V / 220V): 100 kPV (life of machine)
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sold cartridgescolor: 2,500 / 4,500
metered cartridgescolor: 2,500
black: 2,500
black: 6,000 / N/A
black: 6,000
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Service Call Procedures
SCP 5
Figure 5 P6510 Routine Maintenance Items
Table 4 Hardware Kit P6510 and WC6515
TypeShapePL Number Size
Screw for sheet metal
Silver, with washer and
plane washer
E-ringE2D4354W027278 (2)
SM20M3x8mm112W27898 (2)
E6D6354W024278 (2)
Part Number
(Quantity)
Hardware Kit
The spare parts available for repairs and maintenance includes a hardware kit. The kit contains
miscellaneous screws and e-clips that can be used to replace hardware that is lost or dam
aged, Table 4.
Since the P6510 and WC6515 use various types of hardware (screws, E-clips), ensure that the
correct hardware is used when installing parts. Use special caution not to confuse the screws
used for plastic with those used for sheet metal. Using the wrong type of screw ma y result in
damage to the screw threads or other problems.
Xerox P6510 Color Printer/WC6515 Color MFP Service Manual
SCP 6 Final Actions
Final Actions are used to evaluate the total operation of the system and to identif y the actions
required to complete the service call.
Procedure
Complete the following, if a fault is identified, return to SCP 4 Fault Analysis:
1.Perform the end of call subsystem maintenance actions, SCP 5 Subsystem Maintenance.
2.Exercise the machine in all modes, printing from all trays. If a fault message is disp layed
or some other problem is evident, go to SCP 4 Fault Analysis.
3.Make a print of a customer document.
4.If any of the customers selections were changed, return t hem to the cus tomers preferred
settings. Refer to GP 4 System Administration Tools.
5.At the first service and at any subsequent service where changes are made or options are
added, print the configuration report and store it with machine log book. Discard any pre
vious versions of the configuration report.
6.Remove and destroy any copies of test patterns.
7.Ensure the machine and service area are clean before leaving the customer premises.
8.Provide customer training if required.
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Service Call Procedures
SCP 6
Service Call Procedures
SCP 6
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