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Table of Contents
Related Manuals for Xerox 2515
Summarization of Contents
Introduction
About This Manual
Describes the purpose and contents of the service manual, including its relation to product training.
Organization
Outlines the division of the manual into eight main sections for service and maintenance.
How To Use This Manual
Provides guidance on following service procedures, troubleshooting, and using different sections of the manual.
Reference Symbology
Explains symbols used in circuit diagrams and other documents for clarity in procedures.
Tag/MOD Information
Details symbols and information related to Tag/MOD numbers, indicating changes or modifications.
Service Call Procedures
Call Flow Diagram
A map outlining the major activities and decision points for a service call.
Initial Actions
Procedures to guide the service representative in gathering information and preparing the copier for evaluation.
Maintenance Activities
Activities performed after the main cause of a service call is corrected, including Normal Call and Extended Maintenance.
Xerographic Module Maintenance Procedures
Tasks related to cleaning and maintaining the xerographic module for optimal performance.
Media Transport Maintenance Procedures
Procedures for cleaning and maintaining the media transport system components.
Developer Module Maintenance Procedures
Tasks for checking and maintaining the developer module, including toner levels and rotation.
Covers Maintenance Procedures
Procedures for cleaning covers and reducing static build-up for positive customer perception.
Final Action
Recording service activities, checking copy count, and stress testing image quality.
Status Indicator Repair Analysis Procedures
Status Codes
Lists status codes, their causes, clearance procedures, and guidance for further troubleshooting.
Document Sensor RAP
Troubleshooting procedure for the document sensor, addressing status code A.
Cover Interlock Open RAP
Procedure for diagnosing and fixing issues related to open interlock switches (Code C).
Paper Path Jam RAP
Troubleshooting guide for paper jams (Code E), covering obstructions and component checks.
Fuser (2510) RAP
Procedure for diagnosing and resolving fuser overtemperature or warmup issues (Code F).
Fuser (2515) RAP
Procedure for diagnosing and resolving fuser overtemperature or warmup issues (Code F) for the 2515 model.
AC Power RAP
Troubleshooting steps for problems related to the AC circuitry and power supply (Code 1.1).
DC Power RAP
Procedure for diagnosing and resolving issues related to the loss of DC power (Code 1.2).
DC Cooling Fan RAP
Troubleshooting procedure for copier cooling malfunctions, particularly fan issues (Code 1.3).
AC Cooling Fan RAP
Troubleshooting procedure for AC cooling fan issues, especially in power saver mode (Code 1.4).
Ground Fault RAP
Procedure for locating and repairing ground faults in the primary AC power distribution circuitry (Code 1.5).
Control Panel RAP
Troubleshooting procedure for control panel faults that do not indicate a status code (Code 2.1).
Copy Count Meter RAP
Procedure for addressing faults with the copy count meter that do not show a status code (Code 3.1).
Foreign Accessory - No Billing RAP
Procedure for issues where the external billing system does not record copy transactions (Code 3.2).
Main Drive Motor RAP
Troubleshooting procedure for issues with the main drive motor not turning or turning unexpectedly (Code 4.1).
Document Handler RAP
Procedure for document handler faults where the document is not sensed (Code 5.1).
OF1 Noise Isolation Procedure RAP
Procedure to isolate noises to specific subsystems or components within the copier.
OF 2 High Toner Consumption
Troubleshooting guide for high toner consumption issues, checking cartridge yield and developer material.
OF 3 Shutdowns
Procedure for diagnosing copier shutdowns that return to Rest Mode, related to the Watchdog Timer.
OF 4 Toner/Developer Dumping
Troubleshooting steps for toner or developer dumping caused by material issues or housing problems.
OF 5 Charge Voltage Out of Specification
Troubleshooting guide for incorrect charge voltage readings on the photoreceptor drum.
OF 6 Media Will Not Feed
Procedure for diagnosing issues where media does not move into the media transport system.
OF 7 Fuser Heat Rod On at Power Up
Troubleshooting for the Fuser Heat Rod remaining on during Power Up Mode or after thermostat replacement.
Image Quality Repair Analysis Procedures
Copy Quality RAPS
List of various copy quality defects, categorized for analysis and correction.
How to Use the Image Defect Samples
Guidance on using image defect samples to identify and diagnose copy quality problems.
Image Quality Definitions
Definitions of common terms used to describe copy quality issues like background, density, and smears.
Image Quality Analysis RAP
Procedure for analyzing image quality using test patterns and specifications.
Image Quality Specifications
Details on image reference scales and test patterns used for evaluating copy quality.
Copy Defects Flowchart
A visual flowchart categorizing different types of copy defects for easier troubleshooting.
Damaged Media RAP
Troubleshooting guide for copy defects caused by damaged or improperly handled media.
Media Handling Problems
Information on common media transport issues and systematic approaches to solving them.
CQ 1 Uniform Background
Analysis and corrective actions for uniform background defects caused by dry ink contamination.
CQ 2 Background Banding/ Streaks
Troubleshooting guide for background banding or streaks caused by dirty components or drum cleaning issues.
CQ 3 Black Copy
Procedure for diagnosing black copy issues, related to exposure lamp or illumination sensor problems.
CQ 4 Blank Copy
Troubleshooting for blank copies, focusing on corotrons, magnetic roll, and HVPS output.
CQ 5 Border Line
Procedure for addressing border lines on copies, often related to registration or media size mismatch.
CQ 6 Cold Flow
Troubleshooting guide for cold flow defects, related to cleaning blade or photoreceptor drum issues.
CQ 7 Developer Bead Carryover
Diagnosis and correction of developer bead carryover, often linked to charge voltage or developer material.
CQ 8 Edge Banding
Procedure for addressing edge banding defects, potentially caused by background or corotron voltage issues.
CQ 9 Length Distortion
Troubleshooting guide for image length distortion, related to media speed or platen static.
CQ 10 Dry ink Disturbance
Procedure for diagnosing dry ink disturbances before the fuser, related to corotron or toner concentration.
CQ 11 The Light Copy (Overall)
Troubleshooting for light copy quality, covering dry ink levels, developer material, and electrostatic settings.
CQ 11 The Light Copy (Partial)
Troubleshooting for partial light copies, related to component seating or cover alignment.
CQ 12 Localized Deletions
Procedure for diagnosing localized image deletions, caused by damp media or dirty components.
CQ 13 Offsetting
Troubleshooting guide for offsetting or residual image defects, related to fuser lubrication or temperature.
CQ 14 Registration
Procedure for correcting registration issues, often caused by sensor or feed roll alignment problems.
CQ 15 Residual Image
Troubleshooting guide for residual images, related to photoreceptor drum cleaning or electrostatic settings.
CQ 16 Resolution
Procedure for improving copy resolution, focusing on lens, document handler, and platen condition.
CQ 17 Skewed Image
Troubleshooting guide for skewed images, related to media feed alignment or static on the platen.
CQ 18 Skips
Procedure for diagnosing skips, caused by document disturbance or drive belt slippage.
CQ 19 Smears
Troubleshooting guide for smears, related to media speed differences or fuser issues.
CQ 20 Spots
Procedure for diagnosing spots, related to photoreceptor drum contamination or developer material issues.
CQ 21 Streaks (TYPE 1.1, Dry ink Streaks)
Troubleshooting for dry ink streaks following the photoreceptor drum's rotation.
CQ 21 Streaks (TYPE 1.2, Deleted Streaks)
Procedure for diagnosing deleted streaks not following the photoreceptor drum's rotation.
CQ 22 Unfused Copy
Troubleshooting guide for unfused copies, related to fuser temperature or damp media.
CQ 23 Wrinkle Deletions
Procedure for diagnosing wrinkle deletions caused by media wrinkling in the fuser.
CQ 24 Trail Edge Deletion
Troubleshooting for trail edge deletions, often caused by excessive media curl.
CQ 25 Developer Bias RAP
Procedure for adjusting developer bias voltage to ensure correct image density.
CQ 26 High Voltage Power Supply RAP
Troubleshooting guide for issues related to the high voltage power supply (HVPS).
CQ 27 Exposure RAP
Procedure for diagnosing exposure problems, such as no exposure or excessive exposure.
CQ 28 Offsetting and Residual Image Isolation RAP
Procedure to isolate between offsetting and residual image copy quality problems.
CQ 29 Partial Image RAP
Troubleshooting guide for partial images caused by foreign accessory software configuration.
Repair/Adjustment
REP 3.1 Control PWB
Procedure for replacement and adjustments of the Control PWB.
REP 3.2 High Voltage Power Supply (HVPS)
Procedure for removal and replacement of the High Voltage Power Supply (HVPS).
REP 5.1 Upper Document Feed Rolls
Procedure for removal and replacement of the upper document feed rolls.
REP 5.2 Lower Document Feed Rolls
Procedure for removal and replacement of the lower document feed rolls.
REP 6.1 Exposure Lamp
Procedure for replacement of the exposure lamp, including diagnostic tests.
REP 6.2 Lens
Procedure for removal and replacement of the lens, including correct positioning.
REP 8.1 Media Transport Module
Procedure for removal and replacement of the media transport module.
REP 8.2 Upper Media Feed Roll
Procedure for removing and replacing the upper media feed roll.
REP 8.3 Lower Media Feed Roll
Procedure for removing and replacing the lower media feed roll.
REP 8.4 Fabric Guide
Procedure for replacement of the fabric guide, including alignment and retaining rod installation.
REP 9.1 Xerographic Module
Procedure for removal and replacement of the xerographic module.
REP 9.2 Photoreceptor Drum Assembly
Procedure for removal and reinstallation of the photoreceptor drum assembly.
REP 9.3 Photoreceptor Drum
Procedure for removing and installing the photoreceptor drum shaft and related components.
REP 9.4 Cleaner Blade
Procedure for removing and installing the cleaner blade assembly and its components.
REP 9.5 2510 Developer Module
Procedure for removing and installing the developer module for the 2510 model.
REP 9.6 2515 Developer Module
Procedure for removing and installing the developer module for the 2515 model.
REP 9.7 Dispense Arm Return Spring
Procedure for removing and replacing the dispense arm return spring.
REP 9.8 2515 Toner Dispense Solenoid
Procedure for removing and installing the toner dispense solenoid for the 2515 model.
REP 9.9 Developer Material
Procedure for handling developer material, including dumping and replacement.
REP 9.10 Corotron Wires
Procedure for removing and installing corotron wires and related components.
REP 9.11 Toner Sensor Assembly
Procedure for removing and installing the toner sensor assembly.
REP 10.1 Heat Rod
Procedure for removing and installing the heat rod, with safety precautions.
REP 10.2 Fuser Roll
Procedure for removing and installing the fuser roll, including oil dispenser and heat rod removal.
REP 10.3 Fuser Triac
Procedure for replacing the fuser triac, involving thermal compound application.
REP 10.4 2510 Oil Pads
Procedure for removing and installing oil pads for the 2510 model.
REP 10.5 Oil Dispense Assembly
Procedure for removing and reinstalling the oil dispense assembly.
REP 10.6 Media Deflectors
Procedure for removing and installing the media deflectors and clips.
REP 10.7 Stripper Fingers
Procedure for removing and installing the stripper fingers.
REP 10.8 Oil Pads
Procedure for installing new oil pads, including wick and plastic cover alignment.
REP 10.9 Wick
Procedure for removing and installing the wick, including plastic cover and rubber retainer alignment.
REP 10.10 Oil Dispense Roll Assembly
Procedure for removing the oil dispense roll assembly.
REP 10.11 Fuser Drive Gear
Procedure for removing and installing the fuser drive gear.
REP 10.12 Thermistor Assembly (RT1)
Procedure for removing and installing the thermistor assembly (RT1).
REP 10.13 Motion Sensor
Procedure for removing and installing the motion sensor.
ADJ 3.1 Timeout Interval To RestMode
Procedure to set the time interval for the copier to return to rest mode from power saver mode.
ADJ 3.2 Country Configuration
Procedure to set up the correct country configuration for the copier.
ADJ 3.3 Timeout Interval To Power Saver Mode
Procedure to set the time interval for the copier to return to standby mode from run mode.
ADJ 3.4 Foreign Accessory Enablement
Procedure to select or deselect the foreign interface feature and determine interaction.
ADJ 8.1 Registration
Procedure to adjust the timing for correct registration of copy material and document image.
ADJ 9.1 Cleaner Blade Solenoid
Procedure to adjust the cleaner blade solenoid for correct force application to the drum.
ADJ 9.2 Electrostatic Series (Old Type HVPS)
Procedure to obtain good copy quality by adjusting corotron and exposure voltages.
ADJ 9.3 Electrostatic Series 2510/2515 (New HVPS)
Procedure for obtaining good copy quality by adjusting corotron and exposure voltages for new HVPS.
ADJ 9.4 Image Density (2515)
Procedure to adjust image density for the 2515 model.
ADJ 9.5 Toner Dispense Solenoid (2515)
Procedure to adjust the toner dispense solenoid for correct toner dispensing rate.
ADJ 10.1 Fuser Temperature Adjustment
Procedure to adjust the fuser heat for correct fusing of copies.
ADJ 10.2 (2510) Oil Dispense Assembly
Procedure to adjust the amount of fuser oil applied to the fuser roll.
Parts List Section
INTRODUCTION
Identifies part numbers and corresponding locations of all spared subsystem components.
OVERVIEW
Describes the purpose of the parts list section, including illustrations and part number identification.
ORGANIZATION
Explains how items in the parts list correspond to illustrations and subsystems.
PARTS LISTS
Details how each item number corresponds to an item in the illustrated parts list.
ELECTRICAL CONNECTORS AND FASTENERS
Contains illustrations and descriptions of plugs, jacks, and fasteners used in the machine.
COMMON HARDWARE
Lists common hardware items identified by letters, with dimensions in millimeters.
PART NUMBER INDEX
Lists all spared parts numerically, with references to the parts list.
OTHER INFORMATION
Provides sections on abbreviations, subsystem information, and symbology.
ABBREVIATIONS
Lists abbreviations used in the parts lists and exploded view illustrations.
SYMBOLOGY
Identifies symbols used in the parts list sections, including those for adjustments and repairs.
PL 1.1 ELECTRICAL COMPONENTS (PART 1 OF 2)
Illustrates and lists electrical components, including switches, motors, and boards.
PL 1.2 ELECTRICAL COMPONENTS (PART 2 OF 2)
Illustrates and lists additional electrical components like exposure lamps, power supplies, and cords.
PL 5.1 DOCUMENT HANDLER
Parts list for the document handler assembly, including transport frame and feed rolls.
PL 6.1 OPTICS
Parts list for optical components such as lenses, lamps, and illumination sensors.
PL 8.1 FABRIC GUIDE AND MEDIA FEED (2510) (PART 1 OF 2)
Parts list for fabric guide and media feed components specific to the 2510 model.
PL 8.2 FABRIC GUIDE AND MEDIA FEED (2510) (PART 2 OF 2)
Additional parts list for fabric guide and media feed components for the 2510 model.
PL 8.3 FABRIC GUIDE AND MEDIA FEED (2515) (PART 1 OF 2)
Parts list for fabric guide and media feed components specific to the 2515 model.
PL 8.5 TRANSFER/DETACK COROTRON AND TRANSPORT DRIVES (PART 1 OF 2)
Parts list for transfer/detack corotron and transport drive components.
PL 9.1 PHOTORECEPTOR DRUM AND CLEANING (PART 1 OF 2)
Parts list for the photoreceptor drum and cleaning module components.
PL 9.2 PHOTORECEPTOR DRUM AND CLEANING (PART 2 OF 2)
Additional parts list for photoreceptor drum and cleaning module components.
PL 9.3 DRUM COOLING AND CLEANING BLADE SOLENOID
Parts list for drum cooling and cleaning blade solenoid components.
PL 9.4 DEVELOPER MODULE (2510)
Parts list for the developer module specifically for the 2510 model.
PL 9.5 DEVELOPER MODULE (2515)
Parts list for the developer module specifically for the 2515 model.
PL 10.1 XEROGRAPHIC MODULE
Parts list for the xerographic module assembly.
PL 10.2 FUSING (PART 1 OF 2)
Parts list for fusing components, including heat rod and fuser roll.
PL 10.3 FUSING (PART 2 OF 2)
Additional parts list for fusing components, including media deflectors and springs.
PL 10.4 OIL DISPENSER ASSEMBLY
Parts list for the oil dispenser assembly.
PL 10.5 OIL DISPENSER ASSEMBLY
Parts list for the oil dispenser assembly, detailing components and kits.
PL 10.6 OIL DISPENSER ASSEMBLY(BRAZIL)
Parts list for the oil dispenser assembly specific to the Brazil region.
PL 14.1 COVERS (2510)
Parts list for the covers of the 2510 model, including side and rear covers.
PL 14.2 COVERS (2515)
Parts list for the covers of the 2515 model, including side and rear covers.
PL 15.1 STANDS
Parts list for the copier stand and associated accessories.
PL 16.1 ELECTRICAL CONNECTORS
Illustrations and part numbers for various electrical connectors used in the machine.
PART NUMBER INDEX
An index listing all spared parts numerically with references to their location in the parts list.
General Procedures / Information
System Procedures
Covers diagnostic tests, procedures for image on drum, and toner-related maintenance.
Specifications
Details product codes, physical characteristics, copy rate, magnification, electrical requirements, and environmental data.
General Tools and Supplies
Lists necessary tools, cleaning materials, lubricants, consumables, and supply kits.
2510 Change Tag Index
Index of modifications identified by Tag numbers for the 2510 model, including classification codes.
2515 Change Tag Index
Index of modifications identified by Tag numbers for the 2515 model, including classification codes.
Installation
Procedures for installing the copier, including ground checks, space requirements, and component installation.
Removal
Procedures for removing components and preparing the copier for internal moves or repacking.
Installation Checklist
Checklist for site preparation, installation steps, and functional checks.
Product Demonstration Checklist
Checklist for demonstrating copier capabilities, including controls and basic functions.
Wiring Data
Plug / Jack Location Drawing
Illustrations showing the location of plugs and jacks on the copier's rear and side views.
Connector Pin Numbering
Diagrams illustrating pin numbering for various connectors on the copier's internal modules.
Electrical Component Wiring Connections Drawing
Wiring diagrams for AC component panels, showing connections for switches, filters, and triacs.
Connector Wiring
Detailed pin-out information for various connectors, including signal names and wire colors.
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