Profile: 2510 style (Xerox Engineering Copiers) - The Parts Drop

The Parts Drop 201-387-7776 www.partsdrop.com
Originally published in ENX Magazine (www.enxmagazine.com)
Profile: 2510 style (Xerox Engineering Copiers)
2510, 2515, 2520
The engineering copiers are
daunting at first glance… over 3 feet in
length… 36 inch lamps… 36 inch rollers.
Parts are far more expensive than similar
parts for their smaller 8 ½ x 11 copier
cousins. They can be impressive and a bit
discouraging if you’ve never worked on them before. In actuality these machines are
relatively simple analog copiers. Of the folks I’ve spoken to… most techs who try fixing
them wind up liking them. Most tech companies (including the OEM) use a different,
more lucrative, service call rate when working on the engineering copiers. This is partly
because it requires a tech with some specialized knowledge to work on these (not
everyone wants to learn them considering how few there are compared to the smaller
copiers).
There are a few important tips which you’ll want to be aware of… pitfalls to
avoid and such. We’ll also go through a list of the Status Codes and what each of them
means. Then we’ll talk a bit about getting into and using the Diagnostics.
Here’s a quick list of what you should be aware of… we’ll talk in more detail about a few
of these concerns below.
Important Precautions & Tips:
• Always remove the Fuser Lamp before removing the Fuser.
• If you need to run the Main Motor from diagnostics… always turn on the cooling fans
& fuser for 2 minutes first.
• When running tests on the exposure lamp or high voltage, turn on the Main Motor
first to avoid damaging the drum.
• When installing a new Fuser Roll, oil the roller thoroughly.
• Make a habit of checking the Oil Pads whenever you visit the machine to make sure
the fuser doesn’t run out of lubricant.
• While these machines are relatively simple to disassemble… count on having two
people present. The modules are so bulky that one person handling them alone can be
awkward to say the least.
Removing the Fuser Lamp before removing the fuser is pretty critical… a 3 foot
long lamp really does not need much of an excuse to break. The fuser is too bulky to
handle without having an extremely high risk of snapping off the end of the lamp by
accident. It’s an all-too-common and rather expensive mistake.
When you are running diagnostic procedures, you need to do things in sequence
to make sure you don’t damage anything. To some degree, these are common sense
precautions… You must first turn on the cooling fans and then the fuser before you run
the Main Motor. This is because room temperature fuser oil can seize up the fuser and
cause gears to break. Whenever you run a high voltage test, the Main Motor must first be

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running to make sure that the drum is moving (otherwise the voltages can damage the
drum).
The stuff about the lubrication of the fuser is also very important… I’ve been told
that this machine is quite reliable, so long as someone is keeping an eye on the
lubrication not running out. These machines use a few versions of lubrication systems.
If you are going to order new Oil Pads or Fuser Wicks… you’ll need figure out which
version of the fuser oil dispenser your machine has in it. One version has a wick which is
attached to a metal piece (glued on)… the other version has a removable wick. The “Oil
Pad” serves as the reservoir for the fuser oil… new pads come prelubed.
Following are the Status Codes. These apply for the 2510, 2515 and 2520 models.
STATUS CODES:
• A Document was inserted before copy paper was registered.
To clear: Remove document, press ‘Start’, wait for ‘Ready’ to come on.
• b Control PWB failure
• b (flashing) Reset Non-Volatile Memory (NVM)
• C Transport Cover open… or Upper Rear Cover is off.
• E Paper Path Jam.
• F Fuser problem.
• H Foreign accessory problem.
• J (Low Toner Light not Lit): Excessive toner concentration.
• J (Low Toner Light Lit): Insufficient toner concentration.
• U Total Count Meter is disconnected.
• L9 to L0 Copier is warming up.
• Constant P Copier is in the power saver mode.
• Constant L9 or L8 Copier does not warm up.
Copy Quality problems? First make sure the paper the customer is using is fresh
(wet paper can cause poor fusing, deletion areas and other copy quality problems). If
there are smears or wrinkles or poor fusing, you’ll want to make sure that the Fuser
Roller is clean and lubricated… and that the Pressure plate (they call the material on it the
“Fabric Guide”) is in good condition (wrinkles or damage to the fabric guide can cause
problems for sure). Light copies overall may be caused by the developer being worn out.
If you are having Toner Dispensing problems… the 2510 uses an “Arm” with a little
metal adjustment lever on it which turns the toner cartridge around and around. The 2515
and 2520 use a solenoid to activate the toner dispense arm. You’ll also want to make
sure that the Toner cartridge holder clip is in place (a small green clip which goes at the
end of the cartridge where it slides in). If that clip is missing, problems with toner
dispensing will result.
The Diagnostic Mode is the way to test components and adjust some of the
memory settings.
Entering Diagnostics:
2510: Press & hold the ‘Copy Output’ button while powering up.
2515/2520: Press & hold the ‘Bond’ and ‘Film’ buttons while powering up.

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Once diagnostics is entered, the display will light up & then after 3 seconds, the lamps
will turn off & the current software revision level will be displayed as the letter L and a
number… then a ‘0’ will be displayed.
Use the Copy Contrast UP & DOWN buttons to select the test you want to run.
Exiting Diagnostics: Press the ‘Stop’ button.
Once in Diagnostics, you can select a test by scrolling through the possibilities
using the Copy Contrast Up or Down buttons. To test the Motion Sensor, you would
select the “Top Segment” of the 7 segment display and then press ‘Start’. If you were to
then manually turn the Motion Sensor, you’d see an LED on the display turn off and on
as the machine sees the signal hi and low. The Motion Sensor is a wheel which turns
when the copy paper is moving through the machine… it pulses as it turns. If the signal
becomes steady (high or low) during the copy cycle, the machine calls an “E” code to
indicate a paper jam. If you wanted to test the Document Sensor, you’d select the “Top
Right Segment” of the 7 segment display and then press ‘Start’. Then if you were to
manually actuate and deactuate that switch, the LED would again turn on and off.
The Registration Adjustment works in a similar way as well. For that adjustment, you’d
want to select “7” followed by ‘Start’. Then you’d use the Copy Contrast Up and Down
buttons to change the setting. (5 is the default with the range being from 1 to 9). The
Fuser Temperature can also be adjusted in this way, except that you’d use the ‘0’instead
of the ‘7’.
To reset the NVM (non volatile memory) as would be necessary to do if you had a
flashing ‘b’ Status Code… select the “Lower Right Segment” of the 7 segment display
and press ‘Start’.
The Precharge / Detack, Charge, & Transfer are adjustable by their respective
VR’s on the High Voltage Power Supply. As is always the case, make sure to note the
position of the VR’s before you start turning them so that you can return things to where
they were if you need to. There are two versions of the Power Supply as shown in the
illustrations below.
That should be enough information to get you started in
the right direction… I hoped I’ve piqued some of your
interest out there! The Service Manuals for these can be
purchased from Xerox® on their documentation website
www.xdss.com. Gary Cox has also written a “Handi-
Guide” which covers the diagnostic info specifically for
the 2510 model.