Call Maintenance Procedure: DC/ST535F, CC/WC/WCP 35/45/55, CC/WC/WCP165/175, CC/WC232/238/245/255/275, WCP265/275, WC5687F

Located at: GSN Library #5418 Rev 01/07/08

CSE Call Ahead Make initial contact with customer and attempt to diagnose and solve problem
remotely over telephone. Negotiate time of arrival with customer.
First Call - Train the customer on how to install all CRUs. Show them how to change the Charge
Scorotron, how to set up paper trays and what paper type / weight can be run through each tray.
Initial Actions:
Question the operators. Ask about paper jams, print quality, and general performance of machine.
Check that the power cords are in good condition and correctly plugged in to the power source and
free from any defects.
Inspect any rejected prints customer may have available. Look for any physical damage to copies.
Check jams history for potential problems. Initiate corrective actions as appropriate.
Perform all HSFI actions required. (CC-WCP175F, CC-WCP275F, WC5687F only)
If more than 25,000 impressions since the last service, perform the following procedure:

User Interface
Inspect the UI Key Pad for broken buttons.
Optics:
Clean the document glass and CVT glass on every call.
Check the optics cavity for contamination and clean if needed. Refer to ADJ 14.1 in your service
documentation for proper cleaning procedure.
DADH
Check the DADF feed CRU for flat rolls and replace the CRU if any flat spots are found.
Check the condition of the document pad (091K05210). Replace if torn or punctured, clean if
contaminated.
Clean the DADH pinch rolls, drive rolls, and CVT roll.
Inspect for DADH misalignment to scanner assembly. (Twist and Skew)
Fuser and Inverter
If addressing a paper curl issue, record any nip pressure and temperature adjustments on the
service log.
Check fuser stripper fingers for wear. If worn, replace fingers or replace fuser. Clean toner buildup
from stripper fingers. Some wrinkling may be seen on the pressure roll. This is expected and
will not cause problems.
Check that heat roll is clean and does not have any damage from customers clearing jams. If heat
roll is damaged, replace the fuser module. Instruct the customer in proper jam clearance.
Inspect Fuser Latch for damage. Replace if there is hairline fracture on the side of the Latch
Inspect Fuser Web Drive Gear for damage. Replace the Web Drive Gear if damaged.
Check for dog ears on 8.5x11 short edge feed or Legal size paper. If found, install 604K30910
(Bulletin 48)
Check for reinforcement ribs on fuser lower exit guide. If not present, install kit 604K22070. (Bulletin
T5230)
Inspect the nip split solenoid in the inverter. Replace if required.
Xerographic:
Clean the charge scorotron and transfer/detack corotron on every call.
Check image quality using Section 3 (Image Quality Specifications) in your service documentation as
a guide.
Paper Feed and Transport
Clean Trays 1, 2, 3, 4, & Bypass feed rolls, vertical transport rolls, wait, and registration rolls as
needed with Formula A 43P48. Except 5687F must use Film Remover 43P45 on Tray 1, 2, & 5 feed
rolls. All remaining rolls will use Formula A.
Check Trays 3 and 4 for paper cuts on the black top corner guide at the top left inside corner of the
tray. Replace if worn with 801E11400. Also check for cuts in the ribs on the inner front side of the
tray. If paper cuts are found the entire tray needs to be replaced.
Check that the short paper path moves up in the rear smoothly.
(See Bulletin T5202).
Check and compare BOTH Tray 1 and Tray 2 Transport Rolls (PL
8.25 item#8) for equal and free movement. Re-adjust drive belt
(Adj. 8.1) - Replace the roll & bearings as required.
Inspect Tray 1 and 2 Mylar Paper Guides for breakage (PL 7.10
item 11). Replace if needed 604K25190.
If multifeeds are reported on Tray 1 & 2 (excluding 5687f):
o First install the multifeed roll fix kit (rough tread rolls)
604K48610.
o If the problem continues next install the Multifeed Repair
Kit (604K42650). Be aware there is some indication
that this kit can induce jamming problems with heavy
weight paper.
If multifeeds are reported on Tray 3 & 4:
o Install the Multifeed Repair Kit (604K24620). Be aware
there is some indication that this kit can induce
jamming problems with heavy weight paper.
o If multifeeds continue to be a problem check for Tag 052
(Part #604K35490 2004 HCF Paper Feed Assembly
Upgrade Kit). Note this feeder is a standard feature on
CC165F up to WC5687F
o Install the multifeed roll fix kit (rough tread rolls)
604K48620. This roll ONLY fits the 2004 version feeder.
535F, 5030F, CC-WCP55F, CC-WCP175F, CC-WCP275F Only:
o Use DC104 to track each tray usage to determine when to
replace or clean. Use HFSI instead on CC165F up to
WCP275F. Set counter to threshold to if needed.
o Every 100K- Replace Bypass feed roll.
o Every 200K- Replace feed rolls (Trays 1, 2, 3, 4).
o Every 200K - Clean paper feed and transport area.
Every 200K - Remove top cover on MSI and clean paper dust
from area.
5632-5687 Only:
Clean the Trays 1, 2, 4, 5, Registration, Wait, and Duplex
optical feed sensors and surrounding areas. Use a cotton swab
and a white towel.
Every 200K Replace (Trays 3 & 4 only) feed roll. Use HFSI.
Set counter threshold to 200K if needed.
Finisher
1K
Ensure the mounting bracket is not bent causing 11-300,
output device is not docked"
Check for 11-140,11-142 check belt tension (requires minimal
tension), if over 200K clean drive rollers and clean/lubricate
bearings that are driven by Transport Mot 1 and 2
Check for 11-322, 11-320 faults clean/lube Ejector Assembly
rails and bearings. Can also replace bearings with new Teflon
bearings PN (655N00279)
Every 500k - Check LCSS plastic baffles for paper cuts.

Call Maintenance Procedure: DC/ST535F, CC/WC/WCP 35/45/55, CC/WC/WCP165/175, CC/WC232/238/245/255/275, WCP265/275, WC5687F
Located at: GSN Library #5418 Rev 01/07/08

Finisher (cont.)
2K
Check that finisher is level and parallel to machine.
Check for 11-140,11-142 faults, check belt tension (requires minimal tension), Every 400K clean
drive rollers and clean/lubricate roller bearings that are driven by Transport Mot. 1 and Transport
Mot. 2
Check for 11-322, 11-320 faults clean/lube Ejector Assembly rails and bearings. Can also
replace bearings with new Teflon bearings PN (655N00279)
Check that Latch 5b front spring catch mechanism is installed properly. Refer to Bulletin 51 or
Eureka Doc ID 257504 for instruction.
Every 400k - Check LCSS plastic baffles for paper cuts.
HCSS
Check for broken 5a Baffle
Check for broken 5b white J am Clearance Latch(s)
Clean Compiler Carriage Elevator Belts and Drive Roller
Every 500K clean Compiler Belts (tractor Tires) and Drive Roller
Clean all Transport Rollers as needed
Inspect Ejector Assy. and clean Flappers

Booklet Maker
Check for broken 5a Baffle
Check for broken 5b white J am Clearance Latch(s)
Every 500K clean Compiler Belts (tractor Tires) and Drive Roller
Clean all Transport Rollers as needed
Clean BM Paddle Wheel as needed

OCT
On machines with an OCT, check for proper installation and binding of OCT Finger Kit PN
(675K26823). Do not install fingers on 65ppm machines and higher.

Software
Upgrade to the latest SMP if SW is not at the latest version, Save the NVM to MRD after the SW
upgrade. Save the NVM if any changes have been made to the DC131 files or if a DC132 reset
has been performed. On networked machines, clone the ESS settings and save the print
settings to the MRD.

Call Close Out Acti vities:
Check the last forty fault files. Diagnose and repair any faults over threshold, reset counters
afterwards.
Check that the machine copy default settings in tools are setup properly as the store manager
directs. The settings should be the same on all machines in a given location.
Make 10 copies of the Customer Letter. Put output in the DADF and make 4 sets. Place all 50
copies back in DADF and make two sets 12. Put one two-sided set in DADF and make two
more sets 22 stapled. Be sure to run paper from all trays. Fill out service log.
Present a copy of the Customer Demonstration original to the customer and explain what was
fixed. Ask customer if they have any questions / concerns regarding machine that you
may or may not have addressed. Offer training materials as needed referring to:
http://www.xerox.com/Support
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Call Description -
Parts Replaced -
Call Description -
Parts Replaced -
Original Reason for call:
Software
User
Interface
Finisher
XEROX
This document is intended to reside with
each machine.
Use this log for tracking service actions as
well as preventative maintenance activities
performed
DC/ST535F;
CC/WC/WCP 35/45/55;
CC/WC/WCP165/175;
CC/WC232/238/245/255/275;
WCP265/275
Original Reason for call:
Original Reason for call:
Original Reason for call:
Original Reason for call:
Original Reason for call:
Call Description -
Parts Replaced -
Original Reason for call:
Original Reason for call:
Original Reason for call:
Call Description -
Parts Replaced -
Call Description -
Parts Replaced -
Call Description -
Parts Replaced -
Original Reason for call:
Call Description -
Parts Replaced -
Call Description -
Parts Replaced -
Call Description -
Parts Replaced -
Primary Tech Serial No. Account Name Install Date
Optics DADH Call Closeout
Phone No. Key Operator Sys. Admin
Call Description -
Parts Replaced -
Fuser Xerographics Paper Feed and Transport
Located at: GSN Library #5418 Rev C 01/2007