Sei sulla pagina 1di 136

April 2010

701P50480

WorkCentre 7120
Service Training Student Guide
©2010 Xerox Corporation. All rights reserved. Xerox® and XEROX and design® are trademarks of Xerox Corporation in the US and/or
other countries.
Service Training Module Completion Time Sheet
Record in the table below the time you start and end
each module. Also record the total time you spent on
each module.
Ask your instructor to acknowledge your completion
of each module by initialing the Sign Off column.
Give this page to your instructor on completion of
the training course.

Instructor
Module Start Time End Time Total Time
Sign Off
1 Course Introduction

2 Service
Documentation
3 Product Overview
4 Power and Control
5 Image Input

6 Paper Supply
7 Xerographics &
Image Output
8 Fuser

9a Integrated Office
Finisher
9b Office Finisher LX

10 Image Quality

Name: ___________________________________________________

Xerox Badge Number: _______________________________________

Email address: _____________________________________________

Business phone number: _____________________________________

Xerox WorkCentre 7120


Xerox WorkCentre 7120
Module 1 Course Introduction

Introduction

Course overview
Welcome to the Xerox WorkCentre 7120 Service Training Program.
You will be introduced to a new Xerox Digital Color product as you
complete this training.
This training course is designed to serve two groups of students:
• Students training remotely who do not have access to a
machine.
• Students training at a centralized facility, in an instructor-led
class, with access to training machines.
If you are training remotely, read through the hands-on work
projects you find in this course. If you are able to gain access to a
machine, perform these activities, being sure to observe all relevant
safety precautions.
If you are taking this course at a facility where you have access to a
machine, be sure to complete all of the work projects which appear
in the Student Guide.
This first module provides an overview of the training program.

Module objective
By the end of this module you will understand the structure of the
training course and the prerequisite training, hardware, software,
and tools needed. Your instructor will review this information with
you after you finish reading this module.

STUDENT GUIDE 3/14/2010 1-1


1 Course Introduction WorkCentre 7120 Service Training

Course prerequisites and required equipment


The prerequisites for this training course are as follows:
• Color Basic (C10500)
• Network Continuum Basic (C7166)
• Introduction to Digital (C9250) – all 4 modules
• Ishihara Color Test (C1124)
• 7435 Family or 7232/7242 trained
In addition to the course prerequisites, you will require the following
hardware and software:
• PWS with Windows 98, 2000, or XP OS
• GSN version 9.0 or greater.
• Internet Explorer 5.5 or later approved version.
• Minimum of 1GB of disk space on the “C” drive
• Configured Network Interface Card (NIC)
The cables and tools listed below are required to service this
product. Some or all may be required for the training course:
• Ethernet Crossover Cable (600T02252) – Used to connect
the PWS to the Network Controller for printing.
• USB A - B Cable (600T2231) – Used to connect the PWS to
the System Controller for software loading and NVM.
• Micro-probe Tool (600T2177) – Used as an extension of the
standard meter probes in order to probe very small
connectors in the machine without damaging them

1-2 3/14/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 1 Course Introduction

Course Information and Structure


This service training is designed to help you:
• Learn about the operation and capabilities of the machine.
• Learn about and be able to locate relevant service procedures
in the EDOC.
With the foundation established by this training, you will be better
prepared to diagnose and repair electrical and mechanical faults
which arise in the field.

Course Maps and Modules


This course should be completed in a linear fashion (from start to
finish). The Course Map lists the training modules and provides an
estimate of the time to complete each module.

Table 1 – Course Map


Estimated Completion Time
Module
(Classroom / Remote)
1 Course Introduction 15 min / 10 min
2 Documentation 1 hr / 1 hr
3 Product Overview 2 hr / 1.5 hr
4 Power and Run Control 2 hr / 1 hr
5 Image Input 1 hr 30 min / 1 hr
6 Paper Supply 30 min / 30 min
7 Xerographics & Image Output 4 hr / 2 hr
8 Fuser 30 min / 30 min
9 Finishers A = 30 / B = 45 min
10 Image Quality 1 hr / 30 min

SGS content
In addition to the Student Guide, this course uses a Product Technical
Overview and electronic service documentation on an SGS CD. In most
modules there will be checkbox procedures that will direct you to view
particular SGS contents.

Self Checks
There are Self Checks throughout the training modules. Feedback for
Self Checks is provided at the end of each module.

Training Certification
After you finish the training course, you will be required to successfully
complete an on-line Certification Test.

STUDENT GUIDE 3/14/2010 1-3


1 Course Introduction WorkCentre 7120 Service Training

List of Acronyms and Abbreviations


The following list contains definitions of acronyms and abbreviations
that are used in the Service Documentation and the training
materials.
• ADC – Automatic Density Control
• AGC – Automatic Gain Control
• A/P – Advanced / Professional (Finisher)
• ATC – Automatic Toner Concentration
• BTR – Bias Transfer Roll
• BUR – Back Up Roll
• CCD – Charged Coupled Device
• CRUM – Customer Replaceable Unit Meter/Memory
• CVT – Constant Velocity Transport
• EA –EA-HG – Emulsion Aggregate - High Grade (toner)
• FAM – Functional Area Map
• FE – Field Engineer
• HDD – Hard Disk Drive
• IBT – Intermediate Belt Transfer
• I/F – Interface
• IIO – Intermediate Image Overwrite
• IIT – Image Input Terminal
• IOT – Image Output Terminal
• IPS – Image Processing Subsystem
• IRECT – Image Registration Correction Technology
• JBA – Job-based Accounting
• LED – Light Emitting Diode
• MACS – Micro Accurate Control Screen
• MCU – Machine Control Unit
• MFD – Multifunction Device
• MOB – Marks On Belt
• NIC – Network Interface Card
• NTC – New-to-Color
• NTF – New-to-Family
• NTP – New-to-Product
• NTS – National Technical Specialist
• OCT – Offset Catch Tray
• PWS – Portable Work Station
• RegiCon –- Registration Control
• RML – Recommended Materials List
• ROS – Raster Output Scanner
• SGS – Service Guidance System
• TRC – Tone Reproduction Curve

1-4 3/14/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 1 Course Introduction

Module Summary
This module provided you with an overview of the Service Training
Program.
At this time, you should understand the structure of the training
course and the prerequisite knowledge, hardware, software, and
tools needed.
There are no Fault Analysis activities and no test for this module.

STUDENT GUIDE 3/14/2010 1-5


1 Course Introduction WorkCentre 7120 Service Training

NOTES
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________

1-6 3/14/2010 STUDENT GUIDE


Module 2 Documentation

Introduction

Module Overview
This module describes the contents of the Service Training Kit. It
also provides an overview of the types of service tools and
resources that are available for you to diagnose, troubleshoot, and
update software for this product.

Module Objectives
Given the field resources available to you, by the end of this
module you will be able to:
1. Identify the service tools and documentation that are available
for supporting a technician in the field.
2. Connect the PWS to the machine using a USB cable.
3. Locate the service documentation that will enable you to save
NVM values, reset High Frequency Service Items (HFSI), and
activate machine input and output components.
4. Access information using the Service EDOC and the SGS
Clock Dial.

Technology Overview
The WorkCentre 7120 service procedures and documentation are
similar to those for other products. In most cases, the content of
these procedures is the same or nearly identical.
The Technology Overview for this module is provided by
information in this Student Guide as well as information in the
Service Training SGS.

STUDENT GUIDE 3/18/2010 2-1


2 Documentation WorkCentre 7120 Service Training

Included on the launch CDs for this product are several resources
that are useful for servicing the machine. These tools are loaded
on your PWS and include the following software:
Electronic Documentation (EDOC) for the machine provides a
convenient way to access all Service Call Procedures (SCP),
Repair Analysis Procedures (RAPs), Repair and Adjustment
procedures (REPs and ADJs), Parts Lists (PL), General
Procedures (GPs), and Wiring Diagrams (BSDs) used to help you
diagnose and repair problems with this machine. Hypertext links
make accessing the desired information fast and easy.
SGS stands for Service Guidance System. Many Xerox products
are now delivering documentation and training in a format that
combines traditional documentation with additional resources in a
media-rich format that can be used at the point of need.

The training kit contents are listed below:

Qty. Part Number Service Training Kit content descriptions

1 705P01281 WorkCentre 7120 EDOC/SGS CD

WorkCentre 7120 Family PWS & Engine Software


1 701P31020
Download Tool CD

1 701P50481 WorkCentre 7120 Series CSE Read Me First doc – hard copy

2-2 3/18/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 2 Documentation

Service Documentation (EDOC) Installation


‰ Retrieve the EDOC CD located in the Student Service Training
Kit. Install the EDOC Software on your PWS by following the
instructions on the yellow pullout sheet.

Service Notes
Please observe the following cautions when performing any service
or hands-on training on the machine.

CAUTION: Do not plug in or unplug any component while machine


power is ON. The 24VDC which is present at many components
can cause arcing damage to the circuitry of the machine.

CAUTION: Electrostatic Discharge is a concern at all times. Even


after you power off the machine, it is extremely important that you
follow ESD procedures for grounding. The new smaller micro-
circuitry of the PWB’s makes them all the more susceptible to
damage. Worst of all, some ESD damage goes undetected for
weeks or months and then the intermittent problems begin to
surface.

STUDENT GUIDE 3/18/2010 2-3


2 Documentation WorkCentre 7120 Service Training

Work Projects
‰ Perform Work Projects 1 through 5 below from the Contents
pane of the EDOC, not the SGS main menu. Later you will locate
specified items using the SGS main menu.

EDOC Work Project

Project 1 – EDOC

‰ Review the menu bar and the navigational features for accessing
the service information on your EDOC.
‰ Using the EDOC Contents pane (left side of screen), locate the
following. Use the screen features to expand and collapse each
selection to see what each contains. Check off the sections as
viewed.
_____ Service Call Procedures
_____ Repairs and Adjustments
_____ Repair Analysis Procedures (RAPs)
_____ Block Schematic Diagrams (BSDs)
‰ Expand the Service Call Procedures in the Contents pane and
then select the Call Flow.
‰ Work through the Call Flow, navigating its branches to view the
paths it provides.
‰ Answer the following question.
What are the first three steps you should take to service a
machine that does not complete boot-up? Read the descriptions
at the right, determine the correct sequence, then number the
steps in the column at the left (just 1, 2, and 3). You may refer to
the EDOC for assistance in numbering the steps. Check your
answers on the Feedback page at the end of the module.

Step Description
Categorize the problem.
Look at the LEDs on the ESS PWB to determine if
the boot sequence is correct
Go to Call Flow
Reload the software and verify the repair.
Select the Machine Not Ready RAP.
Perform GP14 Special Boot Mode.
Check the software version, if possible.

2-4 3/18/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 2 Documentation

Project 2 – UI diagnostics

‰ In EDOC section 6, refer to the procedure Entering and Exiting


Service Rep. Mode.
‰ Read the procedure for entering and exiting Service Rep Mode.
Notice that the screen appearance is different than on other
models, that is, a Service Rep box appears at the top right
corner of the screen when in Service Rep mode.
‰ In EDOC section 6, refer to the Accessing UI diagnostics.
Review the section.
‰ Refer to 6 General Procedures/Information > UI Diagnostics
> Printing CSE Reports and familiarize yourself with the reports
which can be printed.

Project 3 – Component Control

‰ Using the EDOC, locate the input component control codes for
the following and write the code number in the space provided.
Check the Feedback page at the end of the module for the
correct answers.

Device Code
DADF Feed Out Sensor
Tray 1 Level Sensor
Fuser Exit

‰ Using the EDOC, locate the output component control codes for
the following and write the code number in the space provided.
Check the Feedback page at the end of the module for the
correct answers.

Device Code
Fuser Motor (175mm Speed)
IIT Exposure Lamp
Takeaway Clutch

Project 4 – Save Machine Data

‰ Refer to GP3 – Saving Machine Data


‰ Review the procedure for connecting the PWS to the machine
and saving the NVM data.

STUDENT GUIDE 3/18/2010 2-5


2 Documentation WorkCentre 7120 Service Training

Project 5 – NVM Read/Write

There are two ways to perform NVM Read/Write, one from the UI
(NVM Read/Write), the other from the PWS (dC131).
‰ Locate and read the diagnostic routine dC131 in section 6 of the
EDOC.
‰ Locate the procedure Accessing UI Diagnostics in section 6 of
the EDOC. Select the link for NVM Read/Write and read the
procedure.

SGS work project


The SGS main menu provides an alternate way to access the
service documentation. Each hour on the clock dial links to a
different section of the service documentation.
‰ Display the SGS main menu by selecting the WorkCentre 7120
Family Main Menu from the root of the PWS Xerox Contents
for the product.
‰ If errors occur, ensure your PWS browser is set to allow blocked
content.
‰ Click on 1 Service Call Procedures
‰ Notice that it opens a menu of Service Call Procedure buttons.
‰ Select the Call Flow button. This action launches the Call Flow
in the EDOC.
‰ Click the Back button to return to the Service Call Procedures
menu.
‰ Select the Detailed Maintenance button.
‰ Briefly review the items in the HFSI list.
‰ Click the back button until the SGS main menu reappears.
‰ Click on 5 Parts List.
‰ Notice that it points to parts list information that you earlier
accessed from the EDOC Contents pane.
‰ Click a few other spots on the clock dial.
‰ Return to the SGS main menu.
‰ Using the SGS clock dial, locate each of the Fault Codes listed
at the left. After you locate each code, enter its name and the
associated BSD in the boxes provided. Check your answers in
the Feedback at the end of the module.

Fault Code Fault Code Name BSD ON


010-330
005-210
042-313

2-6 3/18/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 2 Documentation

Support Information (at Instructor’s discretion)


‰ Ask your instructor if you are to perform the following three
activities.
1. Use your PWS to access the BUS.
2. Download the Eureka Database for the machine.
3. Review the latest bulletins and field problems for this
product.

STUDENT GUIDE 3/18/2010 2-7


2 Documentation WorkCentre 7120 Service Training

Module summary
You should now be able to:
1. Identify the service tools and documentation that are
available for supporting a technician in the field.
2. Connect the PWS to the machine using a USB cable.
3. Locate the service documentation that will enable you to
save NVM values, reset High Frequency Service Item
(HFSI), and activate machine input and output components.
4. Access information using the Service EDOC and the SGS
Clock Dial.
‰ Review the learning objectives above. If you feel that you can
perform the objectives, proceed to the next training module. If
you do not feel comfortable in your ability to perform one or more
of the objectives, review the appropriate portions of this module.
‰ If you are training in a classroom/lab setting, ask your instructor
sign you off on this module.
There are no fault analysis activities for this module.

2-8 3/18/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 2 Documentation

Feedback
‰ What are the first three steps you should take to service a
machine that does not complete boot-up??

Step Description
3 Categorize the problem.
Look at the LEDs on the ESS PWB to determine if
---
the boot sequence is correct.
1 Go to Call Flow.
Reload the software, if necessary, and verify the
---
repair.
2 Select the Machine Not Ready RAP.
--- Perform GP14 Special Boot Mode.
--- Check the software version, if possible.

‰ Using the EDOC, locate the input component control codes for
the following and write the code number in the space provided.

Device Code
DADF Feed Out Sensor 005-205
Tray 1 Level Sensor 071-102
Fuser Exit 010-101

‰ Using the EDOC, locate the output component control codes for
the following and write the code number in the space provided.

Device Code
Fuser Motor (175mm Speed) 010-001
IIT Exposure Lamp 062-002
Takeaway Clutch 077-001

‰ Using the SGS clock dial, locate each of the Fault Codes listed
at the left. After you locate each code, enter its name and the
associated BSD in the boxes provided. Check your answers in
the Feedback at the end of the module.

Fault Code Fault Code Name BSD ON


010-330 Fuser Motor Fail RAP 10.1
005-210 DADF Download Fail RAP 3.5
042-313 LV Rear Intake Fan Fail RAP 1.3

STUDENT GUIDE 3/18/2010 2-9


2 Documentation WorkCentre 7120 Service Training

2-10 3/18/2010 STUDENT GUIDE


Module 3 Product Overview

Module Introduction

Module Overview
In this module you will learn about the main configurations of the
machine. You will also learn how to use the machine features and
perform the routine maintenance activities required to keep the
machine operating correctly.

Module Objectives
At the completion of this module, you will be able to:
• Describe the marketing configurations
• Use the copy, scan, print, and fax (if available) features of the
machine
• Perform the maintenance activities that a user is expected to
perform.
• Verify that the machine can receive documents from the network
using your PWS and a crossover cable.

Module Instructions
Part of the Technical Overview section of this module is an instructor
led overview at the machine. When that is complete, you will use the
Work Projects section of the module to guide you through learning how
to use the machine features.
Students training remotely: Be sure to complete all readings in the
PTO, all EDOC activities, and all Self Checks in this module. If a
machine becomes available to you, take the opportunity to perform any
hands-on Work Projects.

Student Guide 3/15/2010 3-1


3 Product Overview WorkCentre 7120 Service Training

Technical Overview

Introduction
The WorkCentre 7120 is a fully featured color multifunction printer that
is designed to support small to medium-sized businesses and
enterprise workgroups. It is a versatile multifunction device that offers
copy, print, fax, and scan capabilities. It also brings a full complement
of color features and functionality to the small business or workgroup.
There are two configurations of the WorkCentre 7120:
• WorkCentre 7120 (two paper trays)
• WorkCentre 7120T (four paper trays)
The speed of the machine is up to 20 color or 20 monochrome pages
per minute (ppm).

Marketing Strategy
The WorkCentre 7120 is positioned as an entry level A3 color
multifunction printer, at the low end of Xerox’s A3 color portfolio. The
entry-level A3 color market is an extremely important segment. In
recent years there has been a significant migration in the market away
from the 1-10 ppm color segment to the 11-20 ppm color segment.
Despite the current economic conditions, activity in the latter segment
has grown significantly.
The WorkCentre 7120 machines provide economical black and white
and full color printing. They are intended to fill the space now occupied
by the WorkCentre 7132 and the WorkCentre 7232/7242.
The 7120 will be marketed with two optional finishers, the Integrated
Office Finisher and the Office Finisher LX.
The WorkCentre 7120 is competitively priced to be aggressively
marketed against such devices as Konica Minolta bizhub C200, C203,
and C220; Ricoh Aficio MP C2030 and Aficio MP C2050; and Canon
imageRunner C2550.

3-2 3/15/2010 Student Guide


WorkCentre 7120 Service Training 3 Product Overview

Machine Configurations
The WorkCentre 7120 and 7120T share the same feature functionality,
the only difference being the number of paper trays. The WorkCentre
7120 comes with two paper trays and a stand, and holds up to 1,090
sheets of paper; the WorkCentre 7120T comes with 4 paper trays that
hold up to 2,130 sheets of paper.

Standard Features
‰ Read the list of standard features in the table below.

Feature Description
Capacity: 110 sheets
Duplex Automatic Document Sheet sizes: 5.5 x 8.5 in. to 11 x 17 in. / A5 to A3.
Feeder (DADF)
Custom sizes: 3.3 x 4.9 in. to 11.7 x 17 in. / 85 x 125 mm
to 297 x 432 mm
Capacity: 50 sheets
Bypass Tray Custom sizes: 3.5 x 3.9 in. to 11.7 x 17 in. / 89 x 98 mm
to 297 x 432 mm
Capacity: 520 sheets each
Sizes: 5.5 x 8.5 in. to 11 x 17 in. / A5 to A3
Trays 1 - 4
Custom sizes: 5.5 x 7.2 in. to 11.7 x 17 in. /
140 x 182 mm to 297 x 432 mm
250-sheets each
Dual Catch Tray
Lower tray offsets
FCOT As fast as 8.1 seconds color / 6.5 seconds B&W
FPOT As fast as 13 seconds color / 11 seconds B&W
600 x 600 dpi copy
Resolution
600 x 600 x 4 dpi print
Automatic two-sided, Electronic pre-collation, Automatic
tray selection, Build Job, Negative/Mirror image,
Automatic booklet creation, Multi-up, Auto RE, Mixed-
Copy Features size originals, Covers insertion, Sample set, Book
copying, Store and recall job programming, Annotation,
Auto color selection, Area designation, Poster mode,
Watermarks, ID Card Copy
Memory and HDD 2 GB plus 80 GB hard drive
10/100Base-TX Ethernet
Connectivity High-Speed USB 2.0 direct print
Wireless Ethernet 802.11b (via third-party adapters)
PDF, XPS®, PCL® 6 emulation, HP-GL2™, Optional
Adobe® PostScript® 3™
Page Description Languages
NOTE: Adobe® PostScript® 3™ is no longer standard
for XC; it is a World Wide Option

Student Guide 3/15/2010 3-3


3 Product Overview WorkCentre 7120 Service Training
Automatic two-sided, Secure print, Delay print, Sample
set, Booklet creation, Cover selection, Paper selection by
Print Features
attribute, N-up, Watermarks, Banner sheets, Fit to new
paper size, Output tray selection, Optional print from USB
Scan Scan to Email, Scan to Folder
Auditron, Xerox Standard Accounting (Copy, Print, Fax,
Accounting Scan), Enabling Color access control, Optional Network
Accounting Enablement Kit (Alliance Partners)
Secure Print, Authentication with
LDAP/Kerberos/SMB/CAC, Password Protected PDF,
Security
FIPS 140-2 encryption, S/MIME Encrypted Email, IPSec,
802.1x, SNMP v3.0
Windows XP/Server 2003/Server 2008/Vista/Windows 7;
Mac OS 10.3 and above; AIX 5 v5.3; HP UX 11.0/11i v2;
Operating Systems
Solaris 8/9/10; Linux Fedora Core 1/5; Red Hat ES4;
SUSE 10/11

Optional Features
‰ Read the list of optional features in the table below.

Option Description
Envelope Tray (replaces Tray 1) Up to 60 envelopes: #10 commercial,
Monarch, DL, C5, Custom sizes: 3.9 x 5.8 in. to 6.4 x 9.5
in. / 98 x 148 mm to 162 x 241 mm
Integrated Office Finisher 500-sheet stacker, 50 sheets stapled, single-position
stapling
Office Finisher LX 2,000-sheet stacker, 50 sheets stapled, 3-position
stapling, optional hole-punch, optional booklet maker
(score, saddle stitch)
Convenience Stapler Staples 50 sheets
Fax Optional Walkup PSTN fax (one-line and three-line
options) with Internet fax, Voice Over IP Fax Kit, Network
Server Fax Enablement Kit (requires Scan Kit)
Fax features LAN fax, Fax Forward, Two-sided Send and Receive,
print on fax up to 11 x 17 in. / A3, Fax Build Job, Optional
Thumbnail Preview
Scan options Scan to USB, Scan Kit (Network Scan, Text searchable
PDF, PDF/A, XPS, MRC compression, Thumbnail
Preview)
Additional software options Scan to PC Desktop®, Various Xerox Alliance Partner
Solutions, SMARTsend®
Security offerings (optional) Data Security Kit (Image Overwrite, Data Encryption,
Audit Log), CAC, Secure Access Unified ID System
Other options USB Enablement (Print from/Scan to USB), Media Card
(see also Software Key Options Reader, Common Access Card Enablement Kit,
below) Thumbnail Preview, Work Surface, Foreign Device
Interface, Text searchable PDF, PDF/A, XPS

3-4 3/15/2010 Student Guide


WorkCentre 7120 Service Training 3 Product Overview

Software Key Options


In addition to the above options, the customer may purchase a number
of software key options.
‰ Read the list of standard features in the table below.

Option Description Availability


Scan Kit Provides Searchable PDF, Scan High World Wide
Compression, and Thumbnail Preview
features
(Kit includes two software keys)
Searchable PDF kit Software key enabled World Wide

Server Fax Kit Software key enabled World Wide


Thumbnail Preview Kit Software key enabled World Wide

VOIP Fax Kit NOTE: Slated for release near World Wide
product launch time.
Job Based Network Software key enabled World Wide
Accounting Kit
Data Security Kit Software key enabled World Wide
USB Enablement Kit Print from/Scan to USB features World Wide
software key enabled
Thumbnail Preview feature included.
This key is required to use Media
Card Reader and CAC

‰ Select 12 Library on the SGS main menu.


‰ Select and read the CED (Customer Expectations Document).
‰ Answer the following by writing your answers on the lines provided.
Check your answers on the Feedback page at the end of the module.
1. What is the Average Monthly Volume of the machine?
_____________________________________________________
2. What is the Maximum Duty Cycle of the machine?
_____________________________________________________
3. What is the Warm Up Time of the machine?
• From Power ON ____________________________________
• From Sleep ________________________________________
• From Low Power ____________________________________
4. What are the Lead Edge, Side Edge, and Trail Edge Deletion
values for all media?
LE: _________________________________________________
SE: _________________________________________________
TE: _________________________________________________
5. What must the user do switch between Print from USB Drive and
Media Card? __________________________________________ .

Student Guide 3/15/2010 3-5


3 Product Overview WorkCentre 7120 Service Training

Customer Maintenance
Customer Maintenance consists of the replacement of the various CRU
assemblies, loading paper and staples, cleaning activities, and jam
clearance. All activities are quick and straightforward with no training or
experience required. The customer maintenance activities are found in
the Maintenance section (chapter 8) of the User Guide (under
12 Library on the SGS). You will soon be directed review the content of
the User Guide.

Customer Replaceable Units (CRU) & HFSIs


The customer may replace several assemblies and components.
These units are:
• Toner Cartridge (listed as a consumable)
• Drum Cartridge (this and the following are listed as Routine
Maintenance Items)
• Waste Toner Container
• Fuser Assembly
• IBT Assembly
• Second Bias Transfer Roller
• Hole Punch Waste Container
• Staple Cartridge
• Staple Cartridge for Booklet Maker

‰ Referring to the EDOC, complete the table below by entering the


Counter Threshold Values (life expectancy) of the CRUs and High
Frequency Service Items.
CRU Threshold Value(s)
Drum Cartridge
Fuser Assembly
Second Bias Transfer Roller
Transfer Belt
DADF Feed, Nudger, and Retard
Rolls

Cleaning Activities
The cleaning activities listed in the Maintenance section of the User
Guide are:
• Cleaning the Document Glass and Document Cover
• Cleaning the Exterior
• Cleaning the Document Feeder Rollers
• Cleaning the ROS lenses

3-6 3/15/2010 Student Guide


WorkCentre 7120 Service Training 3 Product Overview

Work Projects
Each module contains work projects that must be completed in order to
complete the module. The following are general instructions that apply
to all of the work projects in the WorkCentre 7120 service training.

Instructions
Do all the projects in the order listed and check off after you have
completed the task.
Follow all procedures as written in the documentation. Use the
documentation to assist in location of components.
If you have any questions about the procedures ask your instructor.

Customer Documentation
The customer is provided with the following user documents.

Quick Use Guide


The Quick Use Guide contains easy to follow, highly visual instructions
for performing basic copying, printing, faxing, and scanning tasks.
‰ Select the Quick Use Guide in 12 Library in the SGS. Review the
information contained in the Quick Use Guide.
In addition to the Quick Use Guide there are the following more detailed
guides.

Xerox® WorkCentre® 7120 User Guide


The User Guide contains detailed information, technical specifications,
and procedures for using the features of the machine.
‰ Select the User Guide in 12 Library in the SGS. Review the
information contained in the User Guide.
‰ Review the maintenance activities that the user is expected to perform.

System Administration Guide


The System Administration Guide contains detailed information about
setting up and configuring the machine. This information is beyond the
scope of the normal user.
‰ Select the System Administration Guide at 12 Library in the SGS.
Review the information contained in the System Administration Guide.

Student Guide 3/15/2010 3-7


3 Product Overview WorkCentre 7120 Service Training

Copy Functions
Perform the following activities to become familiar with the customer
documentation and the operation of the machine. Refer to 5 Copying in
the User Guide and perform the following.
‰ Ask your Instructor for some A4/ 8.5x11 inch and A3/ 11x17 inch
Demonstration Originals, or make some yourself.
‰ Load 6 single sided A4/ 8.5x11 inch documents into the DADF. Note
that the guides position the documents on the centerline of the
document handler.
Make 3 sets of 1 to 2-sided copies into the output tray.
• Quantity: 3
• Output Color: Auto Detect
• Paper Supply: Auto Select
• 2 Sided Copying: 1 Æ 2 Sided
• Output: Collated
‰ Keep one set of the copies to use as double sided test documents.
‰ If a finisher is installed, use one of the 2-sided sets to make 5 stapled
sets using a single sided A3/ 11x17 inch document
‰ Make 3 copies from the platen of an A3/ 11x17 inch document using
50% reduction. Ensure that the page orientation is maintained.
‰ Press Clear All.
• Quantity: 5
• Output Color: Auto Detect
• Paper Supply: Auto Select
• 2 Sided Copying: 2 Æ 2 Sided
• Copy Output: Collated 1 Staple
‰ Press Start.
‰ Press Clear All after job completes.
‰ Using an A3/ 11x17 inch document and the document handler, make 3
single sided copies with Auto Reduction selected. Maintain the
document orientation and copy onto A4/ 8.5x11 inch paper.
‰ Refer to the Image Quality Adjustment section in the User Guide. Try
some of the settings on the machine and observe the effect.

3-8 3/15/2010 Student Guide


WorkCentre 7120 Service Training 3 Product Overview

Job and Machine Status


The Job and Machine Status buttons enable access to information
about jobs and the machine.
‰ Select the Job Status Button on the Control Panel
‰ Review the different selections for Active Jobs, Completed Jobs, and
Secure Print Jobs & More.
‰ Select the Machine Status button.
‰ Review the selections and features found in the Machine Information,
Faults, Supplies, Billing Information, and Tools tabs.

Print from/Scan to USB


Print from/Scan to USB is a recent addition to selected WorkCentre devices.
‰ Go to 12 Library on the SGS main menu.
‰ Open the User Guide.
‰ Read the section in the User Guide entitled “Printing from USB Flash
Drive and Media Card Reader.”
‰ If a machine is available, follow the instructions in the User Guide and
print a text or graphics file from a USB drive. Save the print.
‰ Read the section in the User Guide entitled “Storing to a USB Flash
Drive.”
‰ Following the instructions in the User Guide, store one of the prints you
just made to the USB drive.
‰ Exit the routine to the Service screen when finished.

Administrator Tools
The System Administrator can change machine defaults, screen
defaults, and settings using the Administrator mode. The customer or
System Administrator sets up the work settings and features using this
protected part of the machine software.
‰ Press the Log In/Out button on the control panel.
‰ Input the default Admin ID admin.
‰ Press Next.
‰ Enter the Admin pass code 1111 and select Enter.
‰ Select the Machine Status button.
‰ Select the Tools tab.
‰ Review the Administrator options. Full descriptions of all the setup
procedures are found in the User Guide and the SA Guide.

Student Guide 3/15/2010 3-9


3 Product Overview WorkCentre 7120 Service Training

Enabling Optional Software Key Features


The WorkCentre 7120 will arrive at the customer with the options that
have been ordered enabled. However, should these options become
disabled during a service call you will need to enable them.
To enable the optional features you will need to locate the customer’s
option kit that contains the license string. Once you have the license:
‰ Enter the Administrator Mode. Press the Log In / Out button
‰ Input the default Admin ID admin, select Next, enter the Admin
password 1111, and select Enter.
‰ Select the Machine Status Button and the Tools tab.
‰ Select System Settings > Common Service Settings > Maintenance
> Software Options.
‰ Input the license string here, using the on-screen keyboard. The code is
case sensitive. The machine must be rebooted to activate the options.
‰ For the E-mail and Server Fax options you will also need to enable the
E-mail send and receive port settings.
‰ In Administration mode select System Settings >in the Group column
Connectivity & Network Setup > Port Settings and enable Receive
E-mail and Send E-mail.
Once an option has been enabled and the machine rebooted, the
option icon will appear on the All Services screen.
NOTE: The options may also be enabled while in the service diagnostics. The
license strings are stored in three different memory locations (ESS
PWB, ESS PROM, and MCU PWB) so if one PWB is replaced the
information will not be lost.

Fax Operation
‰ The following two exercises are about enabling and using the Fax
option. If your training machine is equipped with a fax and connected
to a phone line, follow the steps listed here.
‰ If your machine is equipped with a fax but is not connected to a phone
line, perform the steps on the machine with the exception of sending a
fax.
‰ If your training machine is not equipped with a fax, see your instructor.

3-10 3/15/2010 Student Guide


WorkCentre 7120 Service Training 3 Product Overview

Connecting the Fax


When the machine is connected to the telephone line for the first time
the Date and Time, Local Name, Company Logo, ID, Dial Type and
Line Type must be set.
‰ Access the Administrator Mode by pressing the Login/Logout button
on the control panel and the Tools tab.
‰ Input the default Admin ID admin > Next > Admin password 1111 >
Enter.
‰ Select:
System Settings > > Common Service Settings > Machine
Clock/Timers to set the date and time.

System Settings > Common Service Settings > Fax Service


Settings > Local Terminal Information to set the Local Name,
Company Logo, ID, Dial Type and Line Type.

Sending a Fax
In this section the Fax facilities of the machine are used to conduct
some basic Fax operations. Use the Quick Use Guide or the User
Guide for information.
‰ On the machine select the Fax button on the All Services screen.
Check the options available. To view all the options available select the
feature to check out any further options.
‰ Review the various dialing methods and create a dial directory and a
speed dial number for a fax machine if possible. Check with your
instructor for the telephone number.
‰ Review the procedures for sending a Fax to another Fax machine or
local fax enabled machine. If there is a fax machine available scan and
send a document to that machine.

Student Guide 3/15/2010 3-11


3 Product Overview WorkCentre 7120 Service Training

Network Operations
The following exercises are about enabling and using the network
options. You will perform the following operations:
• Loading and configuring the WC 7120 print drivers on your PWS
• Network printing operation from your PWS
• Verifying machine network operation with a crossover cable
• Verifying scan services operation with a crossover cable

Network Printing
If your WC 7120 and your PWS are connected to the network in your
training location perform this Network Printing exercise. If you do not
have a network connection, skip this exercise and continue with the
Network Troubleshooting activities.
The following steps will enable network printing from your PWS to the
WC 7120 using both the PostScript and PCL print drivers.
‰ Go to the System Administrator Guide and perform the Configuring
IPv4 Dynamic Address Settings procedure. In step 4 select DHCP.

The following will load the PostScript and HP PCL drivers on your
PWS.

PostScript & PCL Drivers


‰ Once you have verified that you can connect to the CentreWare
Internet Services go to the Users Guide. Using Chapter 3 Installation
and Setup, perform the steps to install the PostScript driver from the
Xerox website to your PWS.
‰ Using Chapter 3 Installation and Setup in the User Guide, perform
the steps to install the PCL driver to your PWS.

3-12 3/15/2010 Student Guide


WorkCentre 7120 Service Training 3 Product Overview

Software Download
Software may be downloaded using one of three methods:
ƒ From the PWS, using the PWS Software Download Tool
ƒ From a USB Flash Drive
ƒ Via CentreWare Internet Services
‰ Go to the SGS main menu.
‰ Select 6 General Procedures/Information.
‰ Select the General Procedures button.
‰ Select and familiarize yourself with GP7 Software Download and
GP 16 Downloading Software from USB Flash Drive or CentreWare
Internet Services.
‰ Tell your instructor when you have completed reviewing the above
General Procedures. The instructor may or may not have you download
software to the WorkCentre 7120.

Student Guide 3/15/2010 3-13


3 Product Overview WorkCentre 7120 Service Training

Troubleshooting Network Problems


If the customer is having a problem communicating with their WC 7120
over the network, the following procedures will allow you to verify
correct operation of the hardware and software in the machine. This will
enable you to discuss with the customer whether the problem is in the
network or in the machine.
These procedures are:
• Verifying network printing operation using an RJ45 Crossover
Ethernet cable and your PWS.
• Verifying network scan operation using an RJ45 Crossover
Ethernet Cable and your PWS.

‰ Go to 12 Library on the SGS main menu.


‰ Select the PDF document entitled Network Troubleshooting.
‰ Perform all of the exercises in the document. Ask the instructor if you
have any questions or encounter any problems.
‰ Return here after completing all of the activities in the Network
Troubleshooting document.

3-14 3/15/2010 Student Guide


WorkCentre 7120 Service Training 3 Product Overview

Module Summary
Now that you have completed this module you should be able to:
• Describe the marketing configurations
• Use the copy, scan, print, and fax (if available) features of the
machine
• Perform the maintenance activities that a user is expected to
perform.
• Verify that the machine can receive documents from the network
using your PWS and a crossover cable.
‰ Review the learning objectives above. If you feel that you can perform
the objectives, proceed to the next training module. If you do not feel
comfortable in your ability to perform one or more of the objectives,
review the appropriate portions of this module.
‰ Ask your instructor sign you off on this module.

Student Guide 3/15/2010 3-15


3 Product Overview WorkCentre 7120 Service Training

Feedback
1. What is the Average Monthly Volume of the machine?
4,000 to 8,000 transactions
2. What is the Maximum Duty Cycle of the machine?
Up to 50,000 transactions per month
3. What is the Warm Up Time of the machine?
• From Power ON 40 sec.
• From Sleep 26 sec.
• From Low Power 26 sec.
4. What are the Lead Edge, Side Edge, and Trail Edge Deletion
values for all media?
LE: 4mm
SE: 2mm
TE: 2mm
5. What must the user do switch between Print from USB Drive and
Media Card? Power the machine Off and On

Referring to the PTO and the EDOC, complete the table below by
entering the Counter Threshold Values (life expectancy) of the CRUs
and High Frequency Service Items.

CRU Threshold Value(s)


Drum Cartridge 59,900
Fuser Assembly 100KPV or 18,000,000 time count
Second Bias Transfer Roller 200KPV
Transfer Belt 200KPV
DADF Feed, Nudger, and Retard 300K sheets
Rolls

3-16 3/15/2010 Student Guide


WorkCentre 7120 Service Training 4 Power And Run Control

Module 4 Power and Run Control

Module Overview
This module covers Input Power, Switched Power, the User
Interface, Machine Run Control, and Start Print Power.
You will use the SGS and the EDOC to learn about the major
components in this area of the machine.
Students training remotely: Be sure to complete all readings in
the PTO, all EDOC activities, and all Self Checks in this module. If
a machine becomes available to you, take the opportunity to
perform any hands-on Work Projects.
Students in centralized training: If, after reading the content of
this module, you feel that you have the skill and knowledge to “opt-
out” of the removal procedures or Work Projects for this module,
contact your instructor. Your instructor may test your knowledge
before allowing you to move on to the next module. Allowing
students to move ahead before they complete the entire module is
at the instructor’s discretion.

Module Objectives
Upon successful completion of this module you will be able to:
1. Understand the Input Power, Switched Power, User Interface,
Machine Run Control, and Start Print Power of the WorkCentre
7120.
2. Trace input power in the BSDs.
3. Locate the EDOC sections which are required to diagnose
problems associated with power and control problems.

STUDENT GUIDE 3/18/2010 4-1


4 Power And Run Control WorkCentre 7120 Service Training

Technology Overview
One of the first things you will notice when servicing the
WorkCentre 7120 is the greatly reduced number of PWBs.
Functions which previously were spread across many PWBs are
consolidated in fewer.
• The image processing functions which usually are performed on
a stand alone IIT PWB or IIT/IPS PWB here are performed on
the ESS PWB.
• The IIT PWB on the 7120 receives instructions from the ESS
PWB and carries image data from the IIT to the ESS PWB for
processing.
• The is no NVM PWB on either the ESS PWB or the MCU PWB.
On the 7120 these functions are hard-wired into the PWBs.
• +5VDC Standby, +5VDC, and +24VDC power are produced by
one power supply alone, the Main LVPS, then distributed
throughout the machine.
• As on many similar products, some PWBs produce low voltage
power for their own unique needs, e.g., the IIT PWB produces
the Analog 3.3V, 5V, and 10V required by the IIT PWB and the
CCD Lens Assembly, and the MCU PWB produces +3.3VDC,
+1.2VDC, and +2.5VDC power that it supplies throughout the
IOT.
You will also notice that the power on process is unique. There is a
Main Power Switch under the Front Cover and a Power Switch at
the front corner of the output area. They must be switched on
and off in the correct sequence when powering the machine
on or off.

Input Power
‰ Go to the SGS clock dial.
‰ Select 10 PTO.
‰ From the PTO menu, select 1 Input Power.
‰ Select the Input Power button on the menu and read the
information presented. When you finish the final screen you
will be returned to the Input Power PTO menu.

4-2 3/18/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 4 Power And Run Control

‰ Answer the question below by writing the missing word or


words on the line provided. The correct answer appear on the
Feedback page near the end of this module.
1. +5VDC Standby power is supplied to the ESS PWB when
the _________ Switch is ON.
______________________________________________
Write the answer to the following on the lines provided. Check
the Feedback page to verify that you answered correctly.
2. Based on what you have read in the PTO, name one way
in which you can verify that the Main LVPS is producing
standby power. __________________________________
______________________________________________
‰ At the SGS, with the Input Power PTO menu displayed, select
the Switched Power button.
‰ Select the IOT Switched Power button and read the section.
You will be returned to the four Switched Power buttons when
you leave the final IOT Switched Power screen.
‰ Select the IIT Switched Power button. Read the section.
‰ Select the Finisher Switched Power button. Read the
section.
‰ Select the Interlock Power button. Read the section.
‰ When you are done reading the above selections in the PTO,
return to the SGS clock dial.
‰ Select the 7 Wiring Data item.
‰ Select the BSDs button when the Wiring Data menu appears.
‰ From the menu select Chain 1 – Input Power.
‰ Write the answers to the following on the lines provided.
Answers are in the Feedback section at the end of this
module.
3. Beginning at BSD 1.1 Main Power On, trace (in the BSDs)
the ACH from the Inlet GFI Breaker to the Finisher Outlet.
Record the connector numbers the AC power travels
through to reach the Finisher Outlet.
ACH in to Main LVPS _____________________________
ACH out from Main LVPS to Finisher Outlet ___________
ACH in to Finisher Outlet __________________________
‰ Return to the SGS main menu.

STUDENT GUIDE 3/18/2010 4-3


4 Power And Run Control WorkCentre 7120 Service Training

Component Location: Input Power


‰ Locate components in the service documentation as follows:
ƒ Refer to the SGS Parts List (5 Parts List) and locate all of
the components listed in the table below.
ƒ Record the PL number of each item in the space provided.
Check your answers on the Feedback page near the end of
the module.

Component PL

Main Power Switch Assembly

Power Switch

Front Interlock Switch Assembly

‰ If you are training in a classroom/lab environment, now locate all


of the IOT and IIT interlock devices on the machine.
‰ Return to the SGS main menu.

User Interface
‰ At the SGS main menu, select 10 PTO, select 2 User Interface,
and then select the User Interface Overview button.
‰ Read the entire UI Overview.
‰ After completing the UI Overview, select the Service
Diagnostics button and read the section.
‰ If you have access to a WorkCentre 7120, ensure that it is
powered up, then enter and exit the Service Rep Mode
following the instructions in the PTO.
Notice that the appearance of the Service Rep Mode screen is
different than you have been accustomed to seeing when
switching between User and Service Modes.
‰ Return to the SGS main menu.
‰ Select the 7 Wiring Data item.
‰ Select the BSDs button when the Wiring Data menu appears.
‰ From the menu select Chain 1 – Input Power.
‰ Write your answers to the following on the lines provided. Check
your answers on the Feedback page at the end of the module.

4-4 3/18/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 4 Power And Run Control

4. Referring to the BSDs, what happens to the UI +5VDC


power when the machine enters the Low Power Mode?
________________________________________________
5. On which BSD did you find the answer to the above
question? ________________________________________
‰ Return to the SGS main menu.
‰ A little later in this module you will remove the Control Panel
Assembly. At this time, proceed to Machine Run Control below.

Machine Run Control


‰ Select 10 PTO, select 3 Run Control, then select the Run
Control Overview button. Read through this entire PTO section.
‰ Navigate to the SGS main menu and select 4 Repairs &
Adjustments.
‰ On the Repairs & Adjustments menu select the Repair Videos
button.
‰ Select and view the video repair procedures for the ESS PWB
and the MCU PWB.
NOTE: Should it become necessary to replace either the ESS PWB or
the MCU PWB, perform GP3 Saving Machine Data to save the
current NVMs prior to the replacement. Refer to the repair
procedures for these PWBs (REP 3.3 ESS PWB and REP 3.4
MCU PWB) for complete details.
‰ Select the Billing Meters button and read the section.
‰ Check and record the current Billing Meter readings on your
training machine. Follow the procedure in the PTO to access the
meters.
Black Impressions_____________________________________
Color Impressions_____________________________________
‰ Finally, after completing the Billing Meters section, select the
Diagnostic Routines button and read the information presented
there.

STUDENT GUIDE 3/18/2010 4-5


4 Power And Run Control WorkCentre 7120 Service Training

Component Location: Machine Run Control


‰ Locate components in the service documentation, as follows:
1. Refer to the SGS Parts List (5 Parts List) and locate all of
the components listed in the table below.
2. If there are any Repair procedures associated with the items
in the Parts List, write the REP numbers in the spaces
provided.
3. Navigate to and review the Repair procedures for the ESS
PWB and the MCU PWB (refer to 4 Repairs & Adjustments
on the SGS main menu).

Component REP

ESS PWB Assembly

MCU PWB Assembly

Main Low Voltage Power Supply

CAUTION: In the following exercises, do not disconnect any


of the cables, wiring, chips, or harnesses from the PWBs.

CAUTION: The connections on the cables that carry


information between the ESS PWB and the IIT PWB require
careful handling to prevent damage.

‰ If you are training in a classroom/lab environment, now locate


the following components on the machine. Do not remove any
component. Follow these instructions:
1. Go to the machine, confirm that it is powered down and that
the AC power cord is disconnected from the supply.
2. You will have to remove covers to view the components.
Ask your instructor which covers must be removed and
where to store them. (You will need a 5.5mm driver.)
3. Do not reinstall the covers until you are directed to do so.

Component 9
ESS PWB Assembly

MCU PWB Assembly

Main Low Voltage Power Supply

You will remove the IIT and DADF covers and locate the following
later in the training: IIT PWB, DADF PWB, LED Lamp PWB, Tray
Module PWB.

4-6 3/18/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 4 Power And Run Control

Start Print Power


‰ Go to the SGS main menu, select 10 PTO, and then select 4
Start Print Power. Read this section.

Work Project
‰ Go to 4 Repairs & Adjustments on the SGS clock dial and
locate REP 6.11 Control Panel Assembly.
‰ Following the procedure in REP 6.11, remove the Control Panel
Assembly. Ask the instructor if you have any questions.
‰ Reinstall the Control Panel Assembly.

STUDENT GUIDE 3/18/2010 4-7


4 Power And Run Control WorkCentre 7120 Service Training

Fault Analysis (classroom/lab only)


Ask your instructor if there is a fault analysis exercise for this training
module. If there is, your Instructor will insert the fault.
Follow the steps below to complete the exercise.
1. Team with your lab partner.
2. Record your start time.
3. Document the steps you followed.
4. Summarize the fault description, repair actions, and any parts
required for the fix.
5. Record your end time.
6. Explain the source of the problem to the instructor and your
method of troubleshooting.
7. Be sure to leave the machine in working order.

4-8 3/18/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 4 Power And Run Control

Self Check
Answer the questions below and then check your answers by
referring to the Self-Check Answers page at the end of this module.
There may be more than one correct answer per question. Circle the
letter of the best answer(s).

1. Which best describes the process for powering On the


WorkCentre 7120?
a. Power Switch then Main Power Switch
b. Main Power Switch then Power Switch
c. It makes no difference

2. Which of the following produces analog low voltage power?


a. IIT PWB
b. DADF PWB
c. CCD PWB

3. What occurs when the Power Switch is switched Off?


a. The +5VDC On signal is turned Off
b. The +24VDC On signal is turned Off
c. The +5VDC STBY is turned Off

4. What occurs first when the Front Cover Interlock Switches


open? Select the best answer.
a. The +24VDC power to the MCU PWB is cut
b. The IOT’s motors, clutches, and solenoids shut down
c. The +5VDC INTLK On signal to the Main LVPS is cut
5. The Main LVPS supplies the IIT PWB with which of the
following?
a. +5 and +24VDC power
b. +5VDC power only
c. +24VDC power only

STUDENT GUIDE 3/18/2010 4-9


4 Power And Run Control WorkCentre 7120 Service Training

Module Summary
You should now be able to:
1. Understand the Input Power, Switched Power, User
Interface, Machine Run Control, and Start Print Power of the
WorkCentre 7120.
2. Trace input power in the BSDs.
3. Locate the EDOC sections which are required to diagnose
problems associated with power and control problems.
‰ Review the learning objectives above. If you feel that you can
perform the objectives, proceed to the next training module. If
you do not feel comfortable in your ability to perform one or more
of the objectives, review the appropriate portions of this module.
‰ If you are training in a classroom/lab setting, ask your instructor
sign you off on this module.

4-10 3/18/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 4 Power And Run Control

Feedback
1. +5VDC Standby power is supplied to the ESS PWB when
the _________ Switch is ON.
Main Power
2. Based on what you have read in the PTO, name one way in
which you can verify that the Main LVPS is producing
standby power.
Observe the green LED on the ESS PWB
3. Beginning at BSD 1.1 Main Power On, trace (in the BSDs)
the ACH from the Inlet GFI Breaker to the Finisher Outlet.
Record the connector numbers the AC power travels
through to reach the Finisher Outlet.
ACH in to Main LVPS [ J1-3 ]
ACH out from Main LVPS to Finisher Outlet [ J3-5 ]
ACH in to Finisher Outlet [ J16 ]
4. Referring to the BSDs, what happens to the UI +5VDC
power when the machine enters the Low Power Mode? [
stops ]
5. On which BSD did you find the answer to the above
question? [ 1.4 DC Power Generation ]

Component Location: Input Power

Component PL

Main Power Switch Assembly PL 18.2

Power Switch PL 18.2

Front Interlock Switch Assembly PL 18.2

Component Location: Machine Run Control

Component REP

ESS PWB Assembly REP 3.3

MCU PWB Assembly REP 3.4

Main Low Voltage Power Supply REP 1.1

STUDENT GUIDE 3/18/2010 4-11


4 Power And Run Control WorkCentre 7120 Service Training

Self Check Answers

1. Which best describes the process for powering On the


WorkCentre 7120?
a. Power Switch then Main Power Switch

7 b. Main Power Switch then Power Switch

c. It makes no difference

2. Which of the following produces analog low voltage power?

7 a. IIT PWB

b. DADF PWB
c. CCD PWB

3. What occurs when the Power Switch is switched Off?

7 a. The +5VDC On signal is turned Off

7 b. The +24VDC On signal is turned Off

c. The +5VDC STBY is turned Off

4. What occurs first when the Front Cover Interlock Switches


open? Select the best answer.
a. The +24VDC power to the MCU PWB is cut
b. The IOT’s motors, clutches, and solenoids shut down

7 c. The +5VDC INTLK On signal to the Main LVPS is cut


(Refer to BSDs 1.8 and 1.9 for details.)
5. The Main LVPS supplies the IIT PWB with which of the
following?
a. +5 and +24VDC power
b. +5VDC power only

7 c. +24VDC power only

4-12 3/18/2010 STUDENT GUIDE


Module 5 Image Input

Module Overview
In this module you will learn about the IIT (Image Input Terminal), the
Duplex Automatic Document Feeder (DADF), and the scanner.
You will learn how documents feed through the DADF and how they
are scanned.
Students training remotely: Be sure to complete all readings in the
PTO, all EDOC activities, and all Self Checks in this module. If a
machine becomes available to you, take the opportunity to perform any
hands-on Work Projects.
Students in centralized training: If, after reading the content of this
module, you feel that you have the skill and knowledge to “opt-out” of
the removal procedures or Work Projects for this module, contact your
instructor. Your instructor may test your knowledge before allowing you
to move on to the next module. Allowing students to move ahead
before they complete the entire module is at the instructor’s discretion.

Module Objectives
Upon completion of this module you will be able to:
• Locate and correctly describe the operation of the major
components in the scanner and the DADF.
• Describe the purpose of the IIT registration adjustments and
locate the supporting service documentation in the EDOC.
• Describe the purpose of the DADF skew and registration
adjustments and locate the supporting service documentation in
the EDOC.
• Describe the purpose of the Full/Half Rate Carriage Position
Adjustment procedure and locate the supporting service
documentation in the EDOC.

STUDENT GUIDE 3/16/2010 5-1


5 Image Input WorkCentre 7120 Service Training

Technical Overview: IIT


Both the Scanner and the DADF feature new technologies.
Scanner – The Scanner on the WorkCentre 7120 illuminates documents
using a white LED Lamp, not a Xenon or other rare-gas lamp. Among its
many benefits, this advanced technology provides better illumination and
reduced energy cost.
DADF – The DADF on the WorkCentre 7120 is an entirely new design.
Although its operation is much the same as other DADFs, it is lighter,
faster, and has greater document capacity.
You will find the Technology Overviews for the topics in this module at
10 PTO on the SGS. Additional material also may be found at 12
Library.
‰ Open your SGS and select 10 PTO from the main menu. Select
5 Image Input and then select the IIT Overview button. Read the
overview.
‰ After reading the IIT Overview, select the Power and Control and
the Interlocks buttons and read these sections.
‰ Return here after performing the specified readings in the PTO.

Document Scanning
‰ From 10 PTO on the SGS main menu select the 5 Image Input
button, then select the Document Scanning button. Select the
Scanner Overview button and read the section.
‰ Select each of the remaining topic buttons and read the
accompanying information.
‰ Return to the SGS main menu.
‰ If you are training in a classroom environment and have any
questions about the material you have read, ask an instructor for
assistance.

IIT Covers & Platen Glass Removal


‰ In preparation for a component location activity, refer to PL 1.1 in the
Parts List and remove the IIT covers listed there.
‰ Referring to PL 1.2 and REP 6.3 Platen Glass, remove the Platen
Glass from the scanner.

5-2 3/16/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 5 Image Input

IIT Component Location


‰ If you have a machine available, locate the items in the table below
in the EDOC (and also on the machine). If the part or assembly has
a Repair or an Adjustment procedure associated with it, record the
number of the procedure in the table. Also record the relevant PL
number.
‰ If you are training remotely, locate the following IIT components in
5 Parts List in the SGS. If the part or assembly has a Repair or an
Adjustment procedure associated with it, record the number of the
procedure in the table. Also record the relevant PL number.

CAUTION: In the following exercises, do not disconnect any of


the cables, wiring, chips, or harnesses from the PWBs.

CAUTION: The connections on the cables that carry information


between the IIT PWB and the ESS PWB require careful handling
to prevent damage. The connector for the flat, white ribbon
cable at J723 on the IIT PWB uses a light gauge plastic clamp to
secure the cable end. This clamp is easily damaged and is not
spared. Damaging the clamp requires IIT PWB replacement.

REP ADJ
Part or Assembly PL
Number Number
Carriage Motor
Full and Half Rate Carriage
Assemblies
LED Lamp PWB
CCD Lens Assembly
IIT PWB
IIT Registration Sensor Assembly

‰ Reinstall the Platen Glass.

‰ Reinstall the IIT covers that you removed earlier.

‰ Return to the SGS main menu.

STUDENT GUIDE 3/16/2010 5-3


5 Image Input WorkCentre 7120 Service Training

IIT Adjustments
The IIT adjustments for the WorkCentre 7120 employ the same or
closely similar techniques to most comparable systems.
‰ Locate each of the following adjustment procedures in the EDOC.
Briefly familiarize yourself with each procedure.
______ ADJ 6.1 Optical Axis Alignment
______ ADJ 6.2 Full/Half Rate Carriage Position Adjustment
______ ADJ 6.3 IIT Lead Edge Registration
______ ADJ 6.4 IIT Side Registration

5-4 3/16/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 5 Image Input

Technical Overview: DADF


‰ Select 10 PTO from the SGS main menu. Select 5 Image Input and
then select the Document Feeding button. When the Document
Feeding menu displays, select the Overview button. Read the
overview.
‰ After finishing the reading, select the Document Size Sensing
button and read this section.
‰ Return here after performing the specified readings in the PTO.

DADF Cover Removal


‰ Remove the DADF Rear Cover (refer to REP 5.4).
‰ Remove the DADF Front Cover (refer to REP 5.3)

DADF Component Location


‰ If you have a machine available, locate the items in the table below
on the machine and in the EDOC. If the part or assembly has a
Repair or an Adjustment procedure associated with it, record the
number of the procedure in the table. Also record the relevant PL
number.
‰ If you are training remotely, locate the following components in
5 Parts List in the SGS. If the part or assembly has a Repair or an
Adjustment procedure associated with it, record the number of the
procedure in the table. Also record the relevant PL number.

REP ADJ
Part or Assembly PL
Number Number
DADF APS Sensors 1, 2, and 3
Upper Feeder/Nudger Roll/Feed Roll
Tray Guide Set Sensor 1, 2, 3
Take Away Roll
Registration Roll
DADF Document Set Sensor
DADF Feed Out Sensor
Interlock Switch and Harness
Assembly
Set Gate/Retard Chute

STUDENT GUIDE 3/16/2010 5-5


5 Image Input WorkCentre 7120 Service Training

DADF Adjustments
‰ Locate and review the DADF Lead-Skew Adjustment (ADJ 5.1) in
the EDOC.
‰ Locate and review the DADF registration adjustments, ADJ 5.2 and
ADJ 5.4, in the EDOC.

Work Project
‰ Ensure that the machine is powered Off and that the power cord is
disconnected from the supply before performing the following work
project.

Remove the Nudger, Feed, and Retard Rolls


‰ Go to the repair procedures for the Feeder in the EDOC and perform
the following:
______ REP 5.18 Nudger Roll, Feed Roll
______ REP 5.19 Retard Roll
‰ Inform the instructor when you complete the removals.
‰ Reinstall the components.

DADF Operation
‰ Go to 10 PTO on the SGS main menu and select 5 Image Input.
Next select the Document Feeding button.
‰ Select the Simplex Mode Operation button and read the section.
‰ When finished reading about the Simplex Mode, select the Duplex
Mode Operation button and read this section.
‰ Power up the system (with the DADF Front and Rear Covers
removed).
‰ Run several simplex and duplex practice copying jobs from the
DADF. Use at least 5 sheets for both simplex and duplex copying; 10
would be better.
‰ Observe the operation of the unit as it initializes and handles the
originals.
‰ Power down the system.
‰ Reinstall the DADF Front and Rear Covers.

5-6 3/16/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 5 Image Input

Fault Analysis (classroom/lab only)


Ask your instructor if there is a fault analysis exercise for this training
module. If there is, your Instructor will insert the fault.
Follow the steps below to complete the exercise.
1. Team with your lab partner.
2. Record your start time.
3. Document the steps you followed.
4. Summarize the fault description, repair actions, and any parts
required for the fix.
5. Record your end time.
6. Explain the source of the problem to the instructor and your method
of troubleshooting.
7. Be sure to leave the machine in working order.

STUDENT GUIDE 3/16/2010 5-7


5 Image Input WorkCentre 7120 Service Training

Self-Check
Answer the questions below and then check your answers by referring to
the Self-Check Answers page at the end of this module. There may be
more than one acceptable answer per question. Circle the letters of the
correct answer(s).

1. Which component detects that a document is present in the DADF


document tray.
a. DADF Document Set Sensor
b. DADF Pre-registration Sensor
c. DADF Registration Sensor
d. DADF Invert Sensor

2. Which sensors are used to determine the length of a document in the


document input tray?
a. DADF Document Set Sensor
b. DADF Pre-registration Sensor
c. DADF Registration Sensor
d. DADF Tray Size 1 and 2 Sensors

3. Indicate if this statement is true or false. All the DADF rolls rotate when
the DADF Feed Motor is energized
a. True
b. False

4. What changes when enlargement is selected when copying from the


DADF?
a. DADF transport speed slows
b. Scan speed of the scan carriages
c. Speed of the drum (photoreceptor)
d. Speed of the copy paper
5. What is the function of the CCD?
a. Provides a supply to the exposure lamp
b. Processes the electronic image
c. Converts the optical image into an analog electronic image
d. Converts the optical image into a digital image

5-8 3/16/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 5 Image Input

6. Which activities occur when power is applied to the machine?


a. The exposure lamp comes on
b. The carriage moves to the White Reference Board
c. The AGC is adjusted
d. The AOC is adjusted
7. What is the purpose of AOC?
a. Adjusts the light output of the exposure lamp
b. Adjusts the output of the CCD when the lamp is off.
c. Adjusts the output of the CCD when the lamp is on.
8. What is the purpose of AGC?
a. Adjusts the light output of the exposure lamp
b. Adjusts the output of the CCD when the lamp is off
c. Adjusts the output of the CCD when the lamp is on
9. Which motor drives the Takeaway Rolls?
a. DADF Feed Motor
b. DADF Registration Motor
10. Which component maintains pressure on the Nudger Roll as the
documents feed?
a. The Set Gate
b. The Nudger Springs
c. The Retard Roll

STUDENT GUIDE 3/16/2010 5-9


5 Image Input WorkCentre 7120 Service Training

Module Summary
In this module you have learned about the components used in the
imaging processes. You should now be able to:
• Locate and correctly describe the operation of the major components in
the scanner and the DADF.
• Describe the purpose of the IIT registration adjustments and locate the
supporting service documentation in the EDOC.
• Describe the purpose of the DADF skew and registration adjustments
and locate the supporting service documentation in the EDOC.
• Describe the purpose of the Full/Half Rate Carriage Position
Adjustment procedure and locate the supporting service documentation
in the EDOC.

‰ Review the learning objectives above. If you feel that you can perform
the objectives, proceed to the next training module. If you do not feel
comfortable in your ability to perform one or more of the objectives,
review the appropriate portions of this module.
‰ If you are training in a classroom/lab setting, ask your instructor sign you
off on this module.

5-10 3/16/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 5 Image Input

Feedback
IIT Component Location feedback

REP ADJ
Part or Assembly PL
Number Number
Carriage Motor 1.6 6.9 ---
Full and Half Rate Carriage
1.3 --- 6.2
Assemblies
LED Lamp PWB 1.4 6.6 ---
CCD Lens Assembly 1.2 6.4 ---
IIT PWB 1.6 6.10 ---
IIT Registration Sensor Assembly 1.6 --- ---

DADF Component Location feedback

REP ADJ
Part or Assembly PL
Number Number
DADF APS Sensors 1, 2, and 3 51.17 --- ---
Upper Feeder/Nudger Roll/Feed Roll 51.12 5.18 ---
Tray Guide Set Sensor 1, 2, 3 51.10 --- ---
Take Away Roll 51.9 --- ---
Registration Roll 51.9 --- ---
DADF Document Set Sensor 51.6 --- ---
DADF Feed Out Sensor 51.6 --- ---
Interlock Switch and Harness
51.5 --- ---
Assembly
Set Gate/Retard Chute 51.14 5.15 ---

STUDENT GUIDE 3/16/2010 5-11


5 Image Input WorkCentre 7120 Service Training

Self-Check Feedback

1. Which component detects that a document is present in the DADF


document tray.

7 a. DADF Document Set Sensor

b. DADF Pre-registration Sensor


c. DADF Registration Sensor
d. DADF Invert Sensor

2. Which sensors are used to determine the length of a document in the


document input tray?
a. DADF Document Set Sensor
b. DADF Pre-registration Sensor
c. DADF Registration Sensor

7 d. DADF Tray Size 1 and 2 Sensors

3. Indicate if this statement is true or false. All the DADF rolls rotate when
the DADF Feed Motor is energized
a. True

7 b. False

4. What changes when enlargement is selected when copying from the


DADF?

7 a. DADF transport speed slows

b. Scan speed of the scan carriages


c. Speed of the drum (photoreceptor)
d. Speed of the copy paper
5. What is the function of the CCD?
a. Provides a supply to the exposure lamp
b. Processes the electronic image

7 c. Converts the optical image into an analog electronic image

d. Converts the optical image into a digital image

5-12 3/16/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 5 Image Input

6. Which activities occur when power is applied to the machine?

7 a. The exposure lamp comes on

7 b. The carriage moves to the White Reference Board

7 c. The AGC is adjusted

7 d. The AOC is adjusted

7. What is the purpose of AOC?


a. Adjusts the light output of the exposure lamp

7 b. Adjusts the output of the CCD when the lamp is off.

c. Adjusts the output of the CCD when the lamp is on.


8. What is the purpose of AGC?
a. Adjusts the light output of the exposure lamp
b. Adjusts the output of the CCD when the lamp is off

7 c. Adjusts the output of the CCD when the lamp is on

9. Which motor drives the Takeaway Rolls?

7 a. DADF Feed Motor

b. DADF Registration Motor


10. Which component maintains pressure on the Nudger Roll as the
documents feed?
a. The Set Gate

7 b. The Nudger Springs

c. The Retard Roll

STUDENT GUIDE 3/16/2010 5-13


5 Image Input WorkCentre 7120 Service Training

5-14 3/16/2010 STUDENT GUIDE


Module 6 Paper Supply

Introduction

Module Overview
This module provides an overview of the paper supply and
transport subsystems. The paper handling subsystems contain the
components that feed and transport media throughout the
machine.
Students training remotely: Be sure to complete all readings in
the PTO, all EDOC activities, and all Self Checks in this module. If
a machine becomes available to you, take the opportunity to
perform any hands-on Work Projects.
Students in centralized training: If, after reading the content of
this module, you feel that you have the skill and knowledge to “opt-
out” of the removal procedures or Work Projects for this module,
contact your instructor. Your instructor may test your knowledge
before allowing you to move on to the next module. Allowing
students to move ahead before they complete the entire module is
at the instructor’s discretion.

Module Objectives
‰ Read the following learning objectives for this module.
1. Describe the paper path from the paper trays to the output
trays in both simplex and duplex modes.
2. Locate the major components of these subsystems.
3. Identify and locate the paper transport motors and drives.
4. Identify and locate the paper path sensors.

STUDENT GUIDE 3/11/2010 6-1


6 Paper Supply And Transportation WorkCentre 7120 Service Training

Technology Overview
The machine’s paper trays and paper path are very similar to other
machines you service.
‰ Open your SGS to the main menu.
‰ Select 10 PTO.
‰ From the PTO menu, select 7 Media Supply.
‰ Select the Media Supply Overview button and read the
information presented in the section.
‰ After completing the overview, select the next button (Trays
1 – 4) and read that section.
‰ Select each of the remaining topic buttons and read the
information.
‰ When you are done, return to the SGS clock dial.
‰ Select 10 PTO.
‰ From the PTO menu, select 8 Media Transportation.
‰ Select the Media Feed Overview button, then read the
information in this section of the PTO.
‰ When finished with the overview, select the Duplex Overview
and read this section, too.
‰ If you are training in a classroom setting and have any questions,
ask an instructor for clarification.

6-2 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 6 Paper Supply And Transportation

Paper Supply Capabilities


‰ Enter the tray handling capabilities for paper in the table below.
Refer to the PTO and to the Paper Capacities Table in section
6 General Information in the EDOC.
NOTE: For more information about media specifications, refer to the
Recommended Materials List (RML) at 12 Library on the SGS.

Tray Maximum Minimum Maximum Capacity


paper size paper weight paper weight (20#/75gsm)

1, 2, 3, 4

Component Location: Feed


‰ Refer to the PTO and to the Parts List located in section 5 of
your EDOC. Identify the following Paper Feed components.
Check them off as identified.

Component 9
Tray 1 Level Sensor

Tray 1 Paper Size Sensor

Tray 1 Feed Rolls

Tray 1 Feed/Lift Up Motor

Tray 5 Bottom Plate Assembly

MSI Feed Roll

MSI Feed Solenoid

‰ If you have a machine available, remove Trays 1 and 2 and


locate on the machine the components that appear in the table
above.

STUDENT GUIDE 3/11/2010 6-3


6 Paper Supply And Transportation WorkCentre 7120 Service Training

Component Location: Transport


‰ Refer to the PTO and to the Parts List located in section 5 of
your EDOC. Identify the following Paper Transportation
components. Check them off as identified. If you have a
machine available, also locate the components on the machine.

Component 9
TM Take Away Motor
Take Away Clutch
Tray 2, 3, and 4 Feed Out Sensors
Registration Sensor
Registration Clutch
Take Away Rolls (1 through 4)
Registration Roll

6-4 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 6 Paper Supply And Transportation

Work Projects

Tray 1 Feed/Retard/Nudger Roll Removal


‰ Go to the SGS clock dial and select 4 Repairs &
Adjustments. Navigate to REP 7.3 Tray 1 Feed/Retard/
Nudger Roll.
‰ Read REP 7.3 and then remove these components.
‰ Inform the instructor when you have completed the removal.
‰ Reinstall the Tray 1 Feed/Retard/Nudger Rolls.

Registration Transport Assembly Removal


‰ Go to the SGS clock dial and select 4 Repairs &
Adjustments. Navigate to REP 8.1 Registration Transport
Assembly.
‰ Read REP 8.1 and then remove the assembly.
‰ Inform the instructor when you have completed the removal.
‰ Reinstall the Registration Transport Assembly.

STUDENT GUIDE 3/11/2010 6-5


6 Paper Supply And Transportation WorkCentre 7120 Service Training

Fault Analysis (classroom/lab only)


Ask your instructor if there is a fault analysis exercise for this
training module. If there is, your Instructor will insert the fault.
Follow the steps below to complete the exercise.
1. Team with your lab partner.
2. Record your start time.
3. Document the steps you followed.
4. Summarize the fault description, repair actions, and any
parts required for the fix.
5. Record your end time.
6. Explain the source of the problem to the instructor and your
method of troubleshooting.
7. Be sure to leave the machine in working order.

6-6 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 6 Paper Supply And Transportation

Self-Check
Answer the questions below and then check your answers by
referring to the Self-Check Answers page at the end of this module.
There may be more than one acceptable answer per question.
Circle the letter of the best answer(s).

1. Which PWB monitors paper size information?


a. ESS PWB
b. MCU PWB
c. Tray Module PWB

2. Which functions are performed by the Tray 1 – 4 Level Sensors?


a. Indicate that the media is at the feed position
b. Indicate the level of media in a tray
c. Serve the same function as a no paper sensor

3. When is the Level Sensor signal monitored?


a. At power on
b. At tray insertion
c. Continuously

4. Tray presence is indicated by which of the following?


a. Digital signal from the Paper Size Sensor
b. Signal from any Paper Size Sensor switch
c. Signals from the actuated Paper Size Sensor switches
5. The paper level in a tray is indicated by which of the following?
a. On and Off signals from the Level Sensor
b. Number of prints logged for a selected tray
c. On time of the Feed/Lift Motor
6. The optional Envelope Tray may be installed in which
location(s)?
a. Either Tray 1 or Tray 2; never in the Two Tray Module
b. In Tray 1 only
c. In place of any available tray, 1 through 4
7. Trays 1 – 4 each have a capacity of how many sheets of 24 lb. /
90 gsm paper?
a. 500
b. 520
c. 540

STUDENT GUIDE 3/11/2010 6-7


6 Paper Supply And Transportation WorkCentre 7120 Service Training

8. What preparations must be made to print transparencies?


a. Transparencies must be loaded in Tray 1 only due to the
shorter paper path
b. The media type must be specified as card stock
c. Transparencies must be loaded singly in the Bypass
Feeder.
9. What provides drive to the MSI Feed Roll?
a. Main Drive Motor through gears
b. Fuser Drive Motor through a belt
c. Main Drive Motor through a clutch
10. Under what conditions will the machine stop and eject a sheet
fed from Tray 5?
a. The detected length is greater than the length specified on
the Control Panel
b. The sheet is greater than 297mm long or less than 88.9mm
long
c. The paper does not fall within the specified weight range

6-8 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 6 Paper Supply And Transportation

Module Summary
You now should be able to:
1. Describe the paper path from the paper trays to the output
trays in both simplex and duplex modes.
2. Locate the major components of these subsystems.
3. Identify and locate the paper transport motors and drives.
4. Identify and locate the paper path sensors.
‰ Review the learning objectives above. If you feel that you can
perform the objectives, proceed to the next training module.
If you do not feel comfortable in your ability to perform one or
more of the objectives, review the appropriate portions of this
module.
‰ If you are training in a classroom/lab setting, ask your instructor
sign you off on this module.

STUDENT GUIDE 3/11/2010 6-9


6 Paper Supply And Transportation WorkCentre 7120 Service Training

Feedback

Paper Supply Capabilities

Tray Maximum Minimum Maximum Capacity


paper size paper weight paper weight (20#/75gsm)

1, 2, 3, 4 11 x 17” / A3 16 lb. / 60gsm 68 lb (140 lb 520


SEF index)

256 gsm

5 11 x 17” / A3 16 lb. / 60gsm 216 gsm 50


SEF

6-10 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 6 Paper Supply And Transportation

Self-Check Answers

1. Which PWB monitors paper size information?


a. ESS PWB
7 b. MCU PWB
c. Tray Module PWB

2. Which functions are performed by the Tray 1 – 4 Level Sensors?


7 a. Indicate that the media is at the feed position
b. Indicate the level of media in a tray
7 c. Serve the same function as a no paper sensor

3. When is the Level Sensor signal monitored?


7 a. At power on
7 b. At tray insertion
7 c. Continuously

4. Tray presence is indicated by which of the following?


a. Digital signal from the Paper Size Sensor
7 b. Signal from any Paper Size Sensor switch
c. Signals from the actuated Paper Size Sensor switches
5. The paper level in a tray is indicated by which of the following?
a. On and Off signals from the Level Sensor
b. Number of prints logged for a selected tray
7 c. On time of the Feed/Lift Motor
6. The optional Envelope Tray may be installed in which
location(s)?
a. Either Tray 1 or Tray 2; never in the Two Tray Module
7 b. In Tray 1 only
c. In place of any available tray, 1 through 4
7. Trays 1 – 4 each have a capacity of how many sheets of 24 lb. /
90 gsm paper?
7 a. 500
b. 520
c. 540

STUDENT GUIDE 3/11/2010 6-11


6 Paper Supply And Transportation WorkCentre 7120 Service Training

8. What preparations must be made to print transparencies?


a. Transparencies must be loaded in Tray 1 only due to the
shorter paper path
7 b. The media type must be specified as card stock
7 c. Transparencies must be loaded singly in the Bypass
Feeder.
9. What provides drive to the MSI Feed Roll?
7 a. Main Drive Motor through gears
b. Fuser Drive Motor through a belt
c. Main Drive Motor through a clutch
10. Under what conditions will the machine stop and eject a sheet
fed from Tray 5?
7 a. The detected length is greater than the length specified on
the Control Panel
7 b. The sheet is greater than 297mm long or less than 88.9mm
long
c. The paper does not fall within the specified weight range

6-12 3/11/2010 STUDENT GUIDE


Module 7 Xerographics &
Image Output

Introduction

Module Overview
The Xerographic subsystem contains the components required to
develop an unfused print from a scanned image, a fax, or a
remotely submitted print job. The major functions of the xerographic
subsystem are to:
• Develop the latent image on the drums with toner
• Transfer the developed images from the drums to the transfer
belt.
• Transfer the images from the transfer belt to the media
• Deliver the toner for the development process
• Clean the xerographic imaging components
This module uses the PTO to describe the Xerographic
components. You also will be required to access and review
various sections of the EDOC.
Students training remotely: Be sure to complete all readings in
the PTO, all EDOC activities, and all Self Checks in this module. If
a machine becomes available to you, take the opportunity to
perform any hands-on Work Projects.
Students in centralized training: If, after reading the content of
this module, you feel that you have the skill and knowledge to “opt-
out” of the removal procedures or Work Projects for this module,
contact your instructor. Your instructor may test your knowledge
before allowing you to move on to the next module. Allowing
students to move ahead before they complete the entire module is
at the instructor’s discretion.

STUDENT GUIDE 3/11/2010 7-1


7 Xerographics WorkCentre 7120 Service Training

Module Objectives
‰ Review the list of objectives for this module below.
Upon the successful completion of this module, you will be able to:
1. Identify the major components of the xerographic subsystem.
2. Use the service documentation to locate components and
procedures (Repairs, Adjustments, etc.) required to diagnose
and repair xerographic concerns.
3. Understand how to remove/install the Drum Cartridges, IBT
Assembly, and Toner Cartridge Assemblies.
4. Describe the operation of the Image Output subsystem.

7-2 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 7 Xerographics

Technology Overview
The WorkCentre 7120 features a number of unique Xerographic
technologies:
EA-Eco Toner (Emulsion Aggregate – Eco) - The EA technology
uses a controlled method to chemically ”grow'' toner particles up to
a desired size and shape. The EA-Eco toner used in this machine
fuses to paper at a temperature 20 degrees lower than that of
conventional products, resulting in substantial power savings. The
EA-Eco Toner also produces a slightly glossier image than
conventional EA toners.
No Trickle Development – The WorkCentre 7120 does not employ
Trickle Development. This is made possible by including the
developer in the Drum Cartridges, which are CRUs.
Drum Cartridges - The Drum Cartridges (CRUs) integrate a
Developer unit with a Drum unit in one assembly. The Drum
Cartridges come filled with fresh developer and receive toner, as
concentration warrants, from the Toner Cartridges.
No need to perform ATC Sensor Setup – Integrating the Drum
unit with the Developer unit into one Drum Cartridge Assembly
eliminates the need for this set up.
Toner Cartridges - The Toner Cartridges, also CRUs, deliver only
toner to the Drum Cartridges.
‰ Open your SGS
‰ Go to 10 PTO.
‰ From the PTO menu, select 9 Xerographics.
‰ Click the Xerographic Overview button.
‰ When you finish the overview information the Xerographics PTO
menu will display.
‰ Select the CRUM button and read the section.
‰ If you are training in a classroom/lab environment, ask the instructor
for assistance if you have any questions.
‰ Answer the following questions from your reading of the
Xerographic Overview. You can check your answers by referring to
the Feedback section at the end of the module.
1. What is the color layering order on the IBT Belt for a full color
copy? (Starting at the IBT surface and working up to the top
color layer).
___________________________________________________
2. What is the color layering order on the copy material? (Starting
at the copy surface and work up to the top color layer).
___________________________________________________

STUDENT GUIDE 3/11/2010 7-3


7 Xerographics WorkCentre 7120 Service Training

‰ Now return to the PTO and select the following buttons and read
the information provided for each. Check off each topic as
completed.
_____ Drum Cartridges
_____ Toner Cartridges
_____ Xerographic Drives
_____ IBT Assembly
_____ Transfer Belt
_____ Transfer Belt Cleaning
_____ Second Transfer
_____ Waste Toner Collection
_____ HVPS
‰ When you complete these readings go to the SGS main menu.

Component Location

CAUTION: The coating of the Photoreceptor (Drum) is sensitive


to light and touch. Do not touch the Drum surface. Excessive
exposure to ambient light will cause permanent damage to the
Drum surface. When removing the Drum Cartridge from the
machine, take proper precautions to cover the Drum surface. If
available, place the Drum Cartridge in a black bag.

‰ Select 5 Parts List on the SGS clock dial. Locate the following
components in the PL. Check off each item as identified.

Component 9
IBT Assembly

Drum Cartridges

Toner Cartridges

Waste Bottle Assembly

2nd BTR Assembly

1st BTR

Main Drive Motor (Main Motor Assembly)

Drum Drive Motor

Toner Dispense Motors

7-4 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 7 Xerographics

‰ Navigate to 6 General Procedures on the SGS main menu and


then locate the CRU and Consumables list.
3. What are the Part Numbers for the following:

Waste Toner Container: ____________________________

2nd BTR: _________________________________________

Magenta Toner Cartridge (metered (Worldwide)): ________

Work Project
‰ If you are taking the training remotely, perform the component
location exercise below using the Parts List, then read the
removal procedure in the EDOC.
‰ Students training in a classroom/lab must complete both the
EDOC and the hands-on activities associated with this work
project.

Remove the IBT Assembly

CAUTION: The IBT Assembly Transfer Belt is easily damaged.


Use protective gloves when handling the IBT Assembly. Do not
touch the transfer belt with your bare hands, crease it, or drop
items on it (e.g., screws). Failure to protect the surface of the
Transfer Belt may cause image defects.

CAUTION: The IBT Assembly is designed to be stood up on the


Guide for Transfer Belt replacement. Be sure to install the Guide
carefully. Also do NOT use the Guide to pick up the assembly
when turning it over to the standing position. The stress created
can weaken and crack the IBT frame.

‰ Select 4 Repairs & Adjustments and locate the Repair


procedures for the IBT Assembly and the Transfer Belt.
‰ Prepare a clean work surface for the IBT Assembly.
‰ Remove the IBT Assembly from the IOT (REP 9.4) and place it
on the work surface.
‰ Read the Repair procedure for the removal of the Transfer Belt
(REP 9.7). Do not perform this activity. The procedure for the
removal of the Transfer Belt is similar to other machines you
service.

STUDENT GUIDE 3/11/2010 7-5


7 Xerographics WorkCentre 7120 Service Training

‰ Locate and identify the components listed in the table below.


Locate the components both in the PL and, if available, on the
machine. Check off the items as identified.

Component 9
Transfer Belt

Back Up Roll

IBT Cleaner Assembly

1st BTR Rolls

Tension Roll

‰ Reinstall the IBT Assembly in the machine.


‰ Answer this question. You may check your answer by referring
to the Feedback section at the end of the module.
4. What would you see if the belt has a small indentation on it--
a dark spot or a deletion? ___________________________

7-6 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 7 Xerographics

Work Project
‰ If you are taking the training remotely, perform the component
location exercise below using the Parts List and read the repair
procedure.
‰ Students training in a classroom/lab must complete both the
EDOC and the hands-on activities associated with this work
project.

Remove the Black Drum Cartridge


‰ Inform the instructor that you are at the point to remove the black
Drum Cartridge.
‰ Select 4 Repairs & Adjustments on the SGS clock dial.
‰ Locate the repair procedure for the Drum Cartridge (REP 9.8).
‰ Remove the black Drum Cartridge.

CAUTION: The Drum can be damaged by light shock. Protect the


Drum from light by covering it.

‰ While the Drum Cartridge is out of the machine, locate on it the


Drum, BTR, BTR Cleaning Roller, and Toner fill port.
‰ Place the Drum Cartridge on a solid work surface. Be sure to
cover the Drum to prevent light shock.
‰ Locate the following components on the hardware.

Component 9
Erase Lamp (K)

Drum

BCR

BCR Cleaning Roller

Developer Housing

Toner fill port

Lens Bar

STUDENT GUIDE 3/11/2010 7-7


7 Xerographics WorkCentre 7120 Service Training

Work Project
Students training in a classroom/lab must complete both the
EDOC and the hands-on activities. Students training remotely
should read the indicated procedure.
‰ While the Black Drum Cartridge is out of the machine, prepare to
remove the Erase Lamp (K).

Remove the Erase Lamp K


‰ Navigate to and open the repair procedure for the Erase Lamp
(Y, M, C, K) (REP 9.11).
‰ Read the procedure completely.
‰ Inform the instructor that you are ready to remove the Erase
Lamp (K) only.
‰ Following the procedure in REP 9.11 and the guidance from the
instructor, remove Erase Lamp (K).
‰ Reinstall Erase Lamp (K).

7-8 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 7 Xerographics

Technical Overview

Image Output
‰ Go to the SGS main menu and select 10 PTO.
‰ Select the 6 Image Output button.
‰ Select the first button, ROS Overview, and read the section. Pay
particular attention to the screen that describes ROS handling
precautions. Incorrect handling of the unit may contaminate the
ROS windows, or misalign and damage the internal components,
rendering it useless.
‰ Select each of remaining topic buttons (Laser Diode Control
and ROS Motor Control) are read the sections.

Work Project
‰ Navigate to the SGS main menu and select 4 Repairs &
Adjustments.
‰ Select the Repair Videos button.
‰ Select and view the repair videos for the HVPS and the ROS.
‰ Locate in the EDOC the repair procedure for the removal of the
ROS Assembly (REP 6.2).
CAUTION: The ROS must be handled carefully to avoid
external contamination or misalignment of the internal
components.
‰ Following the ROS removal procedure, remove the assembly
from the machine. Be sure to observe all handling precautions.
‰ Inform your instructor when the ROS is completely removed.
‰ Reinstall the ROS in the machine.
‰ Reinstall all of the components that you had to remove to access
Erase Lamp (K), except the Drum Cartridges and the Transfer
Belt Assembly.

STUDENT GUIDE 3/11/2010 7-9


7 Xerographics WorkCentre 7120 Service Training

Work Projects
‰ Students training in a classroom/lab must complete both the
EDOC and the hands-on activities. Students training remotely
should read the indicated procedures.

Remove the MOB ADC Assembly


‰ Select 4 Repairs & Adjustments on the SGS clock dial.
‰ Locate the repair procedure for the MOB ADC Sensor Assembly
(REP 9.10).
‰ Read through REP 9.10 and then remove the MOB ADC Sensor
Assembly.
‰ Referring to 5 Parts List, locate the following components.
Check off the components as you locate them.

Component 9
MOB ADC Sensor In

MOB ADC Sensor Out

Environment Sensor

‰ Referring to REP 9.10, reinstall the MOB ADC Sensor in the


machine.

Remove the Main Drive Assembly


‰ Select 4 Repairs & Adjustments on the SGS clock dial.
‰ Locate the repair procedure for the Main Drive Assembly (REP
4.2).
‰ Read through REP 4.2 and then remove the Main Drive
Assembly.
‰ Inform the instructor when you finish the removal.
‰ Reinstall the Main Drive Assembly.

Remove the Drum Drive Assembly


‰ Select 4 Repairs & Adjustments on the SGS clock dial.
‰ Locate the repair procedure for the Drum Drive Assembly
(REP 4.1).
‰ Read through REP 4.1 and then remove the Drum Drive
Assembly.
‰ Inform the instructor when you finish the removal.
‰ Reinstall the Drum Drive Assembly.

7-10 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 7 Xerographics

Regicon/Procon
‰ Go to the SGS main menu and select 10 PTO.
‰ Select the 9 Xerographics button.
‰ Select the Process Control and RegiCon buttons and read
these sections.
‰ Return to the SGS main menu.
‰ Select 4 Repairs & Adjustments.
‰ Select the Adjustments button.
‰ From the Adjustments menu, select and familiarize yourself with
each of the following procedures for the WorkCentre 7120:
____ ADJ 9.8 Registration Measurement Cycle
____ ADJ 9.9 Registration Control Setup Cycle
____ ADJ 9.12 Registration Control Sensor Check
‰ If you have access to a machine, refer to the service
documentation as you perform:
_____ ADJ 9.8 Registration Measurement Cycle
_____ ADJ 9.12 Registration Control Sensor Check
‰ Notify the instructor if any error conditions appear in the results
of the above two procedures.

STUDENT GUIDE 3/11/2010 7-11


7 Xerographics WorkCentre 7120 Service Training

Fault Analysis (classroom/lab only)


Ask your instructor if there is a fault analysis exercise for this training
module. If there is, your Instructor will insert the fault.
Follow the steps below to complete the exercise.
1. Team with your lab partner.
2. Record your start time.
3. Document the steps you followed.
4. Summarize the fault description, repair actions, and any
parts required for the fix.
5. Record your end time.
6. Explain the source of the problem to the instructor and
your method of troubleshooting.
7. Be sure to leave the machine in working order.

7-12 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 7 Xerographics

Self Check
Answer the questions below and then check your answers by
referring to the Self-Check Answers page at the end of this module.
There may be more than one acceptable answer per question. Circle
the letters of the correct answer(s).

1. Which of the following should be performed after replacing a


Drum Cartridge?
a. Update HFSI
b. ATC Sensor Setup
c. Forced ADC Setup
2. Process control is based on the signals from which of the
following?
a. Environment Sensor
b. ATC Sensor
c. MOB Sensor
d. ADC Sensor
3. The machine periodically applies a Transfer Toner Band to the
Transfer Belt. What is the purpose of this band?
a. Tests the effectiveness of 1st Transfer
b. Provides a Belt Home indication in lieu of having no Belt
Home Sensor
c. Protects the Cleaning Blade edge
4. When should the CSE replace the Transfer Belt?
a. On every call
b. Never, because it’s a CRU
c. When belt damage is seen during a call
5. Which of the following is not driven by the Drum Drive Motor?
a. Toner Recovery Auger
b. Drum Cleaner Auger (YMCK)
c. IBT Cleaner Auger
6. The dispense system supplies ( __________ ).
a. A developer mixture to the Drum Cartridges
b. Toner to the Drum Cartridges
7. When is the status of a machine’s Toner Cartridges (Sold vs.
Metered) first established?
a. Upon machine installation
b. The first time that any Toner Cartridge is replaced
c. The first time that any Xerographic CRU is replaced

STUDENT GUIDE 3/11/2010 7-13


7 Xerographics WorkCentre 7120 Service Training

8. A process pattern may be detected on the 2nd BTR. If there is no


offset from the roll to the second side of prints, the process
pattern indicates that ( __________ ).
a. The 2nd BTR cleaning process has failed
b. The 2nd BTR must be replaced
c. The foam 2nd BTR is working normally.
9. Which of the following are performed to control Image Density?
a. Changing the Drum charging potential
b. Additional Toner is dispensed
c. The ROS light output is changed
d. The Developer Bias is changed
10. Which methods are used to detect a Toner Empty condition?
a. Count the print volume since the last Toner Cartridge
replacement
b. Monitor the signals from the ATC Sensor
c. Monitor the signals from the ADC Sensors
d. Count pixels

7-14 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 7 Xerographics

Module Summary
You should now be able to:
1. Identify the major components of the xerographic subsystem.
2. Use the service documentation to locate components and
procedures (Repairs, Adjustments, etc.) required to diagnose
and repair xerographic concerns.
3. Understand how to remove/install the Drum Cartridges, IBT
Assembly, and Toner Cartridge Assemblies.
4. Describe the operation of the Image Output subsystem.
‰ Review the learning objectives above. If you feel that you can
perform the objectives, proceed to the next training module. If you
do not feel comfortable in your ability to perform one or more of the
objectives, review the appropriate portions of this module.
‰ Ask your instructor to sign you off on the Module.

STUDENT GUIDE 3/11/2010 7-15


7 Xerographics WorkCentre 7120 Service Training

Feedback
1. What is the color layering order on the IBT Belt for a full color
copy? (Starting at the IBT surface and work up to the top color
layer). YMCK

2. What is the color layering order on the copy material? (Starting


at the copy surface and work up to the top color layer).
KCMY

3. What are the Part Numbers for the following:


Waste Toner Container: 008R13089

2nd BTR: 008R13086

Magenta Toner Cartridge (metered (Worldwide)): 006R01455


4. What would you see if the belt has a small indentation on it--a
dark spot or a deletion?
Deletion

7-16 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 7 Xerographics

Self-Check Answers

1. Which of the following should be performed after replacing a


Drum Cartridge?
a. Update HFSI
b. ATC Sensor Setup
7 c. Forced ADC Setup

2. Process control is based on the signals from which of the


following?
7 a. Environment Sensor
7 b. ATC Sensor
c. MOB Sensor
7 d. ADC Sensor

3. The machine periodically applies a Transfer Toner Band to the


Transfer Belt. What is the purpose of this band?
a. Tests the effectiveness of 1st Transfer
b. Provides a Belt Home indication in lieu of having no Belt
Home Sensor
7 c. Protects the Cleaning Blade edge

4. When should the CSE replace the Transfer Belt?


a. On every call
b. Never, because it’s a CRU
7 c. When belt damage is seen during a call
5. Which of the following is not driven by the Drum Drive Motor?
7 a. Toner Recovery Auger
b. Drum Cleaner Auger (YMCK)
c. IBT Cleaner Auger
6. The dispense system supplies ( __________ ).
a. A developer mixture to the Drum Cartridges
7 b. Toner to the Drum Cartridges
7. When is the status of a machine’s Toner Cartridges (Sold vs.
Metered) first established?
a. Upon machine installation
7 b. The first time that any Toner Cartridge is replaced
c. The first time that any Xerographic CRU is replaced

STUDENT GUIDE 3/11/2010 7-17


7 Xerographics WorkCentre 7120 Service Training

8. A process pattern may be detected on the 2nd BTR. If there is no


offset from the roll to the second side of prints, the process
pattern indicates that ( __________ ).
a. The 2nd BTR cleaning process has failed
b. The 2nd BTR must be replaced
7 c. The foam 2nd BTR is working normally.
9. Which of the following are performed to control Image Density?
7 a. Changing the Drum charging potential
b. Additional Toner is dispensed
7 c. The ROS light output is changed
7 d. The Developer Bias is changed
10. Which methods are used to detect a Toner Empty condition?
a. Count the print volume since the last Toner Cartridge
replacement
7 b. Monitor the signals from the ATC Sensor
c. Monitor the signals from the ADC Sensors
7 d. Count pixels

7-18 3/11/2010 STUDENT GUIDE


Module 8 Fuser

Introduction

Module Overview
The purpose of the Fuser is to bond the toner to the media. This is
done by applying heat and pressure which melt the toner and fuse
it to the media.
Students training remotely: Be sure to complete all readings in
the PTO, all EDOC activities, and all Self Checks in this module. If
a machine becomes available to you, take the opportunity to
perform any hands-on Work Projects.
Students in centralized training: If, after reading the content of
this module, you feel that you have the skill and knowledge to “opt-
out” of the removal procedures or Work Projects for this module,
contact your instructor. Your instructor may test your knowledge
before allowing you to move on to the next module. Allowing
students to move ahead before they complete the entire module is
at the instructor’s discretion.

Module Objectives
‰ Read the following learning objectives for this module.
1. Identify the major components of the Fuser.
2. Describe how Fuser temperature is controlled.

STUDENT GUIDE 3/11/2010 8-1


8 Fuser WorkCentre 7120 Service Training

Technology Overview
The Fuser Assembly on the WorkCentre 7120 is a CRU and
contains no serviceable parts. The customer will be informed via
the User Interface when the Fuser approaches or requires
replacement.
Due to the lower melting point of EA-Eco Toner, fusing is performed
at lower temperatures than in most similar machines.

‰ Open the SGS.


‰ Select 10 PTO.
‰ From the PTO menu, scroll to and select the 10 Fuser
button.
‰ Select the Fuser Overview button.
‰ Read the information in the Fuser Overview section. After
you read the final screen in this section, you will be returned
to the Print Transportation & Fuser PTO menu.
‰ Click the Temperature Control button.
‰ Read the information in the Temperature Control section.
Here, too, you will be returned to the Print Transportation &
Fuser PTO Menu.
‰ Click on the Fuser Cooling button and read the section.
‰ If you are training in a classroom environment and have any
questions, ask the instructor for assistance.

Component Location
WARNING: Fuser components are very hot! If necessary, allow
your fuser to cool down before working in this area.

‰ Locate the Fuser on the machine.


‰ Open the Side Cover and remove the Fuser Assembly. Refer to
REP 10.1 in your EDOC as you remove the Fuser.
CAUTION: Do not attempt to disassemble the Fuser. It is a CRU
and contains no serviceable components.
‰ Go to 1 Service Call Procedures > Detailed Maintenance
Activities and locate the Threshold values (HFSIs) for the
Fuser. Record your findings below:
Print Volume: ________________________________________
Time Count: _________________________________________

8-2 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 8 Fuser

‰ Locate but do not remove the following Fuser subsystem


components. (Refer to the PTO as needed and to the Parts List
on your EDOC.) Also record the PL location and any Repair or
Adjustment procedures which are associated with these
components.

Component PL REP ADJ


Fuser Drive Assembly

Fuser Fan Assembly

‰ Install the Fuser Assembly in the machine and close the Left
Cover.

‰ Proceed to the Self Check on the next page.

STUDENT GUIDE 3/11/2010 8-3


8 Fuser WorkCentre 7120 Service Training

Self Check
Answer the questions below and then check your answers by
referring to the Self-Check Answers page at the end of this module.
There may be more than one acceptable answer per question. Circle
the letters of the correct answer(s).

1. The Fuser Assembly’s life expectancy is based on which of the


following?
a. Area coverage printed
b. Extended machine ON time
c. Number of A4 or equivalent prints run
d. All of the above

2. The fusing temperatures of the WorkCentre 7120 tend to be


( __________ ) than similar machines.
a. Higher
b. Lower
c. The same as

3. Which Heater Rod is turned on to transition from Wait to Ready?


a. Main Heater Rod only
b. Sub Heater Rod only
c. Both of the above

4. When does the control logic use Forced Lighting Control Mode?
a. When running large jobs on narrow media
b. When running wide media
c. When the temperature detected by the NC Sensor is too
low for the media being run
d. When paper is present in the Fuser and both Heater Rods
are Off.
5. The On and Off control of the Heater Rods is based on the input
from which of the following?
a. NC Sensor
b. Thermostat
c. Fuser Thermistor

8-4 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 8 Fuser

6. Customers may notice that prints from the 7120 are ( _____ )
than prints from similar machines.
a. Flatter
b. Glossier
c. The same as
7. What is the purpose of soft start phase control?
a. Extends Heater Rod life
b. Helps prevent flicker
c. Reduces energy consumption

STUDENT GUIDE 3/11/2010 8-5


8 Fuser WorkCentre 7120 Service Training

Module Summary
You should now be able to:
1. Identify the major components of the Fuser.
2. Describe how Fuser temperature is controlled.
If you do not feel comfortable with your ability to perform any of
the learning objectives, review the materials for those objective.
If you have any questions and are in a classroom environment,
ask your instructor.
‰ Ask your instructor sign you off on this Module.

8-6 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 8 Fuser

Feedback
Feedback for the Work Projects you have performed is provided
below.

Fuser Component Location

Component PL REP ADJ


Fuser Drive Assembly 3.1 4.4 ---

Fuser Fan Assembly 4.1 --- ---

STUDENT GUIDE 3/11/2010 8-7


8 Fuser WorkCentre 7120 Service Training

Self- Check Answers

1. The Fuser Assembly’s life expectancy is based on which of the


following?
a. Area coverage printed

b. Extended machine ON time

c. Number of A4 or equivalent prints run

7 d. All of the above

2. The fusing temperatures of the WorkCentre 7120 tend to be


( __________ ) than similar machines.
a. Higher

7 b. Lower

c. The same as

3. Which Heater Rod is turned on to transition from Wait to Ready?


a. Main Heater Rod only

b. Sub Heater Rod only

7 c. Both of the above

4. When does the control logic use Forced Lighting Control Mode?
a. When running large jobs on narrow media

7 b. When running wide media

c. When the temperature detected by the NC Sensor is too


low for the media being run

7 d. When paper is present in the Fuser and both Heater Rods


are Off.
5. The On and Off control of the Heater Rods is based on the input
from which of the following?

7 a. NC Sensor

b. Thermostat

7 c. Fuser Thermistor

8-8 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 8 Fuser

6. Customers may notice that prints from the 7120 are ( _____ )
than prints from similar machines.
a. Flatter

7 b. Glossier

c. The same as
7. What is the main purpose of soft start phase control?
a. Extends Heater Rod life

7 b. Helps prevent flicker

c. Reduces energy consumption

STUDENT GUIDE 3/11/2010 8-9


8 Fuser WorkCentre 7120 Service Training

8-10 3/11/2010 STUDENT GUIDE


Module 09 Finishers

Introduction

Module Overview
This module will prepare you to service the Finisher subsystem.
You will learn how the subsystem operates, locate components,
and perform service procedures.
There are two Finishers available for this product. Each Finisher is
described in a separate section, as follows:
• Module 09a – Integrated Office Finisher
• Module 09b – Office Finisher LX

Module Instructions
All Students: Read both Finisher sections to familiarize yourself
with the configurations you may encounter in the field, whether or
not you have access to the Finishers during training.
Students training remotely: If a machine becomes available to
you, take the opportunity to perform any hands-on Work Projects.
Students in centralized training: If, after reading the content of
this module, you feel that you have the skill and knowledge to “opt-
out” of the removal procedures or Work Projects for this module,
contact your instructor. Your instructor may test your knowledge
before allowing you to move on to the next module. Allowing
students to move ahead before they complete the entire module is
at the instructor’s discretion.

STUDENT GUIDE 03/11/10 9-1


9 Finisher Workcentre 7120 Service Training

Notes:

9-2 3/11/2010 STUDENT GUIDE


Module 9A
Integrated Office Finisher

Introduction

Module Overview

Although students may The Integrated Office Finisher can separate the machine output by
disregard this module if offsetting the printed sets. It is also capable of automatic stapling of
they’re already trained on printed sets.
this finisher, they are This module provides an overview of the Integrated Office Finisher.
encouraged to review it to
refresh their knowledge. This module will prepare you to service the Finisher subsystem. You
will learn how the subsystem operates, locate components, and
perform service procedures.

Module Objectives
‰ Upon completion of this module you will be able to:
Students training remotely 1. Describe the operation of the Integrated Office Finisher.
should read through this
module if not trained on 2. Identify the location and describe the purpose of the major
the Finisher. finisher components.
3. Using the service documentation, remove, replace, and adjust
components.
4. Run a test job to the Integrated Office Finisher.

STUDENT GUIDE 3/11/2010 9A-1


9a INTEGRATED OFFICE FINISHER WORKCENTRE 7120 SERVICE TRAINING

Technology Overview
‰ Open your SGS
‰ Go to 10 PTO.
‰ From the PTO menu, click on 12 Finishing.
‰ Click the Integrated Office Finisher button.
‰ After reading the information, return to the PTO menu.
‰ If you have any questions ask an instructor for assistance.

Integrated Office Finisher Operation

Sample Copy Job with Finishing


‰ Create two sample documents of three pages each using 8.5 x 11
or A4 paper (one portrait and one landscape).
‰ On a WorkCentre 7120 with the Integrated Finisher, load tray 1 with
8.5 x 11/A4 SEF paper and Tray 2 with 8.5 x 11/A4 LEF paper.
‰ Make the following copy job selections:
1. Press the Services Button. If the machine has gone into Sleep
Mode, first press the Energy Saver button.
2. Select Copy.
3. Select Paper Supply > Auto Select.
4. Select Output > 1 Staple.
5. Select a Copy Quantity of 1.
6. Load one set of sample documents into the Document Handler,
adjust the Document Guides and press Start.
7. Load the other set of sample documents into the Document
Handler, adjust the Document Guides and press Start.
8. Notice the staple position for each job.

9A-2 3/11/2010 STUDENT GUIDE


WORKCENTRE 7120 SERVICE TRAINING 9a INTEGRATED OFFICE FINISHER

Location of Major Components


If your training site is equipped with Integrated Office Finishers,
perform the following work projects. If the hardware is not available,
review the named procedures in your EDOC.
‰ If the Integrated Office Finisher is installed on the WorkCentre
7120, perform REP 12.1 in Section 4 of the Service Manual to
remove it.
‰ Refer to PL 22.1 and PL 22.2 in Section 5 of the Service Manual
and remove the following covers:
1. Front Inner Cover
2. Rear Cover
3. Left Cover
4. Bottom Cover
5. Tray Cover
‰ Locate the following components:
1. Staple Assembly (PL 22.4)
2. Finisher PWB (PL 22.7)
3. Set Clamp Home Sensor (PL 22.4)

STUDENT GUIDE 3/11/2010 9A-3


9a INTEGRATED OFFICE FINISHER WORKCENTRE 7120 SERVICE TRAINING

Work Projects: Integrated Office Finisher

Work Project #1 – Removing the Compiler Assembly


‰ Perform REP 12.20 in Section 4 of the Service Manual to remove
the Compiler Assembly.
‰ Reinstall the Compiler Assembly and reassemble the Finisher.
‰ Reinstall the Finisher on your machine.
If you have any questions ask an instructor for assistance.
Otherwise, continue with the Self-Check.

9A-4 3/11/2010 STUDENT GUIDE


WORKCENTRE 7120 SERVICE TRAINING 9a INTEGRATED OFFICE FINISHER

Self-Check
Answer the following questions to test your understanding of the
Finisher. Check your answers in the Feedback section at the end of
this module

1. The maximum number of sheets of 24 lb / 90gsm paper that is


guaranteed to be stapled correctly is:
a. 30
b. 50
c. 70
d. 100

2. The maximum number of sheets of 24 lb / 90gsm paper that the


stacker tray can hold is:
a. 150
b. 300
c. 500
d. 700

3. Tampers are used to:


a. Align Sheets into Registered Sets
b. Offset Sets in the Stacker Tray
c. Hold Sets during the Stapling operation
d. Both a and b
e. All of the above

4. The Stacker Tray moves down when:


a. The Stack Height Sensor is Blocked
b. Stacker Sensor 1 and/or 2 sensor is blocked (high)
c. Stacker Sensor 2 is blocked
d. Both a and b
e. Both a and c
5. The Interlocks on the A-Finisher interrupt:
a. +5VDC to sensors in the finisher
b. +24VDC to motors and solenoid in the finisher
c. Both +24VDC and +5VDC from the Finisher PWB to
components in the finisher.

STUDENT GUIDE 3/11/2010 9A-5


9a INTEGRATED OFFICE FINISHER WORKCENTRE 7120 SERVICE TRAINING

Fault Analysis & Repair


NOTE: Disregard this section if Integrated Office Finisher hardware
is not available.
Ask your instructor if there is a fault analysis activity for this module.
If there is, your Instructor will insert a fault.
Follow the guidelines below.
Once the fault is inserted in your machine, your Instructor will
describe to you the problem that is occurring in the machine.
‰ Proceed through the Fault Analysis exercise following these
procedures:
1. Team up with your lab partner and complete the fault
analysis exercise.
2. Record your start time.
3. Use the Fault Analysis worksheet provided by your
instructor. Document the steps you followed in the service
documentation.
4. Summarize the fault description, repair actions, and any
parts required for the fix.
5. Once properly diagnosed, explain the source of the
problem to the instructor and your method of
troubleshooting.
6. Record your end time.
7. Repair the machine to working order.
8. When you have completed the repairs, print out 10 copies
of the Test Pattern to show to the instructor.
‰ When finished with all fault exercises for these modules, check with
your instructor for hardware availability for any incomplete paths or
modules remaining on your sign off sheet.
‰ To allow access to the IOT and the various other subsystems, it will
be necessary to remove the Finisher. Remove the Finisher and set
it aside.
‰ Ask your instructor to sign you off on Module 9A.

9A-6 3/11/2010 STUDENT GUIDE


WORKCENTRE 7120 SERVICE TRAINING 9a INTEGRATED OFFICE FINISHER

Feedback

1. The maximum number of sheets of 24 lb / 90gsm paper that is


guaranteed to be stapled correctly is:
a. 30

7 b. 50

c. 70
d. 100

2. The maximum number of sheets of 24 lb / 90gsm paper that the


stacker tray can hold is:
a. 150
b. 300

7 c. 500

d. 700

3. Tampers are used to:


a. Align Sheets into Registered Sets
b. Offset Sets in the Stacker Tray
c. Hold Sets during the Stapling operation
d. Both a and b

7 e. All of the above

4. The Stacker Tray moves down when:


a. The Stack Height Sensor is Blocked
b. Stacker Sensor 1 and/or 2 sensor is blocked (high)
c. Stacker Sensor 2 is blocked

7 d. Both a and b

e. Both a and c
5. The Interlocks on the A-Finisher interrupt:
a. +5VDC to sensors in the finisher

7 b. +24VDC to motors and solenoid in the finisher

c. Both +24VDC and +5VDC from the Finisher PWB to


components in the finisher.

STUDENT GUIDE 3/11/2010 9A-7


9a INTEGRATED OFFICE FINISHER WORKCENTRE 7120 SERVICE TRAINING

9A-8 3/11/2010 STUDENT GUIDE


Module 9b Office Finisher LX

Introduction

Module Overview
The Office Finisher LX offers much of the functionality of the
Professional Finishers but at a lower price and with fewer features.

Module Objectives
Upon completion of this module you will be able to.

Although students may 1. Describe the operation of the Finisher


disregard this module if 2. Remove, replace, and adjust any component.
they’re already trained on 3. Run a test job to the Finisher.
this finisher, they are
encouraged to review it to
refresh their knowledge.

Students training remotely


should read through this
module if not trained on the
Finisher.

STUDENT GUIDE 3/11/2010 9B-1


OFFICE FINISHER LX WorkCentre 7120 Service Training

Technology Overview
‰ Open your SGS
‰ Go to 10 PTO.
‰ From the PTO menu, click on 12 Finishing.
‰ Click the Finisher LX button.
‰ Select every link in the Finisher menu and read the
accompanying information.
‰ Return to the PTO main menu.

‰ If you have any questions ask an instructor for clarification.

Office Finisher LX Operation

Sample copy job with Finishing

‰ Create two sample sets of four documents each, one for short
edge feed and one for long edge feed using 8.5 X 11” or A4
paper.

‰ Make sure there is 8.5 X 11” or A4 paper in long edge feed


mode in Tray 1 and short edge feed mode in Tray 2.

‰ Make the following copy selections:


1. Press Services Button.
2. Select Copy.
3. Select Paper Supply > Auto Select.
4. Select Copy Output > Collated 1 Staple.
5. Select a Copy Quantity of 1.
6. Load one set of sample documents into the Document
Handler, adjust the Document Guides and press Start.
7. Load the other set of sample documents into the Document
Handler, adjust the Document Guides and press Start.
8. Notice the staple position for each job.

9B-2 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training OFFICE FINISHER LX

Location of Major Components

‰ Refer to REP 13.6, REP 13.7, REP 13.8, REP 13.10, REP 13.11
and REP 13.12 in Section 4 of the Service Manual and remove
the following covers:
1. Front Cover Assembly
2. Rear Upper Cover
3. Rear Lower Cover
4. Foot Cover
5. Stacker Lower Cover
6. Stacker Upper Cover

‰ Locate the following components:


1. Finisher PWB (PL 23.16)
2. Finisher LVPS (PL 23.16)

‰ After finishing this exercise, reassemble the Finisher and re-dock


it to the machine (REP 13.5).

STUDENT GUIDE 3/11/2010 9B-3


OFFICE FINISHER LX WorkCentre 7120 Service Training

Self-Check
Answer the following questions to test your understanding of the
Finisher. Check your answers in the Feedback section at the end of this
module.

1. The maximum number of sheets the Stacker Tray can hold of A4


or 8.5 x 11” paper is:
a. 200
b. 2000
c. 1000
d. 400

2. There are two media types that the Office Finisher LX cannot
handle. Select them from the list below.
a. Heavyweight coated
b. Heavyweight 2 coated
c. Transparencies
d. Envelopes

3. The Horizontal Transport performs the following functions:


a. Transports sheets from the Exit 1 Assembly to the Finisher
LX
b. The Punch Unit is installed in this Transport
c. Transports sheets from the Compiler Tray to the Stacker
Tray
d. Transports sheets from the Compiler Tray to the Exit Roll
Assembly

4. The Finisher Low Voltage Power Supply supplies the following


Voltage to the Finisher PWB.
a. -5 VDC
b. +5 VDC
c. -24 VDC
d. +24 VDC

9B-4 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training OFFICE FINISHER LX

5. The Finisher PWB provides what voltages to the Finisher LX and


Horizontal Transport motors, sensors, switches, and solenoids.
a. +5 and +24VDC
b. +5, -5 ,+24, and -24 VDC
c. +5, +3.3 and +24VDC
d. -5, -3.3, and -24VDC
6. Indicate what happens if the Finisher Front Door is opened.
a. +24 VDC is removed for the entire machine
b. +24 VDC and +5 VDC is removed for the Finisher
c. +24 VDC and +5VDC is removed for the entire machine
d. +24 VDC is removed for the Finisher
7. When the Stacker No Paper Sensor is triggered, this indicates
what about the Stacker Tray.
a. There is no paper in the Stacker Tray no matter where the
tray is located
b. The Stacker Tray is at the lowest position but empty
c. The Stacker Tray is at the uppermost position
d. The Stacker Tray is at the lowest position
8 The Sub Paddle Assembly drives paper into this area of the
Finisher.
a. The Horizontal Transport
b. The Compiler
c. The Booklet Unit
d. The Exit Roll
9. With the Booklet Unit installed the Crease Assembly is installed
in what location on the Finisher.
a. In the Booklet Unit
b. In the Horizontal Transport
c. In the Finisher to the right of the Compiler
d. In the Finisher inside the Front Cover to the left of the
Compiler
10. Indicate the purpose of the Tampers (select all that apply).
a. they collate the sheets in the Stacker Tray
b. they nudge the sheets in the compiler tray into a neat stack
c. they position the sheets ready for stapling
d. they offset the compiled stack in the Compiler Tray

STUDENT GUIDE 3/11/2010 9B-5


OFFICE FINISHER LX WorkCentre 7120 Service Training

This page intentionally left blank

9B-6 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training OFFICE FINISHER LX

Self-Check Answers

1. The maximum number of sheets the Stacker Tray can hold of A4


or 8.5 x 11” paper is:
a. 200

7 b. 2000

c. 1000
d. 400

2. There are two media types that the Office Finisher LX cannot
handle. Select them from the list below.
a. Heavyweight coated
b. Heavyweight 2 coated

7 c. Transparencies

7 d. Envelopes

3. The Horizontal Transport performs the following functions:

7 a. Transports sheets from the Exit 1 Assembly to the Finisher


LX
b. The Punch Unit is installed in this Transport
c. Transports sheets from the Compiler Tray to the Stacker
Tray
d. Transports sheets from the Compiler Tray to the Exit Roll
Assembly

4. The Finisher Low Voltage Power Supply supplies the following


Voltage to the Finisher PWB.
a. -5 VDC
b. +5 VDC
c. -24 VDC

7 d. +24 VDC

5. The Finisher PWB provides what voltages to the Finisher LX and


Horizontal Transport motors, sensors, switches, and solenoids.

7 a. +5 and +24VDC

b. +5, -5 ,+24, and -24 VDC


c. +5, +3.3 and +24VDC
d. -5, -3.3, and -24VDC

STUDENT GUIDE 3/11/2010 9B-7


OFFICE FINISHER LX WorkCentre 7120 Service Training

6. Indicate what happens if the Finisher Front Door is opened.


a. +24 VDC is removed for the entire machine
b. +24 VDC and +5 VDC is removed for the Finisher
c. +24 VDC and +5VDC is removed for the entire machine

7 d. +24 VDC is removed for the Finisher

7. When the Stacker No Paper Sensor is triggered, this indicates


what about the Stacker Tray.
a. There is no paper in the Stacker Tray no matter where the
tray is located
b. The Stacker Tray is at the lowest position but empty

7 c. The Stacker Tray is at the uppermost position

d. The Stacker Tray is at the lowest position


8 The Sub Paddle Assembly drives paper into this area of the
Finisher.
a. The Horizontal Transport

7 b. The Compiler

c. The Booklet Unit


d. The Exit Roll
9. With the Booklet Unit installed the Crease Assembly is installed
in what location on the Finisher.
a. In the Booklet Unit
b. In the Horizontal Transport
c. In the Finisher to the right of the Compiler

7 d. In the Finisher inside the Front Cover to the left of the


Compiler
10. Indicate the purpose of the Tampers (select all that apply).
a. they collate the sheets in the Stacker Tray

7 b. they nudge the sheets in the compiler tray into a neat stack

7 c. they position the sheets ready for stapling

7 d. they offset the compiled stack in the Compiler Tray

9B-8 3/11/2010 STUDENT GUIDE


WorkCentre 7120 Service Training OFFICE FINISHER LX

Fault Analysis
NOTE: Disregard this section if Office Finisher LX hardware is not
available.
Ask your instructor if there is a fault analysis activity for this module.
If there is, your Instructor will insert a fault.
Follow the guidelines below.
Once the practice fault is inserted in your machine, your Instructor
will describe to you the problem that is occurring in the machine.

‰ Proceed through the Fault Analysis exercise following these


procedures:
1. Team up with your lab partner and complete the fault
analysis exercise.
2. Record your start time.
3. Use the Fault Analysis worksheet provided by your
instructor. Document the steps you followed in the service
documentation.
4. Summarize the fault description, repair actions, and any
parts required for the fix.
5. Once properly diagnosed, explain the source of the
problem to the instructor and your method of
troubleshooting.
6. Record your end time.
7. Repair the machine to working order.
8. When you have completed the repairs, print out 10 copies
of the Test Pattern to show to the instructor.

‰ When finished with all fault exercises for this module, check with
your instructor for hardware availability for any incomplete paths
or modules remaining on your sign off sheet.

‰ Ask your instructor to sign you off on Module 9B.

STUDENT GUIDE 3/11/2010 9B-9


OFFICE FINISHER LX WorkCentre 7120 Service Training

9B-10 3/11/2010 STUDENT GUIDE


Module 10 Image Quality

Introduction

Module Overview
This module provides an overview of Image Quality troubleshooting
for the machine.
In this module, you will learn about techniques to judge if the
machine is providing output that is within specification, and if not,
what you can do to correct the situation.
Once you have read the content of this module, if you feel that you
have the skill and confidence to “opt-out” of the removal procedures
or Work Projects for this module, contact your instructor. Your
instructor may test your knowledge before allowing you to move on
to the next module. Allowing students to move ahead before they
complete the entire module is at the instructor’s discretion.

Module Objectives
Upon completion of this module, you will be able to:
1. Describe the purpose of each area on the Full Color Test
Pattern 82E13120 and the geometric test pattern 82E8220.
2. Describe the image path through the machine and how image
defects can occur in each subsystem.
3. Describe the purpose of Max Setup and how it affects output.
4. Adjust the Variable Color Balance using the UI screen to bring
the machine into proper color balance.
5. Discriminate between poor and good copy color balance.

STUDENT GUIDE 3/17/2010 10-1


10 IMAGE QUALITY WorkCentre 7120 Service Training

Image Quality Specification and Test Pattern Overview


The full color test pattern for the machine provides a means to
determine if it is reproducing color correctly. Various tests can be
performed with this test pattern to check various color output
parameters.
Before you read the section in this training that describes the use of
the full color test pattern, review the following points:
• Photos such as the Vermont Scene, Carousel horse, etc. are
NOT to be used as test patterns for setup purposes.
• The standard color test pattern is 82E13120.
• The geometric test pattern is 82E8220
• The "Tulip Stream" (82E93950) is a printed photo test
pattern. The difference between a photograph and a printed
photo is that the photograph is a continuous tone or contone
image. This is where one color blends into another color
under an eye loupe. A printed photo is made up of small dots
arranged to create various colors depending on how closely
the dots are spaced and how much of each of the four colors
is used. Under an eye loupe, a printed photo will show
thousands of dots or rosettes.
• Remember that even the best photographic papers will age
and yellow. Photographs are not to be used to set up copy
quality specs.
• The machine can be out of specification and still produce a
good-looking copy of the Tulip Stream. The Tulip Stream is
not to be used to set up copy quality specs.
• Test patterns need to be replaced periodically because of dirt,
scratches, fingerprints, fading, and yellowing. This is true of all
full color test patterns.
• It is advisable to carry two of the full color test pattern. One
should be kept as clean as possible and used only for Max
Setup procedures.
• Always use Xerox Color Xpressions paper for all color setups.
If a customer does not use Color Xpressions paper, you must
obtain 24#, brilliance “96” paper when evaluating image quality
and performing Max Setup. There is a part number for a
plastic-zip bag (600T2000) and a carrying case (600T1999) so
that you can carry your own supply of paper for Max Setup
routines. Never use paper other than specified.
• When checking density and color balance, ALWAYS back the
copy with several sheets of white paper to prevent bleed
through. This will prevent distortion of colors, which could lead
to misinterpretation when judging for proper copier output.
Demonstrate with a copy laid on the bare table and then slide
some sheets under it to show the difference.

10-2 3/17/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 10 IMAGE QUALITY

Documentation and Color Test Pattern Overview


‰ Review the following in the EDOC:
• 1 Service Call Procedure - Call Flow
• 3 Image Quality – Image Quality Specifications
• 3 Image Quality – IQ RAPs defect samples
‰ Using the procedure located in 3 Image Quality,
Specifications, make a copy of the 82E13120 test pattern and
determine if the output is within specifications in Areas A through
I. If the copy is out of specification, do not perform any
procedures to correct the problem. You will run Max Setup later
in this module.

Geometric Test Pattern


The 82E8220 test pattern is used to judge IOT registration and
magnification. The directions for the use of the test pattern are
contained in the Image Quality Specifications subsection of
Section 3 in the EDOC.
‰ Go to EDOC Section 3, Image Quality Specifications and review
the information there for the use of the 82E8220 Geometric Test
Pattern.
‰ Test the following geometric settings for your machine:
• Magnification
• Resolution
• LE Registration
• SE Registration

Internal Test Patterns


Individual RAPs call for these test patterns. Many of them have
multiple checks and may be used by more than one RAP.
‰ Go to Print Test Patterns in section 6 of the EDOC and print
one copy of each of the following internal test patterns for the
machine. Write the name of each pattern on the copy:
• 90° Grid
• A1 Patch Pattern
• B Patch Pattern
• C Patch Pattern
‰ Refer to the procedure entitled Print Test Patterns in Section 6
of the EDOC. In Table 1 Test Patterns, review the information
presented for each test pattern you printed.

STUDENT GUIDE 3/17/2010 10-3


10 IMAGE QUALITY WorkCentre 7120 Service Training

Copier Setup Tips


Make sure you record any setup parameters that you change in
the Tools mode so that you can return the machine to the
previous settings. If color correction controls are changed on a
machine in the field, you may want to find out why. It may be
because of preference, but it may also be to compensate for a
failing component that reproduces less than desirable color.

‰ Record the Customer Setup parameters.


Remember that Max Setup is designed to adjust the machine to
a predetermined factory specification. You should only perform
Max Setup when directed to do so.

Max Setup Tips

Mistakes Do Not Go Away


An error near the beginning of Max Setup, such as a poorly done
White Reference or color Density Adjustment, will usually affect
all subsequent adjustments.
Would there be a problem with copy quality if the customer only
had recycled paper that was not as white as the required paper
and you used it to do a white balance setup?
Yes. The paper will not reflect the correct white value to the IPS.
The incorrect value will cause the machine to "see" low level
grays as white and reproduce those grays as white. As a result,
the copy will be visually light overall.

10-4 3/17/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 10 IMAGE QUALITY

Troubleshooting Color Image Quality


Now that you have learned about the machine and how it
controls image quality output, you can learn more about the
techniques available to troubleshoot image quality defects that
occur in the copier.

Work Projects

These work projects will require you to use a full system. Do not
attempt to adjust the copier to meet any specification during
this work project. The purpose of this work project is for you to
become familiar with the test patterns and the image quality
specifications check. You will adjust the copier to meet the
specifications later.
‰ Ensure that the machine is in good working order.
The following exercises will demonstrate the adjustable color
reproduction ranges of the machine. This will produce a
sampling range of the six color variables (R, G, B, C, M, and Y).
The color hard copies you produce can be used as color quality
assessment tools during your training.
‰ Ask your instructor for Test Pattern 82E93950 (Tulip Stream) (or
equivalent). If the instructor does not have an acceptable
pattern, skip Projects #1 and #2.

Project #1

This project will require you to use a full system. Refer to the
Quick Reference Guide if needed.
‰ Use the original of the 82E93950 (Tulip Stream) for the following
projects.
‰ From the Document Glass, run an Auto Detect copy, simplex job
with a quantity of 1.
‰ Label this copy "normal."

Project #2
This project will require you to use a full system. Refer to the
Quick Reference Guide, Chapter 3 if needed.
‰ Use the same original as in project 1.
‰ Press Copy on the touch screen.
‰ Touch the Image Quality tab.
‰ Touch the Color Balance button.
‰ Touch the Basic Color button.
‰ Using the slider, increase the amount of color to +3. Leave the
other colors set at zero (0).
‰ Make a copy and label it "High Yellow."

STUDENT GUIDE 3/17/2010 10-5


10 IMAGE QUALITY WorkCentre 7120 Service Training

‰ Decrease the yellow medium density to – 3.


‰ Make another copy and label it "Low Yellow".
‰ Restore settings to normal.
‰ Compare the two copies.
‰ Now adjust the [cyan].
‰ Using the slider, increase the amount of color to + 3. Leave
the other colors set at zero (0).
‰ Make a copy and label it "High Cyan."
‰ Decrease the Cyan medium density to – 3.
‰ Make a copy and label it "Low Cyan."
‰ Restore settings to normal.
‰ Compare the two copies.
‰ Now adjust the [Magenta].
‰ Using the slider, increase the amount of color to + 3. Leave
the other colors set at zero (0).
‰ Make a copy and label it "High Magenta."
‰ Decrease the Magenta medium density to – 3.
‰ Make a copy and label it "Low Magenta."
‰ Restore settings to normal.
‰ Compare the two copies.
‰ Increase all four colors (Y, M, C, K) to + 3 on the High-
Density scale.
‰ Make a copy and label it "High Density."
‰ Decrease all four colors (Y, M, C, K) to – 3 on the Low-
Density scale.
‰ Make a copy and label it "Low Density."
‰ Return all colors to zero (0) or to the initial settings.

10-6 3/17/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 10 IMAGE QUALITY

‰ Lay the color copies out in the following order:

Low Cyan Low Magenta Low Yellow


(- 3 cyan) (- 3 magenta) (- 3 yellow)

Low Density “Normal” Balance High Density


(- 3 Y, M, C, K) (+ 3 Y, M, C, K)

High Yellow High Magenta High Cyan


(+3 yellow) (+3 magenta) (+3 cyan)

‰ Review and assess the samplings of color copies.


If you require further information about the copies you just made,
discuss the outputs with your instructor.

Project #3

This project will require you to use the SA Guide found in 12


Library.
‰ Click on 12 Library.
‰ Open the SA Guide.
‰ Locate the Color Calibration procedure.
‰ Follow the instructions to calibrate your system for both
copies and prints.
‰ Evaluate the output of your system.

STUDENT GUIDE 3/17/2010 10-7


10 IMAGE QUALITY WorkCentre 7120 Service Training

Max Setup
In this section of the training, you will learn more about Max Setup,
which is used to bring the color output of the machine back into
specifications. You also will have an opportunity to perform Max
Setup.

When to run Max Setup


When should Max Setup be run? The most correct and common
answer to this is “Whenever the EDOC tells you”, which is very
good advice. However, from a general standpoint, there are
judgments that you can make to determine if a Max Setup is
required for the machine upon which you are working.

Judging Test Pattern Copies


The full color test pattern for the machine can be used to determine
if Max Setup is required. Several areas of the test pattern are used
to judge various aspects of the copier output.
The two areas to use to judge output density and balance are the
Color Gradation Check area (Area D) and the Routine Color Check
area (Area E).
Generally, if the color density and balance checks in Area D
appear out of specification, it is a good idea to run Max Setup.
Area E can be used for a more subjective check of the reproduction
of skin tones, green grass, and sky. These elements are commonly
present in photographic images that might be copied using the
machine.

10-8 3/17/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 10 IMAGE QUALITY

Max Setup Overview

NOTE: Make sure that you understand and have the latest
procedures when servicing this machine. In addition, Max Setup is
a procedure that will adjust the machine to a predetermined factory
specification.

The MAX Setup menu contains the following items:


• ProCon On/Off Print Check (see ADJ 9.7)
• Adjust Toner Density (see ADJ 9.4)
• Copy Mode Color Balance Adjustment (see ADJ 9.6)
• IIT Calibration (see ADJ 6.6)
• White Reference Adjustment (see ADJ 6.6)
• CCD Calibration (see ADJ 6.6)
• Optical Axis Correction (see ADJ 6.1)
• 2nd Transfer Voltage Offset Adjustment (see ADJ 9.15)
• TRC Adjustment (see ADJ 9.5)

Name Description
ProCon This procedure performs a Mini-setup, outputs a printed test pattern for visual
On/Off Print analysis, and prints a Job End patch.
Check Selected process control NVM values are displayed, and a check for hidden
process-control-related faults is performed.
Adjust This procedure manually increases or decreases toner concentration (TC). It is
Toner used when a xerographic problem or out-of-toner condition has prevented
Density process control from maintaining the TC target value.
This procedure does not change any parameters; it performs a one-time change
to TC. It is important that the problem that caused the low or high TC condition is
resolved before performing this adjustment.
Color To perform fine adjustment of the center value of the low density/medium
Balance density/high density output balance for each color for copy images.
Adjustment This adjustment is only applicable to the copy function.
Adjustment is carried out in the TRC section of the ESS according to the set
value.
Perform this adjustment only when requested by the customer. The center of
color adjustment in Customer Mode will be changed by this setup.
IIT This routine consists of two parts:
Calibration 1. White Reference Adjustment
2. CCD Calibration

STUDENT GUIDE 3/17/2010 10-9


10 IMAGE QUALITY WorkCentre 7120 Service Training

White The White Reference Adjustment Requires Xerox Digital Color Xpressions+ (XC)
Reference or Colotech+ (XE) paper
Adjustment
CCD The reference points in control logic that match up to the input voltages coming
calibration. from the charge coupled device are balanced for even readings from inboard to
outboard.
ƒ Requires test pattern (82E13120)
Optical Axis ƒ Performed only when Lens unit is replaced.
Calibration ƒ Requires no special paper or test pattern
Routine corrects for any “slant” in the light axis caused by the frame.
nd
2 Transfer Used to adjust the secondary transfer voltage to accommodate the various types
Voltage of paper available in the market.
Offset
Adjustment
TRC Performed only upon customer request to resolve specific color complaints.
Adjustment (Adjust only after customer has first tried Calibration Adjustment and then tried
adjusting UI and/or print driver settings)
Routine can be used to adjust the Low, Medium, and High color (CMYK) densities

Work Project

Perform Max Setup

‰ Inform the instructor that you are ready to perform the Max
Setup procedure.
‰ Ensure that the machine is in good working condition before you
begin the work project.
‰ Refer to your SGS/EDOC service documentation to run Max
Setup on your machine.
‰ Show your completed Max Setup copy to your instructor.

10-10 3/17/2010 STUDENT GUIDE


WorkCentre 7120 Service Training 10 IMAGE QUALITY

Module Summary
In this module, you became familiar with the imaging process and
how the various subsystems of the machine affect image quality.
You learned how to discriminate between poor and good copy color
balance and to perform the various user and service adjustments.
Review the objectives at the beginning of the module. If you do not
feel comfortable with your ability to perform any objective, review
the material for that objective. If you are still not comfortable,
discuss the information with your instructor.
‰ Have your instructor sign you off on the Module.

STUDENT GUIDE 3/17/2010 10-11


10 IMAGE QUALITY WorkCentre 7120 Service Training

10-12 3/17/2010 STUDENT GUIDE

Potrebbero piacerti anche