1996 Xerox 2510 / 2515 Copier Service & Parts Manual (P/N 700P87480)

Xerox’s August 1996 service manual, P/N 700P87480, covers the 2510 (50/60 Hz) and 2515 (60 Hz), including USO, XCL and XLA configurations. Revision documents 700P87481 and 700P87482 are collated into this edition. The 2515 50 Hz product code 4L2 appears in the specifications; the stated 2515 service coverage is for 60 Hz.

• Service calls and maintenance: Call Flow Diagram, Status Code Entry Chart, and Normal Call and Extended Maintenance checklists for xerographic, media transport and developer assemblies.

• Document and media transport: Feed-roll replacement, media transport module removal, fabric-guide installation, motion-sensor replacement and registration adjustment.

• Image quality: Image Quality RAPs, defect samples, developer-bias and exposure diagnosis, Electrostatic Series adjustments, and image-density checks.

• Xerographic and developer service: Photoreceptor drum, cleaner blade, corotron wire and developer-material replacement, plus 2515 toner-sensor and dispense-solenoid service.

• Fuser and oiling: Heat rod, fuser roll, thermistor and stripper-finger replacement, oil-dispenser servicing, wick priming and fuser-roll initialization.

• Electrical troubleshooting: Control PWB, LVPS and HVPS diagnosis, cooling-fan and ground-fault tests, circuit diagrams, connector locations and pin assignments.

• Parts and modifications: Exploded assembly views, a part-number index, and separate Change Tag/MOD indexes for hardware and firmware changes.

This documentation is intended for certified, product-trained Xerox service personnel.

Diagnostic and Maintenance Overview

Status Indicator RAPs address document-sensor errors, cover interlocks, E–Paper Path Jam faults and F–Fuser problems. The 2515 J–High Toner and J–Low Toner procedures distinguish toner-concentration faults from dispensing and developer-mixing problems.

Foreign-accessory procedures cover copier enablement, external billing signals and image-length settings. Normal Call and Extended Maintenance checklists link inspection and replacement work to accumulated media footage.

The electrical sections distinguish AC cooling fans on the 2510 without Tag 5 from DC fans on the 2510 with Tag 5 and the 2515. Electrical Component Wiring drawings and connector tables show connections between power supplies, control-panel logic and fuser components.

Image Defects and Electrostatic Adjustments

The Copy Defect Flowchart and defect samples cover background banding, streaks, deletions and residual images (ghosting). The Image on Drum (Panic Stop) procedure helps separate defects originating before transfer from transfer or fuser faults, narrowing the diagnostic path.

Image-quality checks use Test Pattern 82E5980, Image Reference Scale 82E7030 and Xerox Background Grainness SIR Scale 82P502. The manual also separates old-type HVPS adjustments for the 2510 from new-HVPS procedures for both models.

The manual explains how photoreceptor crystallization causes deletions. Its tools list identifies the Mod IV Electrometer 600T1620 and Probe Holder 600T1969 for electrostatic checks.

Developer Repair Limits and Oiler Variants

The 2510 developer module has repair-kit coverage, including kit 600K14082. The 2515 developer module requires replacement instead of the 2510 rebuild method because its tighter manufacturing tolerances cannot be reset with that repair kit.

Oil Dispenser Assembly exploded views distinguish 2510 configurations with and without Tag 252 and 2515 configurations with and without Tag 88. These distinctions help match replacement parts to the installed oiling arrangement.

The heat-rod procedure warns that oil from fingers can damage the rod. Incorrect cleaner-blade seal positioning can damage the photoreceptor drum; the replacement procedure illustrates the required seal relationship.

Servicing high-voltage copier components presents electrical hazards; follow the manual’s electrical-isolation and hot-fuser precautions.

A Preview of Fuser and Fan Test Values

These examples are a small selection of the electrical reference data in the manual. The 2510 fuser circuit diagrams label thermistor RT1 at 145 kΩ cold and 2 kΩ hot.

For the 2510 with Tag 5 and the 2515, the DC Cooling Fan RAP lists +3.5 to +5.0 VDC at P/J9-7 in Run Mode and +2.0 VDC in Power Saver Mode. These are fan-control signal readings, not fan supply-voltage ratings.

PDF Search, Bookmarks and Page Contents

Search and diagram access: Text search works across much of the manual, but OCR errors and some pages without searchable text limit results. Eight bookmarks provide section access; the Service Call Procedures bookmark opens the repeated cover, while the section starts at PDF p. 21. Small circuit labels need zooming, and some pages need rotation.

One printable English-language PDF contains 408 pages: 20 preliminary pages, 386 pages across the service, parts and wiring sections, and a two-page publication comment form. The preliminary material includes a repeated 10-page opening block; notes and blank pages are already included in the total.