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Xerox 3117 - Phaser B/W Laser Printer, Service Manual

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Xerox 3117 - Phaser B/W Laser Printer Service Manual Download Page 123

Reference Information

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Service Manual

11-5

11.4 Sample Tests Patterns

The sample patterns shown below are the standard test patterns used in the factory.
The life of the toner cartridge, developer cartridge and printing speed are measured with the pattern shown
below (5%).  The A4 ISO 19752 standard pattern samples are reproduced reduced to 70% of the actual A4
size.

A4 ISO 19752 Standard Patterns

Summary of Contents for 3117 - Phaser B/W Laser Printer

Page 1: ...SER PRINTER The keynote of Product Speed 17ppm Ltr 16ppm A4 600dpi Paper Path MPF Type Cassette Emulation SPL Processor 150MHz Jupiter4e CPU Memory SDRAM 8MB MP Cassette 150 pages Face Down 50 pages Fuser Design Lamp Type I O USB1 1 Machine Life 50K pages x Manual SERVICE ...

Page 2: ...ble 2 5 3 System Overview 3 1 System Outline 3 1 3 2 H W Structure and Descriptions 3 7 3 3 S W Structure and Descriptions 3 19 3 4 Initial Product Installation 3 24 4 Alignment and Adjustments 4 1 Sample Pattern 4 1 4 2 Control Panel 4 2 4 3 Consumables and Replacement Parts 4 4 4 4 LED Status Error Messages 4 4 4 5 Periodic Defective Image 4 5 4 6 How to use DCU 4 6 4 7 Paper Path 4 11 ...

Page 3: ... 8 6 4 Bad software environment 6 13 6 5 Bad Image 6 17 7 Exploded Views Parts List 7 1 Exploded Views and Parts List 7 1 8 Block diagram 8 1 System Block Diagram 8 1 8 2 System Timing Chart 8 2 9 Connection Diagram 9 1 Connection Diagram 9 1 10 Schematic Diagram 10 1 Main Board 10 1 10 2 Connector Circuit Diagram 10 5 10 3 SMPS Circuit Diagram 10 6 10 4 HVPS Circuit Diagram 10 7 Continued ...

Page 4: ...e Information 11 1 Troubleshooting Tools 11 1 11 2 Acronyms and Abbreviations 11 2 11 3 Selecting printer locations 11 4 11 4 Sample Tests Patterns 11 5 12 Circuit Description 12 1 Engine Controller 12 1 Continued ...

Page 5: ...ric shock or fire may occur 3 Laser Safety Statement The Printer is certified in the U S to conform to the requirements of DHHS 21 CFR chapter 1 Subchapter J for Class 1 1 laser products and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 825 Class I laser products are not considered to be hazardous The laser system and printer are designed so there is never...

Page 6: ...ther materials on it Do not fix with sta ples If the power cord gets damaged a fire or electric shock can happen A damaged power cord must be replaced immediately Do not repair the damaged part and reuse it A repaired part with plastic tape can be cause a fire or electric shock Do not spread chemicals on the power cord Do not spread insecticide on the power cord A fire or electric shock can be hap...

Page 7: ... heater A fire can be occurred 1 2 4 Assembly Disassembly precaution When replacing parts do it very carefully Memorize the location of each cable before replace parts for recon necting it afterwards Memorize Please perform the steps below before replace or disassembly the parts 1 Check the contents stored in the memory All the information will be erased after replacing main board The information ...

Page 8: ...vent electrostatic charge buildup in the vicinity of the assembly 3 Use only a grounded tip soldering iron to solder or desolder ESDs 4 Use only an anti static solder removal device Some solder removal devices not classified as anti static can generate electrical charges sufficient to damage ESDs 5 Do not use Freon propelled chemicals When sprayed these can generate electrical charges sufficient t...

Page 9: ... Electro photographic Printing Developing system Non Magnetic Mono Component Developing System Print Speed 16 PPM A4 size 17 PPM Letter size Resolution True 600 X 600 DPI Source of Light Laser diode LSU Laser Scanning Unit Warm Up Time Cold Warm up 30sec Sleep mode 30 sec First Print Time Less than 10 seconds Ready to 1st page out Feed Method Cassette Manual Media Size 76 X 128mm 3 x 5 to 216 X 35...

Page 10: ...60 163 g 16 43 lbs 2 2 2 Controller Item Descriptions Processor CPU Jupiter 4e 150MHz Memory Standard Max 8MB Max 8 MB Type SDRAM Expand Memory Slot Type NO Compression Technology MET Memory Enhancement Technology Emulation Standard SPL Auto Emulation Sensing YES Interface Standard USB 1 1 Only Compatible with USB 2 0 Option NO Auto Interface Sensing YES Font Type Windows Fonts Number NO Test Prin...

Page 11: ... Avg or less Power Save 10W Avg or less 2 2 4 Environmental Range Item Operating Storage Temperature 10 30 oC 50 90 oF 20 40 oC 4 104 oF Humidity 20 80 RH 10 80 RH 2 2 5 Toner Cartridge Item Descriptions Remark Life span Starter 1 000 Pages initial A4 Size ISO 19752 Pattern Running 3 000 Pages sailes 5 Coverage SIMPLEX Developing Method Non magnetic Contact Developing Charging Method Conductive Ro...

Page 12: ...16 X 330 8 5 X 13 O Legal Legal14 216 X 356 8 5 X14 O Executive 184 X 267 7 25 X10 5 O Statement 140 X 216 5 5 x8 5 ISO B5 176 X 250 O JIS B5 182 X257 O A5 148 X 210 O A6 105 X148 O No 10 Env 105 X 241 4 15 X 9 5 O 1 sheet Monarch Env 98 X191 3 87 X 7 5 O 1 sheet DL Env 110 X 220 4 33 X 8 66 O 1 sheet C5 Env 162 X 229 6 38 X 9 01 O 1 sheet C6 Env 114 X 162 4 49 X 6 38 O 1 sheet Transparency OHP A4...

Page 13: ... Output Face down 50 Sheet TBD Duplexing N A Paper Weight Plain paper 16 to 24 lb Bond 60 to 90g m2 Thick stock 24 90 lb Index 163g m2 Physical Type Laser Printer with Internal Controller Dimensions w output 358mm x 299mm x 217mm tray extended WxDxH Weight without shipping 5 75kg Carton Dimensions 455mm x 415mm x 325mm WxDxH Weight as shipped 7 65kg Electical Power Requirements Power Consumption P...

Page 14: ...cs Service Manual 3 1 3 3 3 System Overview 3 1 System Outline Paper Path Layout BIN PATH SMPS Fuser Toner Cartridge LSU Exit Roller OPC Pick Up Roller KNOCK UP PLATE KNOCK UP PLATE DOWN ASS Y HOLDER PAD Feed Sensor MAIN PBA SMPS HVPS ...

Page 15: ...x Service Manual System Overview 3 2 Unit Layout HVPS SMPS Main PBA Motor LSU Panel ...

Page 16: ...m Main Motor 8 Pick_up Roller Driver Solenoid 9 Paper detecting Sensor Photo Sensor 10 Paper Size Sensor None 11 Paper Exit Type Face Down 3 1 2 Transfer Ass y The transfer roller delivers the toner of the OPC drum to the paper The life span Print over 50 000 sheets in 16 30 3 1 3 Driver Ass y It is a power delivery unit by gearing By driving the motor it supplies the power to the feeding unit the...

Page 17: ...heat 210 or less 4 Heat roller Length 254 mm Valid length 222 mm GND Type H R Bearing Grounding type By SECC Fuser frame 5 Pressure roller Shaft Length 239 5 mm Rubber Length 222 mm 6 Paper separation method Teflon Coating with SUS Plate Claw System 7 Safety Relevant Facts Protecting device when overheating 1st protecting device H W cuts off when detecting an overheating 2st protecting device S W ...

Page 18: ...e same speed as the paper feeding speed It creates the HSYNC signal and sends it to the engine when the laser beam of the LSU reaches the end of the polygon mirror and the engine detects the HSYNC signal to arrange the vertical line of the image on the paper After detecting the HSYNC signal the image data is sent to the LSU to arrange the its margin on the paper The one side of the polygon mirror ...

Page 19: ...y roller developing roller and blade Doctor blade Developing Method Non magnetic 1 element contacting method Toner Non magnetic 1 element shatter type toner The life span of toner 2 000 sheets ISO 19752 Pattern A4 standard Toner Cartridge Initial 1 000 Sales 3 000 Toner remaining amount detecting sensor None OPC Cleaning Collect the toner by using electric static FILM OPC Management of disusable t...

Page 20: ...ontroller and Bi polar Stepper Motor Controller and has USB interface 3 2 1 1 Main Control Phaser 3117 of Main Control are composed of CPU and Print and operate follows function by CPU Bus Control I o Handling each Driver and PC Interface Main Control operate its full function on the Main B d and CPU control Controller ASIC and build in Memory 3 2 1 2 CPU Use 32Bit RISC Processor of Jupiter4e and ...

Page 21: ...8M Printing System Working Memory Area Access Time 60 nsec 3 2 1 5 ENGINE This recording method is electrophography method using LSU which toner is composed of 1 component and non magnetic 1 Recording Method LSU Laser Scanning Unit 2 Printing Speed 16ppm In continuing printing base A4 printing pages from 2nd to last during 1min 3 Recording Density 600 dpi 4 Cassette Capa Cassette 150sheets 75g Bas...

Page 22: ...Current Imagedml Video Data to LSU to print and have motor Driving and Circuit for the current driving and also include Paper Exit Sensor Cover Open s w panel s w U1 U3 12 0MHz U8 U9 U12 U10 U7 U5 IC DRAM 512K x 16Bit IC POSI ADSUST REG IC CMOS LOGIC INVER TER IC MOTOR DRIVER IC VOLTAGE COMP IC CLOCK GENERATOR IC EEPROM 256x12Bit IC POSI FLXED REG ...

Page 23: ...r Regulator It Supplies the core voltage to CPU by converting 3 3V to 1 3V EEPROM U8 93C66 It is an EEPROM with 12C method SMPS connector CN8 It connects SMPS supplies the power and delivers the high voltage contol signal etc If a harness is not normally connected to this connector power cannot be supplied LSU connector CN12 It connects a LSU DC Motor connector CN11 It connects an main motor and d...

Page 24: ...re Cache 4KByte Instruction cache 4KByte Data cache Single memory bus architecture 3 Built in Flash Memory 4MBits 128Kx32bits Serial programming mode using flash programmer tool Internally flash memory read write operation support Programmable access timing control 4 32MB Special function Register Area 5 Directly connected to 3 external IO banks IOC 32 MB size in each IO bank Programmable setup ac...

Page 25: ...Sample hold period generation Auto Power Control for Laser Diode with PID control method using internal 10 bits DAC LSU clock generation Brushless DC motor control clock generation 13 ADC Interface 4 channels ADC interface for analog devices such as temperature sensor Programmable ADC Clock Cycle Automatic or Manual AD Conversion support 4 Special Function Registers for monitoring the ADC results ...

Page 26: ...1 0 SCKE ADDR18 0 DATA15 0 nOE ADDR DATA BUS MUX IOC 3 CH ROMC 1 CH nIOCS1 0 INTC TCU MISC PLL pll 2096x pll 2073x CLOCK RESET EXTCLK nRESET OM2 0 CAP2 0 MOTORC MOTPAT5 0 LSUC dac1264x_1455 nLREADY nHSYNC VDO ADC INTERFACE adc1275x_pc ADCIN3 0 PWM PWM3 0 LSUCLK SCLK A H B A P B A H B UART RXD1 0 TXD1 0 SHPERIOD nLDON DACOUT TEST XI XO USB CORE USB1 1 D D Dpullup VBUS nSTROBE nINIT nSLCTIN nAUTOFD ...

Page 27: ...pty is detected by the empty sensor mounted to an engine board and the actuator mounted to a frame Paper senses the on off time of the empty sensor by using CPU and informs the normal operation status and the jam occurrence status to CPU 3 2 4 3 Jam Cover Cover Open Sensing Phaser 3117 uses two M S one senses the cover open and the other senses the jam cover open The cover open sensor is located o...

Page 28: ...n board and other board It is consisted of the AMPS part which supplies the DC power for driving the system and the AC heater control part which supplies the power to fuser SMPS has two output channels Which are 5V and 24V Pin No Pin Name 1 24VS2 2 24V 3 24VS1 4 24VS1 5 5V 6 DGND 7 DGND 8 P_REGI 9 FUSER ON CON2 Pin Signal CON1 Inlet Micro Switch CON2 Output Exit Sensor F1 Fuse 250V 5A Power Switch...

Page 29: ...ithin 1 min at 1000Vac 10mA Leaking Current under 3 5mA Running Current under 40A PEAK AT 25 COLD START under 50A PEAK In other conditions Rising Time within 2Sec Falling Time over 20ms Surge Ring Wave 6KV 500A Normal Common No Items CH1 CH2 Remarks 1 Channel 5V 24 0V 2 Connector pin CON 3 CON 3 5V PIN 11 12 24V PIN 2 3 4 GND PIN 8 9 GND PIN 6 7 3 Rated Output 5V 5 24V 5 4 75 5 25V 20 4 27 6V 4 Ma...

Page 30: ... 5 Input Voltage Variation 5 below Variation 21 6V 26 4V Load Variation below Out Voltage Rising Time 100 ms Max Out Voltage Falling Time 100 ms Max Transfer Variation Voltage on Environment Variation 650 V Duty 10 5KV Duty 90 Control Method on environment THV PWM ACTIVE transfer Active signal of environment sensing voltage is input and get feed back current and recalculate it to resistence Contro...

Page 31: ...ply Output Voltage 550 V 8 6 ZENER using DEV Input contrast of the output stability degree under 5 Loading contrast 5 or less Output Voltage Rising Time 50 ms Max Output Voltage Falling Time 50 ms Max Output Loading range 10 1000 Output Control Signal BIAS PWM the CPU is HV output when PWM is low MHV OPC DEV THV Supply CN3 LED1 Error LED CN1 LED2 Toner Save LED Switch Micro Switch Input ...

Page 32: ...the HEATER ON signal is turned on at engine the LED of PC1 Photo Triac takes the voltage and flashes From the flashing light the Triac part light receiving part takes the voltage and the voltage is supplied to the gate of Triac and flows into the Triac As a result the AC current flows in the heat lamp and heat is occurred On the other hand when the signal is off the PC1 is off the voltage is cut o...

Page 33: ... detected this firmware controls the Engine Mechanism according to the printing process and paper feeding state And with the Sleep command or Wake Up command this firmware controls the Engine state 3 3 2 Engine Control F W Overview Engine Control F W is executed every 10msec by timer interrupt of main system And it consists of 3 control modules Engine Main Control Interface Control and Sensing Uni...

Page 34: ...ine Control F W Main F W of the printer controller Device Units Fixing Unit LSU HVPS Fan Unit Motors Solenold Clutch Power On Initial Interface Control Module Engine Main Control Module Sensing Unit Control Module Hardware Devices Mechanical Device Engine F W ...

Page 35: ...ccurrs Lsu Error When the error occurrs it does not indicate an error It accomplishes printing only again If even time when it judges an error it informs an error Concretely speaking if the LReady or Hsync error happens the paper exits out beforehand And then the engine mode is changed to recovery mode and the engine informs the main system of the engine mode And the engine checks the LSU error in...

Page 36: ... 23 START Global Timer Increment Get A DC Value Tempe rature Control the fixing unit Check error condition for the fixing unit Control the fan unit Get status value of each sensor Set present status flag of each sensor F W Architecture ...

Page 37: ...A N A OFF Toner save mode is OFF 3 3 6 LED Behaviors Error LED Operation All LEDs blink the each time interval Service Error LED operation Fuser Error Open Fuser Error All LEDs Toner save LED Error LED blink a time interval of 1 second Low Heat Error All LEDs Toner save LED Error LED blink a timeinterval of 4 seconds Over Heat Error All LEDs Toner save LED Ready LED and Error LED blink a time inte...

Page 38: ...t Installation 3 4 1 Accessory List Remove the printer and all accessories from the packing carton Make sure that the printer has been packed with the following items 3 4 2 Installing the Toner Cartridge 1 Grasp the front cover and pull it toward you to open ...

Page 39: ...ove the toner cartridge from its bag and remove the paper covering the cartridge 3 Gently shake the cartridge from side to side to distribute the toner evenly inside the cartridge 4 Locate the cartridge slots inside the printer one on each side ...

Page 40: ...d the toner cartridge handle and grasp it Insert the cartridge in the printer until it snaps into place 6 Close the front cover Make sure that the cover is securely closed If the cover is not firmly closed printing errors may occur when you print ...

Page 41: ... the paper input tray and pull it toward you to open Pinch the rear guide and pull it out to extend the tray 2 Prepare a stack of paper for loading by flexing or fanning them back and forth Straighten the edges on a level surface 3 Load paper with the print side facing up Make sure that all four corners are flat in the tray ...

Page 42: ... flush against the paper 3 4 4 Connecting a Printer Cable To print from your computer you need to connect your printer to your computer with a Universal Serial Bus USB cable 1 Make sure that both the printer and the computer are turned off 2 Plug the USB printer cable into the connector on the back of the printer 3 Connect the other end of the cable to the USB port on your computer See your comput...

Page 43: ...us USB cable 2 Plug the other end into a properly grounded AC outlet and turn on the printer using the power switch 3 4 6 Printing a Demo Page Print a demo page to make sure that the printer is operating correctly 1 Press and hold down the Cancel button on the control panel for about 2 seconds to print a demo page 2 The Demo page shows the printer s current configuration ...

Page 44: ...tor allows you to see the printing status of the printer For details see Software User Guide 2 If you are printing in Linux Go to Software User Guide for information about installing the Linux driver 3 System Requirements Your machine supports following operating system Windows 98 Me 2000 XP The following table shows Windows requirements Item Requirements Operating System Window 98 Me 2000 XP CPU ...

Page 45: ...atterns check the existence of the abnormality The patterns help to regularly maintain the product 4 1 1 Printing a Demo Page Print a demo page or a configuration sheet to make sure that the printer is operating correctly 1 Hold down the Cancel button for about 2 seconds to print a demo page 2 The Demo page or the configuration sheet shows the printer s current configuration ...

Page 46: ...ror LED blinks red to cancel printing In Manual Feed mode if there is no paper in the tray the OnLine Error LED blinks red Load paper into the tray and the LED stops blinking If the printer is receiving data the On Line Error LED slowly blinks green If the printer is printing the received data the On Line Error LED blinks green fast If you press the Cancel button in Ready mode this LED is on and t...

Page 47: ... Manual Feed for Source from your software application Canceling print job Press this button during printing The On Line Error LED blinks while the print job is cleared from both the printer and the computer and then return to Ready mode This may take some time depending on the size of the print job In Manual Feed mode you can t cancel the print job by pressing this button Toner Save mode on off I...

Page 48: ...n below is for reference only 4 4 LED Status Error Message ERROR LED Status DCU CODE Open Fuser Error The Error LED red and the Toner Save LED are simultaneously 60 flashing every one second Over Heat Error The Error LED orange and the Toner Save LED are 68 simultaneously flashing every one second Low Heat Error The Error LED red and the Toner Save LED are simultaneously 62 flashing every 4 second...

Page 49: ... delinquent or damaged roller Refer to the table in below and check the condition of the roller No Roller Defective image Typical defect 1 OPC Drum 75 5mm white spot on black image or black spot 2 Charge Roller 37 7mm black spot 3 Supply Roller 47 5mm light or dark horizontal image band 4 Developing Roller 35 2mm horizontal image band 5 Transfer Roller 46 2mm image ghost 6 Heat Roller 63 9mm Black...

Page 50: ...03 04 20 30 40 50 69 60 62 68 64 70 71 72 73 95 MAIN MOTOR OPERATING SYSTEM MAIN HIGH VOLTAGE ON TRNSFER HIGH VOLTAGE ON THV REFERANCE VOLTAGE DEV SUPPLY HIGH VOLTAGE ON PTL ON LSU OPERATING SYSTEM PICKUP CLUTCH ON PEEMPTY PWITH NEW CRU TEST FEED EXIT SENSOR TEST COVER OPEN SENSOR TEST FUSER TEST HOT BURN TEST CLEAN MODE PRINT THV TRIGGER ALL HV FAN ON THV REFERENCE ON ERROR STATUS CODE STATUS COD...

Page 51: ...ed Sensor 40 Feed Sensor off The paper has passed out of the Feed Sensor 50 Paper Out The paper has passed out of Exit Sensor 69 Sleep Mode The fuser power turned off to minimize the power consumption Code State Description 60 62 68 Fuser Error The error in the fuser occurred There is a short circuit in the thermistor and the thermostat while printing Low Temperature Error occurs 60 Open Fuser Err...

Page 52: ...ltage probe should be used 02 Transfer High Voltage On THV 1000 voltage output by MHV terminal Caution High voltage probe should be used 03 Transfer High Voltage Reference on THV 1300 voltage output by MHV terminal Caution High voltage probe should be used 04 DEV supply High Voltage DEV Supply High Voltage Test The left one of the three LEDs in the self test panel is on when DEV high voltage Suppl...

Page 53: ...s up to Printing Mode If you press the button once more the left LED is on and temperature of the fuser is up to overheat Mode 11 Hot Burn Test If the enter button pressed the printer is continuously printing without detection Turn the power off to stop operation 12 Cleaning Mode Print Mode Print the paper to clean the OPC Drum in the Cartridge 13 THV TRIGGER ALL HV All high voltage output by each...

Page 54: ...Burn On 12 Clean Print Clean Printing 13 Thv Refer ence low adequate high 14 PTL PTL On P PTL 없음 TL Off 15 FAN Fan On Fan Off 16 Manual PickUp Manual Pickup On Manual Pickup Off 17 Manual Sensor Manual Sensor 4 6 4 Self Test Button If the Self Test button pressed vertical lines are printed Turn the power on while pressing this button 89 shows in the DCU and the printer is warming up After warming ...

Page 55: ...oves to the paper exit sensor via printing process Jam 1 occurs if the sensor is not operated after certain time passes 4 The paper passed the paper exit sensor moves out from the set Jam 2 occurs sometime after if the tailing edge of the paper is not coming out from the set after the leading edge of paper passes the paper exit sensor BIN PATH SMPS Fuser Toner Cartridge LSU Exit Roller OPC Pick Up...

Page 56: ...ported size range has been If a paper jam occurs the On Line Error LED on the control panel lights red Find and remove the jammed paper If it is invisible look inside the printer 4 7 2 In the Paper Exit Area 1 If the paper jams as it exits to the output tray and a long portion of the paper is visible pull the paper straight out When you pull the jammed paper if there is resistance and the paper do...

Page 57: ...per if it is caught in the heat rollers Then pull the paper gently out 4 Close the inner cover and the top cover 5 Open and close the front cover Printing can be resumed Alignment and Adjustments x Service Manual 4 13 ...

Page 58: ... Feed Area 1 Remove any missfeed paper by pulling it out by the visible edge from the tray Make sure that all of the paper is properly aligned in the tray 2 Open and close the front cover Printing can be resumed 4 7 4 Around the Toner Cartridge 1 Open the front cover ...

Page 59: ...ove it from the printer 3 Gently pull the paper toward you 4 Check that there is no other paper in the printer 5 Reinstall the toner cartridge and then close the cover Printing can be resumed Alignment and Adjustments x Service Manual 4 15 ...

Page 60: ...y curled paper Do not mix paper types in the input tray Use only recommended print media Ensure that the recommended print side is facing up when loading paper into the input tray 4 7 6 Solving Print Quality Problems Print Quality Checklist Print quality problems can be resolved by following the checklist below Redistribute toner in the toner cartridge Clean the inside of the printer Adjust the pr...

Page 61: ...te the cable routing that will be affected Whenever servicing the machine you must perform as follows 1 Check to verify that documents are not stored in memory 2 Be sure to remove the toner cartridge before you disassemble parts 3 Unplug the power cord 4 Use a flat and clean surface 5 Replace only with authorized components 6 Do not force plastic material components 7 Make sure all components are ...

Page 62: ...m the lock of the frame by pulling the right bottom of the cover toward the arrow direction Pull out the front cover to the left as shown as below 1 For separating only cassette tray open the tray 2 Hold the set and lift up the hook on the left bottom toward the arrow direction Separate the cassette tray by pulling it out to the left as shown as below Front Cover Cassette Tray 2 1 Cassette Tray 2 ...

Page 63: ...by holding the left side of the cover and pulling it toward the arrow direction Remove it with carefulness that the power switch is not hooked on SMPS cover as shown as below 1 Before Disassembling Separate the font cover Refer to 5 2 Separate the SMPS cover Refer to 5 3 2 Release 4 screws as shown as below Screw x 4 Silver_M3 6003 000196 SMPS Cover 2 1 ...

Page 64: ...ard the arrow direction as shown as below 4 Separate it by holding the both sides of the main cover and carefully lifting it up 5 If necessary remove the jam cover Open the cover take out the hook on the right toward the arrow direc tion and then take out the jam cover to the right side Jam Cover 2 1 Main Cover ...

Page 65: ... lens and the On Line key release the 5 screws connected to the main cover and then 4 locks on the front and rear of the top cover by using a screw driver Remove the top cover from the main cover Screw x 5 Silver_M3 6003 000196 3 Unscrew 2 screws from the separated top cover as shown as below and then separate the LED Lens from the On Line key Screw x 2 Silver_M3 6003 000196 LED Lens On Line Key M...

Page 66: ... to 5 3 Separate the Main cover Refer to 5 4 2 Remove the sheet by releasing the 5 screws which connects the HVPS and the Sheet Screw x 3 Gold_M3 6003 000269 3 Separate the HVPS with HVPS ground from the frame by releasing the remaining 3 screws Screw x 3 Gold_M3 6003 000269 4 Remove the connector from the separated HVPS HVPS Sheet HVPS HVPS Ground ...

Page 67: ...ected to the engine shield and 6 screws Screw x 6 Gold_M3 6003 000296 connected to the frame Separate the RX drive by pulling it out toward the arrow direction 3 Remove the connector from the separated RX drive 4 After removing the RX drive RDCN Gear OPC Gear Fuser Gear and Feed Gear can be removed from the frame RX Drive RDCN Gear OPC Gear Fuser Gear Feed Gear Please be careful not to touch the p...

Page 68: ... motor remove the motor brack et first by removing 4 screws as shown as below and then remove the 2 screws from the motor bracket 1 Before Disassembling Separate the font cover Refer to 5 2 Separate the SMPS cover Refer to 5 3 Separate the Main cover Refer to 5 4 2 Separate 2 connectors from the SMPS and the Main PBA as shown as below ...

Page 69: ...on At this time roller_main roller_FR F Down Holder and spring are separated with theses 6 Remove the thermo cap by releasing 2 screws as shown as below Screw x 2 Black_M3 6003 000282 Note Under the condition that the fuser is connected to the frame the exit roller F Down can be separat ed However be careful that the Roller_Main the Roller_FR and F Down Holder could get into the inner frame due to...

Page 70: ...lease the screw as shown as below remove the harness from the cover and then pull out the ther mistor Screw x 1 Black_M3 6003 000196 9 After separating the CBF harness connected to the left right side of the halogen lamp release 2 screws from the halogen lamp Screw x 2 Black_M3 6003 000196 10 Separate the Cover M by releasing 2 screws as shown as below Screw x 2 Black_M3 6003 000196 ...

Page 71: ...utch Fuser LSU Motor HVPS 11 Remove the halogen lamp from the heat roller by pulling it out to the arrow direction 1 Before Disassembling Separate the font cover Refer to 5 2 Separate the SMPS cover Refer to 5 3 Separate the Main cover Refer to 5 4 2 Disconnect all connectors except the connector which connects the SMPS to the Main PBA ...

Page 72: ...sor lever Screw x 6 Silver_M3 6003 000196 4 For removing only SMPS perform the follows in order separate the SMPS cover Refer to the 5 3 release 5 screws separate the fuser connector and the main PBA connector and then take out the SMPS Screw x 5 Gold_M3 6003 000269 5 For removing only Main PBA perform the follows in order separate the SMPS cover Refer to the 5 3 release 3 screws separate the main...

Page 73: ...and then disconnect 2 connectors from the separat ed LSU Screw x 2 Silver_M3 6003 000196 1 Before Disassembling Separate the font cover Refer to 5 2 Separate the SMPS cover Refer to 5 3 Separate the Main cover Refer to 5 4 Separate the Fuser Refer to 5 8 Separate the Engine shield Refer to 5 9 2 After releasing 4 screws as shown as below take it out toward the arrow direction with carefulness of g...

Page 74: ...ove the solenoid MP by releasing the screw from the left side of the frame Screw x 1 Gold_M3 6003 000301 5 2 12 Pick_Up Roller 1 For separating the pick up roller sponge open the front cover and then take out the toner cartridge 2 While pressing the hooks on the left right side of the pick up housing B pull out the pick up housing U as shown as below Then replace the sponge Toner Cartridge Housing...

Page 75: ... to repair the printer first obtain a detailed description of the problem from the customer Power On Indicate Lamp toggle On Line LED Green OK Print test pattern printing Quality is Nomal Refer to Solution of Image Problem Refer to Chapter 4 4 END No Power Power Module error Main PBA On Line LED ON ...

Page 76: ...ble harness 3 Check the Paper Path Is there a Paper Jam Remove any paper fragments caught in the paper path Paper Jam occurs repeatedly at a specific point in the Paper Path Open the fuser cover Jam clear Dismantle the machine and carefully inspect the region where the jam occurs Especially check if paper fragments are caught in the Fuser 4 Print the Information Page Configuration Try printing a t...

Page 77: ...ification If necessary move the printer 3 Ensure that the printer is position away from any air conditioning or other heating or cooling equipment Also ensure that is not positioned in a direct draft from any air conditioning fan or open window If necessary move the printer 4 Ensure the printer is not positioned in direct sunlight If it is unavoidable use a curtain to shade the printer 5 Ensure th...

Page 78: ...g of the side pad 3 Check the surface of the roller pickup for foreign mat ter 4 If the paper feeds into the printer rand Jam 0 occurs perform DCU to check feed sensor of the engine board 1 Replace the solenoid 2 Replace the side pad Assembly L or R if necessary 3 Clean with soft cloth dampened with IPA Isopropyl Alcohol or water 4 Replace the SMPS HVPS or Sensor 6 2 2 JAM 0 Description 1 Paper is...

Page 79: ... Roller This occurs when a Guide claw is broken away or transformed It occurs when the Spring of a Guide claw is broken away or transformed It occurs when the Heat Roller or Pressure Roller is seriously contaminated with the toner 3 Paper is accordion in the fuser 1 Check if the exit sensor actuator is defective Check if the actuator exit is unformed Check if the lever part is unformed in shape Ch...

Page 80: ...paper 6 2 6 Paper rolled in the Fuser Description If contaminated at intervals of 57mm on the back of a paper Check and Cause Solution 1 Contamination of the pressure roller or heat roller Background Hot off set 2 Check the claw of the fuser whether it is unfit ted 1 After disassembling the fuser clean contami nation between the heat roller and the ther mostor and remove the contamination of the p...

Page 81: ... OPC Drum Description Paper is rolled up in the OPC Check and Cause Solution 1 Paper is too much thin 2 The face of paper is curled 1 Recommend to use normal paper 2 How to remove the rolled in the OPC Drum Remove the paper while turning the OPC Drum against the ongoing direction ...

Page 82: ...ck if the overheat circuit works properly 5 The fuser gear is defective due to melting away 1 If the thermostat is open replace the fuser and check following items 2 If the thermistor sensor device is located deep in the sponge replace the fuser 3 Check if the circuit of overheat mode works properly 4 Run DCU mode Perform DCU diagnostic code 10 5 Replace Fuser 6 3 2 All LEDs blinking Scan Error De...

Page 83: ...n when paper is loaded in the cassette Check and Cause Solution 1 Bending or deformation of the actuator of the paper sen sor 2 The function of the engine board is defective Perform DCU mode Perform DCU diagnostic code 8 1 Replace the defective actuator 2 Replace the engine board 6 3 5 Paper Empty without indication Description The paper lamp on the operator panel does not come on when the paper c...

Page 84: ...ver Open Error 1 Replace the hook lever if defective 2 Check the insertion of the Cover Open S W Connect 3 Replace the Main Control board or Cover Open S W 6 3 7 No lamp on when the cover is open Description The ERROR lamp does not come on even when the printer cover is open Check and Cause Solution 1 Check the connector and circuit of the cover switch department in the Main Control board Perform ...

Page 85: ...the motor operation 1 Check the motor harness replace it if defective 2 Replace the SMPS if necessary 6 3 9 No Power Description When system power is turned on all lamps on the operator panel do not come on Check and Cause Solution 1 Check if the power input and SMPS output are normal 2 Check the inferiority of LED Panel on the front cover if the LED of Panel does not appear after normal warming u...

Page 86: ...ting Curved Description When printing vertical line gets curved Check and Cause Solution 1 If the supply of 24v is unstable in the Main Control board linking with LSU check drive by DCU Mode LSU Check 05 LSU Motor on 1 Replace LSU 2 Replace the Main Control board ...

Page 87: ... DCU to check the Error Status 2 Replace the printer cable If the problems not solved even after the cable replaced check the amount of the remaining tone 3 Check if the connection between PC and printer port is proper If you use windows check if the printer dri ver in the controller is set up If the printer driver is properly set up check in which program the printing is not working The best way ...

Page 88: ...than the RAM problem In this case provide more space for the hard disk Secure more space using the disk utilities program 2 The connection of the cable and printer port is not proper Check if the connection is properly done and if the parallel port in CMOS is rightly set up 3 As a printer port Select ECP or SPP among SPP Normal ECP and EPP modes increase print ing speed SPP normal mode support 8 b...

Page 89: ...t in the CMOS SETUP 2 Printer Driver Error 3 Error message from insufficient memory The printing job sometimes stops or due to insufficient virtual memory but it actually comes from the insuffi cient space of the hard disk 1 Select SPP Normal or ECP LPT Port the among ECP EPP or SPP in the CMOS Setup 2 Check the printer in My Computer to see if the printer driver is compatible to the present drive...

Page 90: ...nnecessary files to provide more space to start printing job 2 If there are some files with the extension name of jnl Delete them and Reboot the Windows to restart printing job 3 Shut down all other programs except the current one if possible 4 Delete the printer driver completely and reinstall it 5 After rebooting the computer check for viruses restore the damaged files and reinstall the program ...

Page 91: ...inter Digital Printer Digital Printer Check and Cause Solution 1 Foreign matter stuck onto the window of internal lenses of LSU mirror 2 Foreign matter or toner particles between the developer roller and blade In case the life of the developer has been expired white lines or light image occur in front of the image 3 It may occur when Burr and foreign sub stances are on the window of the devel oper...

Page 92: ...printing Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer Check and Cause Solution 1 If dark or blurry black spots occur periodi cally the rollers in the Developer may be contaminated with foreign matte or paper particles Charge roller 37 7 mm interval OPC drum 75 5 mm interval 2 If faded areas or voids occur in a black image at intervals of 75 5 mm or black spots oc...

Page 93: ... print out 3 Wait 30 minutes after printer is powered on before you start printing 4 Clean up the contaminated area by the toner 5 Replace the HVPS if the problems are not solved by the above four directions 6 5 6 Dark Image or a Black Description The printed image is dark Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer Check and Cause Solution 1 No charge voltage i...

Page 94: ...to print out 6 5 8 Background Description Light dark background appears in whole area of the printing Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer Check and Cause Solution 1 Does character exist less than 2 per a page and hasn t it been used long time 2 Does recycle paper be used 3 Has the life span of the developer ended 4 Is the movement Up and Down of the tran...

Page 95: ...he terminals when contaminated by toner particles 2 Occur in the developer cartridge replace the developer and try to print out 3 Replace the engine board if not solved by the above directions 1 2 4 If not solved by the direction 3 check the transfer roller lifetime and replace it 5 Wait about 1 hour after power on before using printer 6 5 10 Ghost 2 Description Ghost occurs at 75 5 mm intervals o...

Page 96: ...gital Printer Digital Printer Digital Printer Digital Printer Digital Printer 47 5 or 63 9mm Check and Cause Solution The temperature of the fuser is maintained high 1 Disassemble the fuser and remove the contaminated toner particles on the roller and clean the foreign matter between Thermistor and Heat roller Caution can be deformed 6 5 13 Stains on the Face of Page Description The background on ...

Page 97: ...e deformed 6 5 15 Blank Page Print out 1 Description Blank page is printed Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer Check and Cause Solution Bad ground contacts in OPC and or devel oper Remove contamination of the terminals of the developer and the unit 6 5 16 Blank Page Print out 2 Description 1 Blank page is printed 2 One or several blank pages are printed ...

Page 98: ...format and assist when ordering spare parts This format is used on all product ranges Typically it is used for small components and electronic parts This format is controlled by individual Divisions and is used on specific products typically for mechanical parts Type 2 format part numbers fall into 2 categories Assemblies consisting of 2 or more parts Also used for Service manuals user guides and ...

Page 99: ...x Service Manual Exploded Views Parts List 7 2 7 1 Main Assembly 0 2 1 12 4 9 6 7 11 8 18 19 10 20 14 5 15 1 15 2 15 16 17 13 2 4 2 6 2 7 2 8 2 3 24 2 1 2 2 2 5 3 3 1 3 2 3 3 3 4 ...

Page 100: ...Exploded Views Parts List x Service Manual 7 4 7 2 Frame Assembly 1 2 20 4 4 5 8 7 9 10 10 11 12 13 14 17 15 16 2 1 2 2 2 3 2 3 2 4 0 19 6 5 1 5 3 5 2 5 4 5 5 ...

Page 101: ...x Service Manual Exploded Views Parts List 7 5 7 3 Fuser Unit 0 1 2 33 4 32 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 34 25 24 23 20 21 22 26 27 28 29 30 31 6 7 ...

Page 102: ...Exploded Views Parts List x Service Manual 7 6 7 4 Paper Path Unit 0 1 2 3 4 5 25 6 7 8 9 9 1 9 2 9 3 10 10 11 11 1 11 2 11 3 12 13 14 16 16 15 17 18 19 20 21 24 23 24 22 26 ...

Page 103: ... 1 SA 7 1 6 T2060 JC96 03352B ELA UNIT DEVE INITIAL 1 SNA 7 1 7 F4038 JC96 03401A ELA HOU FUSER 220V 1 SA 126N00245 7 1 7 F4038 JC96 03400A ELA HOU FUSER 110V 1 SA AC 110V 7 1 8 E2108 JC63 00632A SHIELD P ENGINE 1 SNA 120N00480 7 1 9 L7002 JC39 00406A CBF HARNESS LSU 1 SA 7 1 10 S7050 JC44 00081A SMPS V2C 1 SA 105N02062 7 1 10 S7050 JC44 00080A SMPS V1 1 SA AC 110V 7 1 11 Z1024 JC92 01640A PBA MAI...

Page 104: ...39 83 1 SA 7 2 5 4 P2119 JC31 00020D MOTOR BLOWER STEP 7 5 1 SA 127N07405 7 2 5 5 K4023 JC72 00825A PMO IMPELLER_DRV 1 SNA 7 2 6 B0101 JC97 02175A MEA UNIT FRAME PAPER PATH 1 SA 7 2 7 K2015 JC70 00500A ADJUST M CASSETTE_R 1 SA 026N00764 7 2 8 K2014 JC70 00499A ADJUST M CASSETTE_L 1 SA 026N00765 7 2 9 G0369 JG66 40003A GEAR PINION SF4000 POM WHT M1 Z1 1 SA 007N01178 7 2 10 F1011 JC61 00836A FOOT FR...

Page 105: ... 7 3 14 K2297 4713 001203 LAMP HALOGEN 110V 1 SA 7 3 15 R1083 JC66 00824A ROLLER M EXIT MAIN 3 SNA 7 3 16 R1084 JC66 00830A ROLLER M EXIT FR 3 SNA 7 3 17 D4085 6107 001168 SPRING CS 2 SNA 7 3 18 D4086 6107 001163 SPRING CS SUS304 WPB PI0 4 D3 9 L13 3 SA 009N01496 7 3 19 W3071 1404 001298 HERMISTOR NTC 7KOHM 3370K 0 3MW C 1 SA 130N01266 7 3 20 K4279 JC47 00005B THERMOSTAT 150 1 SA 130N01411 7 3 21 ...

Page 106: ...NIT PICK UP GEAR 1 SA 130N01419 7 4 11 1 P2056 JC66 00803A GEAR PICK_UP B 1 SA 7 4 11 2 P2057 JC66 00802A GEAR PICK_UP A 1 SA 7 4 11 3 D4089 6107 001167 SPRING CS 1 SA 7 4 12 S8014 JC33 00015B SOLENOID MP_R2 SCX 4720F DC24V 1 SA 121N01078 7 4 13 F6071 JC66 00809A GEAR FEED 35 19 1 SA 007N01375 7 4 14 K2886 JC61 00588A BUSH M TR L ML 1400 POM M90 44 BL 1 SA 016N00261 7 4 15 K3856 JC72 00102A PMO BU...

Page 107: ...Block diagram Service Manual 8 1 x 8 8 8 Block Diagram 8 1 System Block Diagram ...

Page 108: ...Service Manual Block diagram 8 2 x 8 2 System Timing Chart ...

Page 109: ...READY AC IN LET POWER SWITCH AC wire F G 110V for USA 240V for EU SMPS LD 1 1 1 1 1 1 1 1 1 1 1 LSU Motor 1 Thermistor1 2 Thermistor2 1 HOT 2 Neutral 1 OUT1A 2 OUT1B 3 OUT2A 4 OUT2B 1 LSU_CLK 2 nLREADY 3 nPMOTOR 4 DGND 5 24VS2 1 nHSYNC 2 5V 3 DGND 4 DAC_OUT 5 VDO 6 LSU_READ DCU Serial J4e debugging 1 5V 2 DCU_CUT 3 DCU_CLK 4 DGND 1 3 3V 2 RXD 3 T XD 4 DGND 1 T CLK 2 T DI 3 1 8V 4 3 3V 5 DGND 6 nTR...

Page 110: ...10 10 Schematic Diagram Service Manual 10 1 This Document can not be used without authorization x 10 Schematic Diagrams 10 1 Main Board 1 4 ...

Page 111: ...Schematic Diagram Service Manual 10 2 This Document can not be used without authorization x Main Board 2 4 ...

Page 112: ...Schematic Diagram Service Manual 10 3 This Document can not be used without authorization x Main Board 3 4 ...

Page 113: ...Schematic Diagram Service Manual 10 4 This Document can not be used without authorization x Main Board 4 4 ...

Page 114: ...Service Manual Schematic Diagram Service Manual 10 5 x 10 2 Connector Circuit Diagram ...

Page 115: ...Schematic Diagram Service Manual 10 6 This Document can not be used without authorization x 10 3 SMPS Circuit Diagram ...

Page 116: ...Schematic Diagram Service Manual 10 7 This Document can not be used without authorization x 10 4 HVPS Circuit Diagram 1 3 ...

Page 117: ...Schematic Diagram Service Manual 10 8 This Document can not be used without authorization x HVPS Circuit Diagram 2 3 ...

Page 118: ...Schematic Diagram Service Manual 10 9 This Document can not be used without authorization x 10 4 HVPS Circuit Diagram 3 3 ...

Page 119: ...ded safe and easy troubleshooting as described in this service manual DVM Digital Volt Meter Standard Indicates more than 3 digits Driver Standard type type M3 long M3 short M2 long M2 short Tweezers Standard For general home use small type Cotton Swab Standard For general home use for medical service Cleaning Equipments Standard An IPA Isopropyl Alcohol dry wipe tissue or a gentle neutral deterge...

Page 120: ...Central Processing Unit dB decibel dbA decibel A dBM decibel milliwatt DC direct current DCU Diagnostic Control Unit DPI Dot Per Inch DRAM Dynamic Random Access Memory DVM Digital Voltmeter ECP Enhanced Capability Port EDC Embedded Diagnostic control EEPROM Electronically Erasable Programmable Read Only Memory EMI Electro Magnetic Interference EP electrophotographic EPP Enhanced Parallel Port FPOT...

Page 121: ...ce NVRAM nonvolatile random access memory OPC Organic Photo Conductor OPE Operate Panel Equipment PBA Printed Board Assembly PCL Printer Command Language Printer Control Language PDL Page Discription Language PPM Page Per Minute PPS Pulse Per Second PS Post Script PTL Pre Transfer Lamp PWM Pulse Width Modulation Q PID Quick Printer Initiating Device Q ty quantity RAM Random Access Memory ROM Read ...

Page 122: ...o open the printer trays covers and allow for proper ventilation see diagram below Provide the proper environment A firm level surface Away from the direct airflow of air conditioners heaters or ventilators Free of extreme fluctuations of temperature sunlight or humidity Clean dry and free of dust ...

Page 123: ...n below are the standard test patterns used in the factory The life of the toner cartridge developer cartridge and printing speed are measured with the pattern shown below 5 The A4 ISO 19752 standard pattern samples are reproduced reduced to 70 of the actual A4 size A4 ISO 19752 Standard Patterns ...

Page 124: ...Photo TRIAC is connected Then it emits light By this light the TRIAC unit a light receiving unit becomes on and electricity is supplied to the gate of the TRIAC Then the TRIAC is turned on As a result AC current flows in a heat lamp and the heat lamp radiates heat On the other contrary if the signal is turned off the PC1 becomes off and the TRIAC is turned off due to no elec tricity at the gate of...

Page 125: ...x Service Manual Circuit Description 12 2 ...

Page 126: ...gh At this time the resistance value of the thermister becomes low When the resistance value of the thermister becomes low the electric potential of the circled A gets low and when the temperature goes over the certain temperature the comparator U11 gets a low output As a result even though the fuser port is abnormally activated it is disable to be over the regular tem perature For maintaining a r...

Page 127: ...nce the polygon motor regularly rotates it sends the page sync signal nPSync to PVC by writing 1 at LSUCON 5 in LSUC and PVC starts operating for one page printing After that every time nHSYNC signal is created PVC sens es the signal and outputs the video data PVC_VDO to LSUC At this time LSUC creates the video window Printing area and masks it on the video data sent by PVC LSUC sends the complete...

Page 128: ...Clear LSU_VDO LSU_CLK nPSync nLREADYFlag nHSYNC nLREADY_FO LSUC DAC PD THER THV DAC_OUT PI Control Block PRDATA 31 0 PWRITE APB BRIDGE APCCON 11 0 apcOnTime 20 0 apcOffTime 20 0 SHOffTime 20 0 SHOnTime 20 0 ENGIN ADC E Pmax 9 0 Pmin 9 0 Ka 14 0 REF 24 0 Kp 15 0 Ki 4 0 Ky YMAXH 8 0 YMAXL 31 0 YMINH 8 0 YMINL 31 0 YINITH 8 0 YINITL 31 0 KU 5 0 U_VALUE 25 0 SEH 4 0 SEL 4 0 L_VALUE 9 0 HCLR 20 0 PVC A...

Page 129: ...f 3 rd channel ends for the PI Control of LSU it sends the 10bit digital data converted with the latch short pulse signal to LSUC Name Direction Description PVC VDO I The video data output from PVC nLREADY I Its activity becomes low as the polygon motor of LSU gets the regular speed nHSYNC I It informs the beginning of one line It is the same as nLSYNC of PVC nPSync 0 It is inputted to nFSync of P...

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