Xerox 3150 - Phaser B/W Laser Printer Service Manual Download Page 65 | Manualshive

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Alignment and Adjustments

Service Manual 6-1

This chapter describes some of the main service procedures including:

■

Using the DCU for diagnostics

■

Clearing paper jam and test patterns

Much of this chapter is also included in the user's guide.

6.1 How to Use the Diagnostic Control Unit (DCU)

6.1.1 DCU Setup

You can use the DCU test unit as an aid to diagnosing printer problems. To connect the DCU to the printer, open the
rear access cover and then connect the DCU harness wire (10 pin/4 pin) to CN2 on the main controller board.

6

Alignment and

Adjustments

ML SERIES DIAGNOSTIC CONTROL UNIT

04

05

07

08

09

10

DEV 300

LSU READY

PAPER EMPTY

COVER OPEN

COER HEATING

DEV 350

LSU MT & LD

PAPER WIDTH

EXIT SENSOR

PRINTING TEMP

DEV 350

LSU MOTOR

NEW CRU

FEED SENSOR

READY HEAT

ON

OFF

STATUS

SELF

TEST

DIAGNOSTIC

DIAGNOSTIC CODE

00
01
02
03
04
05
06
07
08
09
10
11
12
13
14

61

00
01
02
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

NORMAL STATUS CODE

WARM UP

READY (REGAL)
READY (LETTER)
READY (A4)
READY (EXECUTIVE)
READY (B5)

PRINT START
FEED SENSOR ON
FEED SENSOR OFF
PAPER OUT

SLEEP MODE

OPEN FUSER ERROR
LOW TEMPERATURE ERROR
OVER HEATING ERROR
COVER OPEN ERROR
NO PAPERR
PAPER JAM 0
PAPER JAM 1
PAPER JAM 2

LSU NOT READY

DIAGNOSTIC
MODE

DOWN

UP

ENTER

SEC CODE : ML+5000 KC/XRX

SHIFT

STOP

TO ENTER DIAGNOSTIC MODE, PUSH THREE BUTTONS SIMUL ANEOUSL

AND TURN THE PRINTER POWER ON.

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Summary of Contents for 3150 - Phaser B/W Laser Printer

Page 1: ...laser printer Phaser 3150 Service Manual ...

Page 2: ......

Page 3: ...llowing servicing instructions are for use by qualified service personnel only To avoid personal injury do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so First Printing July 2004 721P58540 ...

Page 4: ... United States and or other countries Apple AppleTalk LaserWriter LocalTalk Macintosh Mac OS TrueType Apple Chancery Chicago Geneva Monaco New York and QuickDraw are trademarks of Apple Computer Inc in the United States and or other countries PCL and HP GL are trademarks of Hewlett Packard Corporation in the United States and or other countries IBM is a trademark of International Business Machines...

Page 5: ...al Range 3 3 3 6 Media Specifications 3 3 3 6 1 Approved Paper Size and Weights 3 3 3 6 2 Print Margins and Skew 3 3 4 Product Summary 4 1 Printer Components 4 1 4 1 1 Front View 4 1 4 1 2 Rear View 4 2 4 1 3 Control Panel 4 2 4 2 Printer Theory of Operation 4 4 4 2 1 System Summary 4 4 4 2 2 System Layout 4 5 4 2 3 Paper Feed 4 5 4 2 4 Transfer Assembly 4 6 4 2 5 Drive Assembly 4 6 4 2 6 Fuser As...

Page 6: ...mbly 5 21 5 16 1 Tray 1 MPT Assembly 5 22 5 16 2 Feed Roller 5 23 5 17 Pick Up Assembly Solenoids and Pick Roller 5 25 6 Alignment and Adjustments 6 1 How to Use the Diagnostic Control Unit DCU 6 1 6 1 1 DCU Setup 6 1 6 1 2 Status Monitoring Code 6 2 Normal Code Table 6 2 Error Codes 6 2 6 1 3 Self Diagnostic Mode 6 3 6 2 Paper Path 6 6 6 3 Clearing Paper Jams 6 7 6 3 1 Jam2 Paper in the Exit Area...

Page 7: ...ultiple Pick 7 10 7 2 6 Paper Rolled in the Fuser 7 10 7 2 7 Paper Rolled in the OPC Drum 7 10 7 3 Printer Faults 7 11 7 3 1 All LEDs Blinking Fuser Error 7 11 7 3 2 All LEDs Blinking Scan Error 7 11 7 3 3 Fuser Gear Melted Due to Overheating Causing a Paper Jam 7 11 7 3 4 Paper Empty Error 7 12 7 3 5 Paper Empty Error Without Indication 7 12 7 3 6 Cover Open 7 12 7 3 7 No Error Lamp When the Cove...

Page 8: ... Assembly 8 10 Fuser Assembly Parts List 8 4 8 11 8 5 Main Drive Unit Assembly 8 12 Main Drive Unit Assembly Parts List 8 5 8 12 8 6 Tray 2 Cassette Unit Assembly 8 13 Tray 2 Cassette Unit Assembly Parts List 8 6 8 14 8 7 Tray 3 SCF Optional Cassette Unit Assembly 8 15 Tray 3 SCF Optional Cassette Assembly Parts List 8 7 8 16 Xerox Options and Accessories 8 17 9 Block Diagram 10 Connection Diagram...

Page 9: ... THIS COVER OPEN DO NOT OPEN THIS COVER VORSICHT UNSICHTBARE LASERSTRAHLUNG WENN ABDECKUNG GEÖFFNET NICHT DEM STRAHL AUSSETZEN ATTENTION RAYONNEMENT LASER INVISIBLE EN CAS D OUVERTURE EXPOSITION DANGEREUSE AU FAISCEAU ATTENZIONE RADIAZIONE LASER INVISIBILE IN CASO DI APERTURA EVITARE L ESPOSIZIONE AL FASCIO PRECAUCION RADIACION LASER IVISIBLE CUANDO SE ABRE EVITAR EXPONERSE AL RAYO ADVARSEL USYNLI...

Page 10: ...to a fire When removing the power connector grip it firmly and pull 7 Do not allow the power cable to become twisted bent sharply round corners or otherwise damaged Do not place objects on top of the power cable If the power cable is damaged it could overheat and cause a fire or exposed cables could cause an electric shock Replace a damaged power cable immediately do not reuse or repair the damage...

Page 11: ...f any user settings These will be erased if the mainboard or network card is replaced 2 Ensure that power is disconnected from the wall socket before servicing or replacing any electrical parts 3 Disconnect printer interface cables and power cables before servicing or replacing any parts 4 Only use approved spare parts Ensure that part number product name any voltage current or temperature rating ...

Page 12: ...inter 3 When you moving the printer This printer weighs 12 7 kg including the toner cartridge and tray Use safe lifting and handling techniques Use the lifting handles located on each side of the printer Back injury could result if you do not lift the printer properly 4 Ensure the printer is installed properly Ensure the printer is installed on a flat level surface capable of supporting its weight...

Page 13: ... before applying power to the unit under test to avoid potential shock After removing a static sensitive assembly from its anti static bag place it on a grounded conductive surface If the anti static bag is conductive you may ground the bag and use it as a conductive surface Do not use freon propelled chemicals These can generate electrical charges sufficient to damage some devices Do not remove a...

Page 14: ...Precautions 1 6 ...

Page 15: ...eshooting the Printer The following tools are recommended for safe and easy troubleshooting as described in this service manual Digital Voltage Meter DVM standard indicating more than 3 digits Screwdrivers Tweezers Cotton swabs Cleaning equipment dry lint free cloth and or mild detergent Toner Type II Vacuum Soft bristle brush Printer Installer and Utilities CD ROM Diagnostic Control Unit DCU 2 Re...

Page 16: ... Color Toner Density Sensor I F Interface dB Decibal I O Input Output dBA A Weighted Decibel lb Pound s dBm Decibel Milliwatt IC Integrated Circuit DC Direct Current ICC International Color Consortium DCU Diagnostic Control Unit IDE Intelligent integrated Drive Electronics DIMM Dual In line Memory Module IEEE Institute of Electrical and Electronics Engineers Inc DPI Dots Per Inch IOT Image Output ...

Page 17: ...inter Language OPC Organic Photo Conductor Spool Simultaneous Peripheral Operation Online PBA Print Board Assembly SW Switch PCI Peripheral Component Interconnect SURF Surface Rapid Fusing PCL Printer Command Language Sync Synchronous PDF Portable Document Format T1 ITB or Transfer Belt Imaging PDL Page Description Language T2 Transfer Roller Imaging Ping Packet Internet or Inter network Grouper T...

Page 18: ...er ventilation Provide the proper environment A sturdy level surface Away from the direct airflow of air conditioners heaters or ventilators Free from extreme fluctuations in temperature sunlight or humidity Clean dry and free from excessive dust 552 mm 21 7 in 100 mm 3 9 in 954 6 mm 37 5 in 482 6 mm 18 8 in 100 mm 3 9 in 100 mm 3 9 in ...

Page 19: ...development system Exposure System Semiconductor laser diode beam scanning Fuser toner fixing Thermal rollers fusing with pressure heat lamp 600 Watts Resolution True 600 x 600 dpi Addressable 1200 x 1200 dpi Grayscale level 128 Gray Print Speed A4 20 ppm Letter Executive 22 ppm Legal 18 ppm Warm up time Cold warm up and sleep mode 42 seconds FPOT 10 seconds Feed Method Tray 1 MPT Multi Purpose Tr...

Page 20: ...X Test Print Demo Mode Press the Cancel key for 2 seconds Configuration Mode Press the Cancel key for 6 seconds Cleaning Mode Press the Cancel key for 10 seconds Operating System Compatibility Windows 98 NT4 2000 Me XP Linux OS including Red Hat Caldera Debian Mandrake Slakware SuSE and Turbo Linux Item Description Input Voltage Low voltage 100 127 VAC High voltage 220 240 VAC Input Range 90 135 V...

Page 21: ...xecutive ISO and JIS B5 16 24 lb 60 90 g m2 Tray1 MPT Plain Paper 50 sheets OHP film Label Envelope 10 Card stock Custom A4 A5 A6 Letter Legal Folio Oficio Executive ISO and JIS B5 Monarch No 10 C5 C6 DL International Postcard Letter A4 Min 75 x 125 mm 16 43 lb 60 163 g m2 Print Area Margin Guaranteed Print Quality Area Paper Width A B Paper Length C D A Left Margin B Right Margin C Top Margin D B...

Page 22: ...Specifications 3 4 ...

Page 23: ...es the functions and operating principals of the printers main components 4 1 Printer Components 4 1 1 Front View 4 Product Summary Output Support Top output tray Face down Control Panel Power switch Paper level indicator Tray Multi Purpose Feeder Front Cover ...

Page 24: ...Summary of Product 4 2 4 1 2 Rear View 4 1 3 Control Panel USB Port Parallel Port Power Receptacle Rear Output Tray Face up Top Output Tray Face down ...

Page 25: ...function is present Refer to Section 6 6 for troubleshooting procedures The Toner Save LED comes on when Toner Save mode is enabled This can be set in the printer driver Cancel Button Functions Printing the Demo Page In Ready mode press and hold the Cancel button until all LEDs blink slowly and then release approximately 2 seconds Printing the Configuration Page In Ready mode press and hold the Ca...

Page 26: ...sm The main drive is a bi polar two phase motor It drives the drum paper pick and paper feed rollers using a gear train mechanism 4 Image development unit Using a Laser Scanner Unit LSU this portion of the mechanism creates the image on the OPC drum part of the integrated toner cartridge 5 Image transfer unit This unit uses the high voltages supplied by the HVPS to move the image from the OPC drum...

Page 27: ...first sheet of paper as it is fed through the printer Both the rear and side paper guides are adjustable for various paper sizes There is a Paper Empty sensor which detects the presence of paper Capacity 250 sheets There is an indicator flag on the front of the tray which indicates the amount of paper remaining 3 Pick up roller The pick up roller is used to pick and feed paper into the printer It ...

Page 28: ...nto the main processor If the heat lamp becomes too hot the thermostat cuts off the power to the lamp in order to prevent overheating and any potential fire hazard is removed 4 2 6 2 Heat roller The heat roller transfers the heat from the heat lamp to the paper The surface of the heat roller is coated with Teflon so that toner does not stick to the surface 4 2 6 3 Pressure roller A pressure roller...

Page 29: ...aper In other words after the HSYNC signal is detected the image data is sent to the laser unit to adjust the left margin on the paper 4 2 8 Toner Cartridge The toner cartridge is an integral unit containing the OPC unit and toner unit The OPC unit consists of the OPC drum and charge roller The toner cartridge unit consists of the toner supply roller developing roller and blade doctor blade Develo...

Page 30: ...supply board 1 U1 Low drop fixed and adjustable positive voltage regulators LD1117DT 2 U2 Low power dual bi polar comparators LM393D 3 U4 Spread spectrum clock generator CY25811 4 OSC1 CPU X TAL 12 MHz 5 U6 U15 SDRAM K4S641632H 6 U7 Low voltage HEX inverter with 5 V tolerant Schmitt trigger inputs 74LCX14 7 U9 Motor driver A3977SLP 8 U11 Graphics processor ASIC SPGPm 9 U24 Low voltage HEX inverter...

Page 31: ...ry and Lookup Table Memory 512 x 8 4096 x 16 Engine Controller Motor control unit Motor speed lookup table memory 128 x 16 x 2 Pulse width modulation unit 4 channels are supported ADC interface unit 3 ADC Channels are available ADC Core ADC8MUX8 maximum clock frequency 3 MHz USB 2 0 Interface Package 272 pins PBGA Power 1 8 V Core 3 3 V IO power operation Speed 166 MHz core ARM946ES operation 60 M...

Page 32: ... 5 4 Toner Remaining Sensing The printer does not have a toner remaining sensor 4 3 5 5 Paper Exit Sensing This detects that paper exits cleanly from the printer using an exit sensor on the engine board and actuator on the frame The CPU detects the on off time of the exit sensor and normal operation or a jam status is reported If a Jam2 error occurs the red error LED is lit 4 3 5 6 Cover Open Sens...

Page 33: ...istor is out of the controlled range while controlling the fusing process an error is reported See the error table below to identify fuser temperatur errors 4 3 5 11 Laser Scanner Unit LSU The Laser Unit consists of the laser diode and the polygon motor control When the printing signal occurs the laser diode is turned on and the polygon motor is enabled When the light sensor detects the beam H SYN...

Page 34: ... outputs the 5 V and 24 V supplies to the main board The HVPS creates the high voltage for the THV MHV Supply Dev and supplies it to the toner cartridge The CPU is used to modify some of these voltage settings to provide the ideal voltages to create the image The HVPS uses the 24 V and outputs the high voltage for THV MHV BIAS and the outputted high voltage is then supplied to the toner OPC cartri...

Page 35: ...hanging the duty cycle of the THV PWM Signal 10 duty 650 V 90 duty 5K V 5 2 Charge Voltage MHV Input Voltage 24 VDC 15 Output Voltage 1 3K V 1 8K VDC 50V Output Voltage Rise Time 50 ms maximum Output Voltage Fall Tim 50 ms maximum Output Loading range 30 Mž 1000 Mž Output Control Signal MHV PWM CPU is HV output when PWM is low 3 Cleaning Voltage THV The Transfer Voltage is not output because the T...

Page 36: ...e AC 198 V 264 V AC 90 V 135 V AC 198 V 264 V EXP version Rated Frequency 50 60 Hz Frequency range 47 63 Hz Input Current Under 4 0A RMS 2 0A RMS When the fuser lamp is off and input output voltages are in range 2 Rated Output Power 3 Consumption Power No Item CH1 CH2 CH3 Remark 1 Channel name 3 3 V 5 V 24 0 V 2 CONNECTOR PIN CON 3 3 3 V PIN 3 4 GND PIN 5 6 CON 3 5 V PIN 8 GND PIN 7 CON 3 24 V PIN...

Page 37: ...sor is not ON the printer will re pick If after re picking the feed sensor is still not reported as ON this error will occur Even though the paper reaches the feed sensor the feed sensor is not ON Jam 1 This is an indication that the leading edge of the paper has already passed the feed sensor After the leading edge of the paper passes the feed sensor the trailing edge of the paper does not pass t...

Page 38: ...Summary of Product 4 16 ...

Page 39: ...r component malfunctions Caution Many of the parts are held in place with plastic latches The latches break easily Remove them carefully To remove such parts gently pull the hook end of the latch away from the part where it is latched Caution To prevent damaging the toner cartridge and degrading print quality protect the toner cartridge from light when removing it from the printer 5 1 1 Precaution...

Page 40: ...cause an electrical shock Take extra care when handling boards containing sensors motors or lamps as they may get hot Take care when fitting or removing screws Check for hidden screws Always ensure that the correct screw is used When toothed washers are removed ensure they are refitted in their original positions ...

Page 41: ...pen the front door and remove the toner cartridge 3 With the front cover fully open carefully release the plastic hinge supports from the guide hooks by pulling inward 4 Pull the front cover away from the printer to remove Cassette Front Cover A Front Cover Latch Latch Holder ...

Page 42: ...3 Tray 1 MPT Assembly 1 Open the Tray1 MPT assembly 2 With the tray at a 45o angle carefully release the plastic hinge supports from the guide hooks 3 Lift the Tray1 MPT assembly off the hinge pins on the front cover 45 ...

Page 43: ...to the OFF position When reassembling the rear cover move the power switch to the ON position 1 Remove 2 screws securing the rear open cover and remove 2 Open the face up cover 3 Remove the 2 screws as shown below 4 Using a screwdriver carefully release the 2 tabs securing the rear cover Rear Open Rear Cover ...

Page 44: ...e rear cover see 5 4 Rear Cover on page 5 5 3 Remove 4 screws securing the top cover as shown below Caution When removing the top cover lift the front of the top cover slowly to avoid damaging the exit rollers Use caution to avoid damaging the exit rollers when reassembling the top cover Exit Roller ...

Page 45: ... on page 5 5 2 Remove the top cover see 5 5 Top Cover on page 5 6 3 Open the front cover 4 Remove 4 screws securing the middle cover 5 Disconnect and free the wiring harness from the middle cover 6 Lift up on the left side of the middle cover to release it from the retaining pin Middle Cover ...

Page 46: ...Rear Cover on page 5 5 3 Remove the top cover see 5 5 Top Cover on page 5 6 4 Remove the 2 screws securing the right or left cover 5 Slide the cover towards the rear of the printer while releasing the top latch as shown below to remove the right or left cover Side Cover RH Top Latch Bottom Latches Side Cover LH Top Latch Bottom Latches ...

Page 47: ... page 5 5 3 Remove the top cover see 5 5 Top Cover on page 5 6 4 Remove the left and right covers see 5 7 Side Cover Left and Right on page 5 8 5 Remove the exit gear bearing and exit roller as shown below Note It is not necessary to remove the laser unit or middle cover although the image below shows them removed from the printer Exit Gear Bearing ...

Page 48: ...om the SMPS on the right side printer the fan CN3 and the control panel CN4 On the rear of the printer disconnect the fuser CN1 and exit sensor CN6 7 Disconnect the following wiring harnesses connected to the main board Caution Be sure all 12 wiring harnesses are diconnected from the assembly Caution In the next step you will be turning the printer over use caution when working on the printer in o...

Page 49: ...ws on the bottom of the printer securing the engine shield assembly 9 Remove 2 screws securing the Exit Board to the print frame Caution When reassembling the engine shield assembly be sure the paper out sensor flag is up and out of the way to avoid damaging the flag Engine Shield Ass y Exit Board ...

Page 50: ...5 6 4 Remove the left and right covers see 5 7 Side Cover Left and Right on page 5 8 5 Remove the engine shield assembly see 5 9 Engine Shield Assembly and Exit Board on page 5 10 6 Remove the 3 screws one is to ground securing the inlet bracket and remove the bracket 7 Unplug 1 connector from the main board 8 Remove the 6 screws securing the SMPS to the shield Inlet Bracket Connector SMPS ...

Page 51: ...page 5 5 2 Remove the SMPS shield see step 5 in 5 9 Engine Shield Assembly and Exit Board on page 5 10 3 Disconnect all harnesses from the main board 4 Remove the 8 screws securing the main board to the printer and remove the main board Note 2 screws are securing the network card or plate Main PBA ...

Page 52: ...Disassembly 5 14 5 10 3 Removing the Network Card or Optional Memory Modules You only need to open the rear open cover to access the memory modules and network card Thumb Screws Memory Board ...

Page 53: ...ge 5 5 2 Unplug 2 connectors one from the main board and one from the SMPS 3 Remove 4 screws securing the fuser assembly Caution When removing the thermostat the 2 screws are secured by nuts that are not captured These can fall out and get lost if you tip the fuser assembly 4 Remove the 2 screws securing the thermostat and lift the thermostat out Fuser Ass y Thermostat ...

Page 54: ...use the fuser to malfunction 5 Remove the 2 screws securing the Halogen lamp Then remove the lamp from the heat roller as shown below Caution When disassembling the fuser note the orientation of the spring loaded stripper fingers claws If reassembled improperly the claws will damage the heat roller causing the fuser to malfunction 6 Remove the 4 screws securing the fuser cover and 2 screws securin...

Page 55: ...Disassembly Service Manual 5 17 7 Free the thermister harness as shown below 8 Remove 1 screw securing the thermister and remove from the fuser assembly Thermistor Harness Thermistor ...

Page 56: ...r on page 5 3 2 Remove the rear cover see 5 4 Rear Cover on page 5 5 3 Remove the top cover see 5 5 Top Cover on page 5 6 4 Remove the right cover see 5 7 Side Cover Left and Right on page 5 8 5 Disconnect the connector from the SMPS 6 Remove 1 screw securing the fan Fan ...

Page 57: ...t covers see 5 7 Side Cover Left and Right on page 5 8 5 Remove 1 screw to the control panel board and remove the board 6 Remove the 4 screws securing the LSU Caution Be careful not to get fingerprints on the window of the laser unit bottom of assembly Note The laser unit securing screws are numbered and need to be tightened down in the correct order when reassembling 7 Disconnect the two connecto...

Page 58: ...ver see 5 5 Top Cover on page 5 6 4 Remove the left and right covers see 5 7 Side Cover Left and Right on page 5 8 5 Remove the 6 screws securing the drive assembly Note The drive assembly screws are numbered and need to be tightened down in the correct order when reassembling 6 Disconnect 1 connector from the drive assembly to remove the drive Drive Ass y Drive Ass y ...

Page 59: ... middle cover see 5 6 Middle Cover on page 5 7 5 Remove the top cover see 5 5 Top Cover on page 5 6 6 Remove the left and right covers see 5 7 Side Cover Left and Right on page 5 8 7 Remove the LSU see 5 13 Laser Scanner Unit LSU on page 5 19 8 Using a screwdriver unlatch the transfer roller as shown below 9 Pull the transfer roller up and to the right in order to remove it from the printer Transf...

Page 60: ...ge 5 6 5 Remove the left and right covers see 5 7 Side Cover Left and Right on page 5 8 6 Disconnect the MP solenoid and MP sensor connectors from the main board 7 Remove the 4 screws from the front of the assembly and remove Caution There is a flexible mylar paper guide that needs to rest between the metal idler shaft and the feed rollers when reassembling the Tray 1 MPT assembly MP Ass y Place p...

Page 61: ...Tray 1 MPT assembly see 5 16 1 Tray 1 MPT Assembly on page 5 22 3 Remove the 3 screws gold from the feed bracket Note The feed bracket screws are numbered and need to be tightened down in the correct order when reassembling 4 Remove the feed gear 2 lower and then feed gear 1 upper as shown below Feed Bracket Feed Gear2 Feed Gear1 ...

Page 62: ...screw from the right idler bushing plate 6 Remove the plate idler spring and bushing 7 Slide the feed shaft idler to the right and out of the printer 8 Remove the feed roller and feed roller 1 as shown below Feed Roller1 Feed Roller ...

Page 63: ... Remove the engine shield assembly see 5 9 Engine Shield Assembly and Exit Board on page 5 10 7 Remove the drive assembly see 5 14 Drive Assembly on page 5 20 8 Remove the feed bracket see 5 16 2 Feed Roller on page 5 23 9 Remove the pick up gear and then the pick up assembly as shown below Note Note the orientation of the gear for reassembly 10 Disconnect the main clutch and registration clutch h...

Page 64: ...Disassembly 5 26 13 Remove the pick roller as shown below on the right Regi Solenoid Pick up Solenoid Rubber Pickup ...

Page 65: ...R READY HEAT ON OFF STATUS SELF TEST DIAGNOSTIC DIAGNOSTIC CODE 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 61 00 01 02 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 SENS...

Page 66: ... A4 03 EXEC 04 B5 05 Other 20 Print start The engine controller received the print order from the video controller 20 Tray 2 21 Tray 1 MPT 22 Optional Tray 3 30 Feed sensor ON The paper is passing out of the feed sensor 40 Feed sensor OFF The paper has passed out of the feed sensor 50 Paper out The paper has passed out of the exit sensor 69 Sleep Mode The fuser power is turned OFF to minimize powe...

Page 67: ...r buttons together Code Description 00 Main motor operating system The main motor is tested 01 Main high voltage ON MHV 1550 voltage output to MHV terminal Note Note Note High voltage probe should not be used 02 Transfer high voltage on THV 1200 voltage output to THV terminal Note Note Note High voltage probe should not be used 03 Transfer high voltage on THV 1300 voltage output to THV terminal No...

Page 68: ...cle to be repeated continously Turn the power OFF to stop this test 13 THV Trigger All HV High voltage is output to each high voltage terminal The laser unit and fan are started In this mode the electronic resistance of the transfer roller is detected and the THV is checked 14 PTL Test Tests the pre transfer lamp The ON and OFF LEDs indicate the lamp status 15 Fan test Tests the fan The ON and OFF...

Page 69: ... V 05 LSU LSU Run On Off Ready LSU Stop 06 PICK UP Pick Up On Pick Up Off 07 P EMPTY Paper Empty 08 SENSOR Exit Feed 09 COVER Cover Open 10 Fuser Fuser On Fuser Off 160 C 11 HotBurn HotBurn On 12 Clean Print Clean Printing 13 Thv Reference Low Adequate High 14 PTL PTL On PTL Off 15 Fan Fan On Fan Off 16 Regi Clutch Regi Clutch Regi Clutch Off 17 Regi Sensor Manual Sensor 18 MP Pickup MP Pickup On ...

Page 70: ...cond illustration to the left Jam2 A Jam 2 occurs if the paper does not leave the exit sensor in the specified amount of time while exiting the printer See the third illustration to the left PIC K R L S U Toner Cartridge PR Fuser EXIT Sensor OPC CR DR SR TR FR 1 1 2 2 3 6 3 4 Cassette Manual Feeder Transfer Roller 5 6 5 Fuser LSU Laser Scan Unit Toner Cartridge 4 MP Sensor MP Sensor Empty Sensor L...

Page 71: ...ntially damage wiring leading to the potential for electric shock Note If the paper tears while removing a jam ensure that ALL fragments of paper are removed from within the printer otherwise jamming will still occur 6 3 1 Jam2 Paper in the Exit Area Warning Paper jammed in this area is very close to the fuser and burns can occur 1 If the paper jams as it exits to the output tray and a long portio...

Page 72: ...he paper is properly aligned in the tray 4 Slide the tray back into the printer Open and close the front cover Printing can now be resumed 6 3 3 Jam1 Paper Around the Toner Cartridge 1 Open the front cover and remove the toner cartridge 2 Gently pull the paper toward you Check that there is no other paper left in the printer 3 Reinstall the toner cartridge and then close the cover Printing can now...

Page 73: ...gularly maintain the product The following patterns are available Demo Page Configuration Page Cleaning Sheet 6 4 1 Printing a Demo or Configuration Page Print a Demo Page or a Configuration Sheet to make sure that the printer is operating correctly The Demo Page or Configuration Page shows the printer s current configuration 1 Hold down the Cancel button for about 2 seconds to print a Demo Page 2...

Page 74: ...hing at 1 second intervals 60 Over Heat Error The Error LED orange and the Toner Save LED are simultaneously flashing at 1 second intervals 68 Low Heat Error The Error LED red and the Toner Save LED are simultaneously flashing at 4 second intervals 62 Laser not Ready Error Motor Error The Error LED green and the Toner Save LED are simultaneously at 1 second intervals 95 Laser Not Ready Error 6 HSY...

Page 75: ...efect and refer to the table below to identify the problem component PTL No Roller Defective image Typical defect 1 OPC Drum 75 5 mm white spot on black image or black spot 2 Charge Roller 37 7 mm black spot 3 Supply Roller 44 9 mm light or dark horizontal image band 4 Developing Roller 35 3 mm horizontal image band 5 Transfer Roller 47 1 mm image ghost 6 Heat Roller 78 mm black spot and image gho...

Page 76: ...Alignment and Adjustments 6 12 ...

Page 77: ...ions There are white vertical voids in the printed image 1 Contamination on the window or internal lens of the laser mirror 2 Foreign object inside the toner cartridge 3 Low toner 4 If the fuser is defective voids occur periodically at the top of a black image 5 Contamination on the OPC drum 6 Depression or deformation on the surface of the transfer roller a Clean the laser window with a recommend...

Page 78: ... appear the rollers in the developer may be contaminated Charge roller 37 7 mm OPC drum 75 5 mm 2 If faded areas or voids appear every 75 5 mm or if black spots occur elsewhere the OPC drum surface is damaged 3 If a black image is partially broken the transfer voltage is incorrect or the transfer roller is at its end of life 4 If the spots appear at 78 mm the fuser heat roller is contaminated a Pr...

Page 79: ...try printing again d Clean the cartridge and printer contacts e Clean the inside of the printer f Replace the HVPS if none of the above procedures fix the problem Example Possible Cause Sequence of Repair Actions The printed image is dark or the page is entirely black 1 Charge voltage fault due to bad contact between the toner cartridge and printer contacts 2 No charge voltage in the engine board ...

Page 80: ... cartridge and retest c Replace the left and right bushings and spring assemblies d Clean the laser window Example Possible Cause Sequence of Repair Actions Light or dark background contamination appears all over the paper 1 Using unsupported media 2 Printing large quantities of low coverage 2 pages or not using the printer for a long period of time 3 The toner cartridge life has expired 4 The tra...

Page 81: ...age terminals the printer and the electrodes of the toner cartridge 2 Bad contacts caused by contamination from toner particles between the high voltage terminals the printer and the one on the high voltage supply board 3 The toner life has expired 4 The transfer life has expired 5 The ambient temperature is too low 6 There is a damaged cleaning blade in the toner cartridge a Clean all high voltag...

Page 82: ...he cartridge and in the printer d Replace the HVPS Example Possible Cause Sequence of Repair Actions 1 Toner leakage due to an improperly sealed toner cartridge 2 The charge roller may be contaminated a Run the PC cleaning mode print 2 to 3 times and perform the self test 2 to 3 times to remove contamination b Replace the toner cartridge Digital Printer Digital Printer Digital Printer Digital Prin...

Page 83: ...er b Check the OPC ground or the OPC diode for defects or an open circuit inside left side of printer Example Possible Cause Sequence of Repair Actions Blank page is printed one or several blank pages are printed or when the printer is first powered on several blank pages are printed 1 Bad ground contacts in the OPC and or toner cartridge 2 Defective solenoid a Delete all print jobs in the queue a...

Page 84: ...ve feed sensor 3 Problem with the MP lift plate and springs 4 Defective paper separator pad 5 Contaminated or defective pick roller 1 Use diagnostics to test the solenoid Replace the solenoid if defective 2 Test the feed sensor Replace if defective 3 Replace the tray if defective 4 Clean the pick roller Replace if defective 5 Ensure all rollers are free from debris and rotating freely 6 Check the ...

Page 85: ...If the paper has exited the printer and a Jam2 occurs the exit sensor is defective After paper passes the exit sensor the flag should return to its normal position The flag may stick or return too slowly due to contamination or foreign objects obstructing its path 2 If there is an accordian paper jam in the fuser The guide claw is damaged The spring on the guide is damaged The heat roller or press...

Page 86: ...iction pad or replace if damaged e Replace the solenoid Description There is an accordian jam in the fuser Possible Cause Solution 1 The pressure roller or heat roller is damaged or not functioning properly 2 The paper guides or springs are damaged a Replace the fuser Description Paper is caught or rolled up in the OPC Possible Cause Solution 1 The paper is too thin 2 The paper is curled a Use the...

Page 87: ...s faulty 3 The drive gear melted a Use the DCU to test the fuser b Replace the fuser Description All LEDs are blinking on the control panel Possible Cause Sequence of Repair Actions 1 The laser cable or connector is faulty 2 The laser motor is faulty 3 The HSYNC signal a Replace the laser unit or cable b Replace the main board if the error persists after replacing the laser unit Description Consta...

Page 88: ...pty Possible Cause Sequence of Repair Actions 1 The paper empty sensor or actuator is damaged or faulty 2 The main board is faulty 3 Faulty cable or connector a Use the DCU test 08 b Replace the defective actuator or sensor c Check and replace the wiring to the control panel if faulty d Replace the main board Description The error LED is lit even though the cover is closed Possible Cause Sequence ...

Page 89: ...sulting in a Jam0 Possible Cause Sequence of Repair Actions 1 The main motor harness or motor board may be faulty 2 The main board may be faulty 3 The SMPS may be faulty a Use the DCU test 00 to test the main motor b Replace the motor or harness if faulty c Replace the main board d Replace the SMPS Description When the printer is powered ON the LEDs on the control panel do not come on Possible Cau...

Page 90: ...he vertical lines are not straight Possible Cause Sequence of Repair Actions 1 The 24 V supply to the laser unit is faulty a Use the DCU test 05 to test the laser motor b If the voltage is stable replace the laser unit c If the voltage is not 24 volts replace the SMPS d Replace the main board ...

Page 91: ...e the problem 7 4 3 Redistributing Toner When toner is low faded or light areas may appear on a printed page You may be able to temporarily improve the print quality by redistributing the toner The following procedures can allow you to finish the current print job before replacing the toner cartridge 1 Grasp the front cover and pull it toward you to open 2 Remove the toner cartridge from the print...

Page 92: ... the problem is within a single application adjust the printing properties within that program f If changing the properties in the application print dialog box does not solve the problem uninstall and reinstall a new driver g If the printer is not printing from all programs and the user is printing using the parallel port check the port settings Ensure the following settings CMOS is on ECP the add...

Page 93: ... possible 4 When an application program or the printer driver is damaged a Delete the printer driver completely and reinstall it 5 When some files related to the OS are damaged or virus infected a After rebooting the computer check for viruses restore the damaged files and reinstall the application program which is not working properly 6 Computer memory is insufficient to support printing a Add up...

Page 94: ...Troubleshooting 7 18 ...

Page 95: ...anual 8 1 Contents 8 1 Main Assembly 8 2 Frame Unit Assemly 8 3 MP Assembly 8 4 Fuser Unit Assembly 8 5 Main Drive Unit Assembly 8 6 Tray 2 Cassette Unit Assembly 8 7 Tray 3 SCF Optional Cassette Unit Assembly 8 Parts List ...

Page 96: ...2 8 1 Main Assembly 0 Toner Cartridge 3 6 6 4 6 7 6 8 6 9 6 10 6 5 2 Opt Tray 3 7 17 16 9 23 20 14 15 11 10 8 5 18 19 6 10 6 6 6 1 6 2 6 11 6 3 7 3 5 1 5 2 5 3 7 2 7 1 4 13 12 2 1 2 2 2 6 2 3 2 4 2 5 14 1 14 2 21 22 ...

Page 97: ...ONT 1 6 2 KNOB M LOCKER 1 6 3 HOLDER M LOCKER 1 6 4 TRAY EXIT MP 1 6 5 ADJUST M MP L 1 6 6 ADJUST M MP R 1 6 7 TRAY M COVER MP 1 6 8 GEAR PINION 1 6 9 TRAY M CASE MP 1 6 10 TRAY M LINK MP 2 6 11 SPRING CIS C2 1 7 MEA UNIT COVER MID 1 002N02315 7 1 COVER M MIDDLE 1 7 2 PMO M SUB ACTUATOR 1 7 3 CAP M SUB ACTUATOR 1 8 COVER M SMPS REAR 1 9 PBA MAIN PANEL 1 101N01330 10 PBA MAIN CONTROLLER 1 140N62926...

Page 98: ...20 MEA UNIT CASSETTE PAPER TRAY 1 109R00749 21 PLATE CHANNEL 1 22 MOTOR HARNESS DRIVE 1 152N11566 23 TONER CARTRIDGE 3 5k STANDARD CAP 1 109R00746 23 TONER CARTRIDGE 5k HIGH CAPACITY 1 109R00747 No Part Name and part description Qty Part number Remark ...

Page 99: ...5 43 44 45 47 39 46 17 26 42 47 1 46 1 46 2 47 2 47 3 47 4 47 5 45 1 45 2 45 3 40 41 51 5 62 5 5 2 48 4 3 65 25 33 19 1 19 2 50 7 6 37 36 38 49 49 28 29 30 34 31 32 Transfer Roller 56 23 61 63 73 61 65 1 65 4 65 2 65 3 63 2 63 1 20 66 22 19 27 2 27 27 1 27 3 27 4 27 5 27 6 27 6 27 4 21 21 2 21 1 21 3 ...

Page 100: ... 2 17 GROUND PUSH BUSHING 1 18 PMO PLATE GUIDE DEVE_L 1 032N00391 19 MEA UNIT ACT FEED 1 19 1 PMO ACT FEED R2 1 120N00444 19 2 SPRING TS 1 20 PMO ACTUATOR EMPTY 1 120N00425 21 MEA UNIT ACT MANUAL 1 21 1 PMO ACT MANUAL R2 1 120N00446 21 2 HOLDER ACT MANUAL R2 1 21 3 SPRING TS 1 22 GROUND EARTH TR R2 1 23 GROUND TERMINAL TR 1 24 ROLLER FEED ROLLER 1 1 022N02080 25 PMO BUSHING FEED 5 016N00274 26 SHA...

Page 101: ...1 022N01609 47 1 GEAR FEED 1 1 47 2 PMO COLLAR_SPRING 1 47 3 SPRING TS 1 47 4 PMO HUB CLUTCH 1 47 5 SHAFT FEED 1 48 ELA HOU FUSER 110V 1 126N00229 110V ELA HOU FUSER 220V 1 126N00230 220V 49 PLATE PUSH BUSHING 2 50 GEAR FEED 2 1 51 GEAR IDLE 23 1 52 SPRING TS 1 54 IPR P TERMINAL DEVE KEY 3 56 PBA SUB PTL 1 58 HOLDER TERMINAL R2 1 60 FAN DC 1 127N07328 61 MEC BEARING EXIT 2 62 GEAR EXIT F DOWN 1 63...

Page 102: ...Parts List 8 8 8 3 MP Assembly 0 11 18 24 31 10 2 12 15 29 16 17 13 19 27 19 5 4 8 22 6 7 14 26 14 23 28 23 1 30 20 9 3 21 25 25 ...

Page 103: ...P_MP 1 9 HOLDER M SENSOR_MP 1 10 PLATE P KNOCK UP_MP 1 11 BRACKET P PICK UP_MP 1 12 GEAR IDLE 23 1 13 SHAFT P PICK_UP 1 14 ROLLER M IDLE FEED 2 15 GEAR M PICK UP_MP 1 16 GEAR M HOLDER_MP 1 17 CAM M PICK UP_MP 1 18 PMO ROLLER CAM_MP 1 19 PMO IDLE PICK UP 2 20 PMO M ACT EMPTY MP 1 21 RPR FRICTION PAD 1 019N00742 22 RUBBER PICK UP_MP 1 23 SPRING ETC EXIT ROLL FD 2 24 RPR PAD CASSETTE 1 25 SPRING ES 2...

Page 104: ...Parts List 8 10 8 4 Fuser Unit Assembly 0 1 31 3 2 4 5 29 29 37 35 6 17 36 12 14 34 38 37 13 15 32 30 11 16 33 19 18 23 24 25 28 26 27 20 21 36 38 10 7 22 8 9 ...

Page 105: ...2 1 13 THERMISTOR NTC 1 130N01266 14 ELECTRODE RIGHT R2 1 15 CBF HARNESS FUSER 110V 1 WHITE CBF HARNESS FUSER 220V 1 BLACK 16 BUSH HR R_R2 1 17 LABEL P CAUTION HOT_FUSER 1 18 RMO RUBBER_EXIT 2 19 ROLLER M EXIT F UP 1 20 ROLLER PRESSURE 1 21 BEARING PRESSURE R 2 22 SPRING CS 2 23 PMO BUSHING TX 3 24 HOLDER ACTUATOR 1 25 PMO ACTUATOR EXIT R2 1 26 FRAME FUSER R2 1 27 GUIDE INPUT R2 1 28 SPRING TS 1 2...

Page 106: ...No Part Name and part description Qty Part number Remark 0 ELA UNIT DRIVE 1 007N01270 1 BRACKET GEAR MAIN X 2 GEAR RDCN 53 26 1 3 GEAR RDCN 113 33 1 4 GEAR RDCN 57 18 2 5 WASHER PLAIN 2 6 BRACKET MOTOR MAIN 1 7 GEAR RDCN 1 8 GEAR RDCN 1 9 MOTOR STEP HUMMINGBIRD 1 0 1 2 3 4 4 5 6 8 7 9 5 ...

Page 107: ...Parts List Service Manual 8 13 8 6 Tray 2 Cassette Unit Assembly 0 1 2 3 4 6 7 6 4 6 3 6 2 6 1 5 5 10 11 9 15 12 13 14 8 16 ...

Page 108: ...EXTENSION SMALL 1 4 PLATE P KNOCK_UP 1 5 SPRING CS 2 6 MEA UNIT HOLDER PAD 1 6 1 HOLDER M PAD 1 6 2 SHEET HOLDER PAD R2 1 6 3 RPR FRICTION PAD 1 019N00742 6 4 IPR PLATE PAD 1 7 SPRING ETC EXIT ROLL FD 1 8 COVER SUB CASSETTE R2 1 9 INDICATOR M CST PAPER 1 10 PMO PLATE_LOCKER 1 11 SPRING ETC LOCKER PLATE 1 12 ADJUST M CASSETTE_L 1 13 ADJUST M CASSETTE_R 1 14 GEAR PINION 1 15 RPR PAD CASSETTE 1 16 CA...

Page 109: ...ay 3 SCF Optional Cassette Unit Assembly 0 5 4 2 3 31 15 16 36 34 34 35 24 21 20 22 23 19 18 17 39 39 2 39 1 39 9 39 5 39 4 39 7 39 6 39 3 39 8 27 33 32 25 26 28 27 1 30 37 38 39 10 41 1 1 1 2 40 39 11 39 12 42 11 13 10 14 6 9 7 12 8 29 43 ...

Page 110: ...SHING PICK_UP R 1 13 SHAFT P PICK_UP 1 14 PMO IDLE PICK_UP 2 15 ROLLER FEED 1 16 PMO BUSHING FEED 2 17 PMO GEAR PICK_UP A 1 18 PMO GEAR PICK_UP B 1 19 SPRING CS 1 20 RING CS 1 21 CAM M PICK_UP 1 22 SHAFT FEED 1 23 GEAR FEED 2 1 24 SPRING TS 1 25 PCB SENSOR 1 26 PBASUB SCF 1 27 CBF HARNESS SCF GND 2 28 CBF HARNESS SCF 1 29 COVER M SIMM R2 1 30 SHEET COVER SENSOR 1 31 PMO ACTUATOR EMPTY 1 32 IPR GND...

Page 111: ... BUSH CABLE 1 41 SCREW TAPTITE 14 42 GUIDE M KNOCKUP 1 43 MEA UNIT CASSETTE 1 109R00749 Part Name and part description Qty Part number Remark POWER CORD 110 V 1 117N01602 USB CABLE 1 117N01313 DCU Tool 1 600T80340 OPTIONAL TRAY 3 1 097N01439 MEMORY 32 MB 64 MB 128 MB 1 097N01434 097N01435 097N01436 NETWORK CARD 1 097N01438 POSTSCRIPT OPTION 1 097N01437 No Part Name and part description Qty Part nu...

Page 112: ...Parts List 8 18 ...

Page 113: ...UPPLY DEV THV SMPS Bloc lock FUSER ASSY USER ASSY EXIT SENSOR FEED SENSOR P MP SENSOR FAN IN LET GND 24V 5V Freq Spread Cover Open Switch HVPS PS Block ock Co Controller Block To Controller USB2 0 3 3V IEEE1284 SC SCF Opt ption ion EEPROM Voltage Detector A39 A3977 77 Mot Motor Driver or Driver CART ARTRID RID GE GE IN IN FO FO NI NIC MAIN MOTOR FLA FLASH SH MEMORY MEMORY 2MB 2MB EMPTY SENSOR SDR ...

Page 114: ...Block Diagram 9 2 ...

Page 115: ...9 20 21 22 23 24 25 26 24VS nPMOTOR nLREADY LSU_ CLK nHSYNC 5V nLD_ON VDO GND GND MHV_ PWM 5V P_EMPTY 5V GND FAN THV_ PWM BIAS_PWM THV_ EN SC SCF O OPTIO IO N 8PIN DCU DCU 3 3V DCU_ DATA 1 2 3 4 1 2 3 4 DCU_ CLK GND GND FEED GND GND GND GND 24VS 24VS 24V MP_EMPTY THV_ READ FUSER P_EXIT UART UART 3 3V RXD 1 2 3 4 1 2 3 4 TXD GND CARTRIDGE CARTRIDGE INFO INFO 4PIN 30 PIN 100PIN 100PIN ROMDIMM RAMDIM...

Page 116: ...Connection Diagram 10 2 ...

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