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Xerox Phaser 6100, Service Manual

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Xerox Phaser 6100 Service Manual Download Page 6

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Front View  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2

4.1.2 Motor and Fan Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-6
4.1.3 Clutch and Solenoid Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7
4.1.4 Sensor and Switch Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-8
4.1.5 Main Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-9
4.1.6 LVPS (SMPS) Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-13
4.1.7 HVPS (High Voltage Supply) Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

5 System Outline

5.1 Color Laser Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

5.1.1 Imaging Unit (Drum Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1
5.1.2 LSU (Exposure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-2
5.1.3 Toner Cartridge (Development Section)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-2
5.1.4 Image Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-4
5.1.5 Fuser (Fusing Process) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-7
5.1.6 Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-8
5.1.7 Waste Toner Collection Process  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-8

5.2 System Start-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-9

5.2.1 System Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-9
5.2.2 Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-9
5.2.3 Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-10
5.2.4 Processing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-10
5.2.5 Print  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-11
5.2.6 Post-Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-12

6 Disassembly

6.1.1 Precautions for Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.2 Precautions When Removing Circuit Boards  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-1

6.2 Maintenance and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-2

6.2.2 Printer Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-3

6.3 Information Related to Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-4

6.3.1 Service Part Assemblies Warnings and Cautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-4

Screws Used in the Printer (Hardware Kit)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-5

6.3.2 Removing Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-6
6.3.4 Replacing the Waste Toner Cartridge (PL 9.1.57). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-9
6.4.1 Top Cover (PL 9.1.17) and Front Cover (PL 9.1.15). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-11
6.4.2 Control Panel (PL 9.2.19)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-14
6.4.3 Rear Cover (PL 9.1.16)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-15
6.4.4a Duplex Cover - Door C (PL 9.6.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-16
6.4.4b Duplex Unit (PL 9.6.2) and Transfer Roller (PL 9.1.54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-17
6.3.5a Fuser (PL 9.1.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-18
6.4.5b Fuser Base Cover (PL 9.13.29)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-19
6.4.6 Exit Cover - Door B (PL 9.5.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-20
6.4.7a Low-Voltage Power Supply - LVPS/SMPS (PL 9.1.19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-21
6.4.7b Main Controller Board (PL 9.1.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-23
6.4.8 Fuser Fan Assembly (PL 9.1.27) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-24
6.4.9 Main Drive Assembly (PL 9.1.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-25
6.4.10 HVPS (High Voltage Power Supply) (PL 9.1.20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-27

Summary of Contents for Phaser 6100

Page 1: ...Service Manual X XEROX P h a s e r C o l o r L a s e r P r i n t e r 6100 ...

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 February 2003 071 0872 00 ...

Page 4: ...neva Monaco and New York are registered trademarks of Apple Computer Inc in the United States and or other countries QuickDraw is a trademark of Apple Computer Inc PCL and HP GL are registered trademarks of Hewlett Packard Corporation in the United States and or other countries IBM is a registered trademark of International Business Machines Corporation in the United States and or other countries ...

Page 5: ...Federal Communications Compliance 1 6 1 6 2 Declaration of Conformity 1 6 2 Reference Information 2 Reference Information 2 1 2 1 Tools for Troubleshooting the Printer 2 1 2 2 Acronyms and Abbreviations 2 2 2 3 Selecting a Location for the Printer 2 4 2 4 Printer Serial Number Format 2 5 3 Specifications 3 1 General Specifications 3 1 3 2 Controller Specification 3 2 3 3 Electrical Specification 3...

Page 6: ... 1 6 1 2 Precautions When Removing Circuit Boards 6 1 6 2 Maintenance and Supplies 6 2 6 2 2 Printer Cleaning 6 3 6 3 Information Related to Disassembly and Reassembly 6 4 6 3 1 Service Part Assemblies Warnings and Cautions 6 4 Screws Used in the Printer Hardware Kit 6 5 6 3 2 Removing Consumables 6 6 6 3 4 Replacing the Waste Toner Cartridge PL 9 1 57 6 9 6 4 1 Top Cover PL 9 1 17 and Front Cover...

Page 7: ...eed Roller PL 9 19 13 6 50 6 4 26 Paper Feed Roller Mid PL 9 19 9 6 51 6 4 27 Feed Sensor PL 9 20 2 6 52 6 4 28 Fuser Exit Sensor PL 9 14 5 6 53 6 4 29 500 Sheet Feeder PL 9 1 44 6 54 7 Maintenance and Diagnostics 7 1 Paper path and Paper jam 7 1 7 1 1 Paper path 7 1 7 1 2 Jams 7 2 7 2 Jam Removal 7 4 7 2 1 Factors that Cause Paper to Jam 7 4 7 3 Sample Prints 7 5 7 3 1 Printing a Demo Page 7 5 7 ...

Page 8: ... 8 13 8 4 1 Fuser Error 8 13 8 4 2 Laser Error 8 13 8 4 3 Fuser Does Not Work Due to the Drive Gear Having Heat Damage 8 13 8 4 4 Paper Empty 8 14 8 4 5 Paper Empty not Detected 8 14 8 4 6 Cover Open 8 14 8 4 7 Cover Open Not Detected 8 15 8 4 8 Defective Motor 8 15 8 4 9 No Power 8 15 8 4 10 Curved or Distorted Vertical Lines 8 16 8 4 11 Low Toner 8 16 8 4 12 Replace Toner Color 8 16 8 5 Error Me...

Page 9: ...Base Frame Assembly 9 34 9 17 MPT Assembly 9 36 9 18 Pickup Assembly 9 38 9 19 Feeder Assembly 9 39 9 20 Paper Guide Assembly 9 41 9 21 Transfer Belt Cam Assembly 9 42 9 22 Fuser Base Assembly 9 44 9 23 Xerox Kits and Accessories 9 45 10 Block Diagram 10 Block Diagram 10 1 10 1 Controller Block Diagram 10 2 11 Connection Diagram ...

Page 10: ...vi ...

Page 11: ...ndicates an operating or maintenance procedure practice or condition that is neccessary to efficiently accomplish a task A note can provide additional information related to a specific subject or add a comment on the results achieved through a previous action Caution A caution indicates an operating or maintenance procedure practice or condition that if not strictly observed results in damage to o...

Page 12: ...n the printer Use caution to avoid personal injury The surface is hot while the printer is running After turning off the power wait 30 minutes Avoid pinching fingers in the printer Use caution to avoid personal injury Use caution or draws attention to a particular component Refer to the manual s for information 0 30 min ...

Page 13: ...rly grounded outlet If the product loses its ground connection contact with conductive parts may cause an electrical shock 1 3 2 Disconnecting Power Turning the power off using the On Off switch does not completely de engergize the printer You must also disconnect the printer power cord from the AC outlet Position the power cord so that it is easily accessible during servicing so that you may powe...

Page 14: ...ective material from the leads of a replacement device touch the protective material to the chassis or circuit assembly into which the device will be installed Minimize body motions when handling unpackaged replacement devices Motion such as your clothes brushing together or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro statically sensitive device...

Page 15: ... only because the laser beam is totally enclosed during all modes of customer operation When servicing the printer or laser unit follow the procedures specified in this manual and there will be no hazards from the laser 1 5 4 Servicing Electrical Components Before starting any service procedure switch off the printer power and unplug the power cord from the wall outlet If you must service the prin...

Page 16: ...this product To ensure compliance use shielded interface cables A shielded parallel cable can be purchased directly from Xerox at www xerox com office 6100supplies Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards These standards are designed to mitigate interference caused or received by this product in a normal office environment This produ...

Page 17: ... 2 1 Tools for Troubleshooting the Printer The following tools are recommended for safe and easy troubleshooting as described in this service manual DVM Digital Voltage Meter standard indicating more than 3 digits Screwdrivers Tweezers Cotton swabs Cleaning equipment Standard dry lint free cloth and or mild detergent Toner Type II Vacuum Soft bristle brush Printer Installer and Utilities CD ROM 2 ...

Page 18: ...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 Pots Per Inch IOT Image Output T...

Page 19: ...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 20: ...en the printer trays covers and allow for proper 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 ...

Page 21: ...elds in the serial number indicate the modification level of the printer the date of its manufacture and the sequence number of the printer produced on that day The serial number is coded as follows RENXXXXXX 110V Printer REPXXXXXX 220V Printer 1st three alpha Product Code 1st numeric value Revision of the Printer Remaining 5 numeric values indicate the printers serial number BD serial number rang...

Page 22: ...Reference Information 2 6 ...

Page 23: ...e heat lamp 800 watts Resolution True 600 x 600 dpi Addressable 1200 x 1200 dpi Warm up time 110 and 220 volt units 120 seconds 2 minutes from power on to ready FPOT Mono Less than 15 seconds Ready to 1st page out Color Less than 24 seconds Ready to 1st page out Feed Method MPT Multi Purpose Tray Tray 1 FCT First CassetteTray Tray 2 SCT Second Cassette Tray Dimensions Width 510 mm 20 07 in Depth 4...

Page 24: ...allel port IEEE 1284 1994 compliant Bi directional ECP Nibble Byte Mode One USB port USB v 2 0 compliant Color coded to meet WHQL requirements connector must be Pantone 426C One 10 100 BaseT NIC connector The printer supports an internal Network Interface Card NIC which can be installed pre configured at the factory This NIC supports all of the major Network Operating Systems such as the Novell Ne...

Page 25: ...replaceable Fuser 100 000 pages mono 50 000 pages color User replaceable Transfer Roller T2 50 000 pages simplex prints User replaceable Waste Toner Cartridge 3 000 to 5 000 pages color 5 User replaceable Printer 300 000 images or 5 years Item Life based on 5 coverage Standard Toner Cartridge Black High capacity 3 000 7 000 Standard Toner Cartridge Cyan High capacity 2 000 5 000 Standard Toner Car...

Page 26: ...ecutive 7 25 x 10 5 184 x 267 mm MPT Statement 5 5 x 8 5 140 x 216 mm MPT ISO B5 176 x 250 mm MPT JIS B5 182 x 257 mm MPT A5 148 x 210 mm MPT A6 105 x 148 mm MPT Com 10 Envelope 4 15 x 9 5 105 x 241 mm MPT 9 Envelope 3 88 x 8 88 MPT Monarch Envelope 3 88 x 7 5 98 x 191 mm MPT DL Envelope 110 x 220 mm 4 33 x 8 66 MPT C5 Envelope 162 x 229 6 38 x 9 MPT C6 Envelope 114 x 162 4 5 x 6 38 MPT B5 Emvelop...

Page 27: ... Paper 250 sheets 20 lb Paper 500 sheets 20 lb A4 Letter 16 24 lb 60 90 gsm MPT Paper 100 sheets Envelope 10 Label 10 sheets Transparency 30 sheets Card stock N A A4 Letter Legal Folio Executive A5 ISO and JISB5 A6 Statement Monarch COM10 9 C5 B5 Env and DL 16 43 lb 60 163 gsm Auto Duplex Paper A4 Letter Folio Legal 20 24 lb 75 90 gsm Output Tray Paper 250 sheets 20 lb Print Margins Side print pos...

Page 28: ...Specifications 3 6 ...

Page 29: ...enta DEV Cyan CASSETTE LSU Feeder DUPLEX Fuser Unit EXIT Unit M P F M P T DEV Black DEV Yellow Pick up Roller DEV Magenta DEV Cyan SCF Tray 2 Tray 1 LSU Deve Cover Deve Cover Transfer Belt Transfer Belt Feeder DUPLEX Transfer Roller Transfer Roller Imaging Unit w OPC Drum Imaging Unit w OPC Drum Fuser Unit EXIT Unit PTL PTL SCF Path Pick up Roller Pick up Roller Pick up Roller Pick up Roller ...

Page 30: ...Toner Sensor Waster Toner Motor LVPS LVPS Main Drive Main Drive FuserFan FuserFan Conrtoller Board Conrtoller Board Deve Drive Deve Drive DeveDrive Board DeveDrive Board Duplex Cover Open Switch Duplex Cover Open Switch Deve Cover Open S W Interlock Door A Deve Cover Open S W Interlock Door A ...

Page 31: ...or FCT First Cassette Tray Tray 1 stores and feeds paper to the printer A pick roller picks paper controls drive feeds paper and removes static electricity from the paper Tray 1 Specifications Paper Feed side registration Paper Direction Long edge Paper Discharge Separation Claw Capacity 250 Sheets Paper Size A4 Letter Paper Weight average 60 90gsm 16 24lbs Paper Type see the approved Xerox media ...

Page 32: ... Roller Drive Driven by the main motor DC rotating clockwise for normal feed and counter clockwise to reverse feed for duplex printing 10 Toner Cartridges There are four toner cartridges one each for C Cyan M Magenta Y Yellow and K Black 11 Fuser Unit The fuser unit consists of 2 heat lamps 2 heat rollers 2 thermostats and one thermister After the image is transferred from the transfer roller onto...

Page 33: ...noids Memory Block Stores video data and print orders from the computer ROM Block The printer operating system and PDL interpreter are stored here USB 2 0 Block IEEE 1284 Block Option Block and Control Panel 18 DEVE Drive Board Each toner cartridge requires high voltage when that color is being processed The DEVE drive board using four solenoids selects which cartridge is to receive the supply vol...

Page 34: ...s the toner cartridges and transfer belt cleaning cam 3 Fuser Fan Cools the fuser 4 Waste Toner Motor Transfer collected waste toner from the imaging unit and transfer belt to the waste toner cartridge 3 Fuser Fan 3 Fuser Fan 1 Main Motor 1 Main Motor 2 DEVE Motor 2 DEVE Motor 4 WasteToner Motor 4 WasteToner Motor 3 Fuser Fan 1 Main Motor 2 DEVE Motor 4 WasteToner Motor ...

Page 35: ... the transfer roller from the transfer belt 9 Transfer belt cleaning solenoid cam Operates the transfer belt cleaning blade No Clutch Name Description 1 Y DEVE clutch Controls the yellow toner cartridge drive 2 M DEVE clutch Controls the magenta toner cartridge drive 3 C DEVE clutch Controls the cyan toner cartridge drive 4 K DEVE clutch Controls the black toner cartridge drive 5 Feed Clutch Contr...

Page 36: ...ensity sensor detects toner density for each color transferring to the drum 7 Waste toner sensor Detects amount of toner in the waste cartridge and if a waste cartridge is installed See page 4 2 for location of sensor 8 Exit sensor Detects whether or not media has exited the printer 9 DEVE cover open switch Door A interlock Detects the open or closed condition of the DEVE cover Door A See page 4 2...

Page 37: ...3 T2 HOME BLDC1 FSR_ROLL FUSER_FAN SMPS MP EMPT MP SOL FEED CN25 PICK_UP CN23 CLT_FEED CN21 EMPT CN9 CN1 CN16 SCF CN12 LSU CN6 OPC KEY CN5 DEVE_DRIVER DEVE_DRIVER DEVE_DRIVER CN14 LSU SW CN8 ERASER CN35 LSU_FAN CN24 DUPLEX CN19 EXIT CN4 PANEL CN7 HVPS CN10 ITB CN17 WASTE TONER CN15 TH3 CN11 PTL CN13 TH4 NIC For Test ...

Page 38: ...Summary of Product 4 10 RAM DIMM SPGPm Main Control FLASH MEMORY ENGINE CONTROL ...

Page 39: ...roller supports PC 66 PC 100 and PC 133 SDRAMs running at 60MHz Up to 128MB per array up to 512MB totally Wide supports for various SDRAM configurations including programmable band and column address Programmable SDRAM refresh time interval IEEE1284 compliant parallel port interface Compatible ECP communications are supported Direct support for IEEE1284 compliant data transceivers High performance...

Page 40: ...d the OS is run from within memory 5 USB 2 0 Block Is used to provide support for USB 2 0 and is capable of interface speeds up to 480 Mbps 6 IEEE 1284 Block An IEEE 1284 controller is controlled directly by the SPGPm processor ECP mode is supported 7 Option Block An Ethernet card can be attached using the 100 pin connector It is connected directly to the SPGPm processor and communicates using a 1...

Page 41: ...put Main board control panel Tray 1 developer drive board interlocks sensors imaging components motors clutches solenoides and HVPS 2 AC output Fuser 3 Output voltage No Item CH1 CH2 CH3 CH4 1 Channel Name 3 3 V 5 V 24 V 24 V 2 Rated output voltage 3 3 V 4 5 V 4 24 15 10 24 V 15 10 3 Uses MICOM CMOS LOGIC MICOM CMOS LOGIC MOTOR FAN MOTOR FAN CON4 CON3 CON4 CON4 CON3 CON3 CON4 CON3 CON1 CON1 Fuse C...

Page 42: ...ridge imaging unit T1 transfer belt T2 and transfer roller For the best print quality images these hifh voltages must be controlled and maintained accurately Warning High Voltage Be sure to follow the steps outlined in Section 1 5 4 when servicing this assembly SUPPLY T1 T2 CHARGER CN1 CN2 SUPPLY SUPPLY T1 T1 T2 T2 CN1 CN1 CN2 CN2 SUPPLY T1 T2 CHARGER CHARGER CHARGER CN1 CN2 ...

Page 43: ...oller to the paper Output voltage 400 V 5K VDC 3 Duty is changeable no loading Error type If the secondary transfer voltage was not present it is not possible to transfer toner from the transfer roller to the paper As a result print output could be fain or blank 4 Cleaning voltage T2 Used in the cleaning process to transfer clean off the negative toner reamaining on the transfer roller to the wast...

Page 44: ...Summary of Product 4 16 ...

Page 45: ...s with a negative high voltage 1 KV 1 5 KV while in contact with the drum and produces a uniform voltage on its surface of approximately 500 800 V 2 Type Life span 50 000 Images Color 12 500 pages Waste toner removal Transferred to a user replaceable tank Waste cartridge sensors LED type detects cartridge presence and full OPC drum diameter 120 mm Power Main motor BLDC Charge method Charge roller ...

Page 46: ...tions Toner on the developer roller is charged to the developing voltage see page 5 7 Toner is attracted to the drum in those areas where the surface charge is 50V Toner is not attracted to those areas of the surface carrying a 600 V charge 1 Type Developing method Non magnetic Mono component developing system Toner cartridge order K Y M C from top Developing sequence Y M C K Life span High Capaci...

Page 47: ...ed on the transfer roller from the transfer belt is then transferred to the media Fuser and Exit The image on the page is then fused and the paper is ejected into the output tray 3 Toner Cartridge Empty Detection The toner cartridge empty state is detected by the CRUM NVRAM contained in each cartridge Developing and Image Transfer Developing and Image Transfer Developing and Image Transfer Paper P...

Page 48: ...er being placed on the drum It is also used to detect a toner cartridge empty state The drum surface and toner have different light reflecting characteristics the CTD sensor uses this to detect the difference in the amount of toner present on the drum Caution Be careful not to contaminate the surface of the CTD sensor this will cause problems with color reproduction and quality Process The TRC Ton...

Page 49: ...s activates a cam which moves the transfer roller into contact with the belt After the transfer has taken place any remaining charge on the paper is removed by applying a charge removal bias generated in the HVPS to a detack saw Transfer method Semi conductive roller contact method Effective transferring range 218 mm i e maximum image length 6 Transfer Belt Home Sensor This sensor is used to ensur...

Page 50: ...condary Image Transfer Transfer Roller T2 OPC DRUM Transfer Unit CTDSensor OPC Drum LED PBS Polarized Beam Splitter PD Photo Diode TONER OPC DRUM Paper Image Transfer Bias Charge Removal Bias ImageTransfer Belt Image Transfer Roller HVPS ...

Page 51: ...ollers 3 Heat Roller 2 Halogen lamps are used to heat the heat rollers The heat rollers have a special Teflon surface which ensures that any melted toner coming into contact with the heat roller surface does not stick Paper passes between the two rollers which evenly heat the paper from both sides to melt the toner and fusing it onto the media 4 Safety Information Warning Overheat protection 1st l...

Page 52: ... toner from the transfer belt and deposits waste toner into the waste toner cartridge 1 Waste toner cartridge sensor The waste toner cartridge sensor is used to detect the presence of the waste toner cartridge and its full condition No waste toner cartridge If a waste toner cartridge is not installed in the printer the waste toner sensor actuator blocks light from the sensor LED and displays a car...

Page 53: ...itialize system variables 3 Initialize a virtual timer 4 Initialize fuser control 5 Initialize ADC 6 Establish ITB HOME interrupt 5 2 2 Warm Up During the warm up stage the following tasks are performed 1 Self Test System check Cover open check Device Transfer Belt Imaging Unit Toner cartridge check Fuser check Motion of motors jams and paper empty check Check feed and exit sensors If paper is det...

Page 54: ... after timeout Wakeup condition When a wakeup order is received When a cover is opened or closed When the level of the paper empty sensor changes Heat lamp is off 5 2 4 Processing There is a preparation stage before processing a print job and after receiving a print command 1 Start Laser Run scanning motor Check motor ready Turn LD on 2 Start Main Motor Eraser PTL ON Run main motor Check lock sign...

Page 55: ...and K is set up e If home is not detected every 3 seconds an error is reported on the control panel 2 Paper Path Printing a Paper is picked from Tray 1 Tray 2 or MPT b Control paper path Paper pick stops when the leading edge of the paper reaches the feed sensor If the leading edge doesn t reach the feed sensor an error is reported While transferring the last color to the transfer belt transports ...

Page 56: ...2 5 2 6 Post Print This is the last stage of the printing process Its functions are described below a Clean transfer rollers b Stops all virtual timers c Re initialize parameters used in the print process d Stops motors ...

Page 57: ...the ESD precautions in Section 1 of this manual when handling or storing a board Precautions when moving and storing boards Place boards in an approved anti static discharge bag Do not store a board where it is exposed to direct sunlight Precautions when replacing boards Disconnect power connectors first before disconnecting other cables Do not touch any soldered connections connector terminals or...

Page 58: ...is replaced it is necessary to reset the life used stored in memory To reset the fuser and transfer roller life usage from the printers control panel a From the main menu select Menu Setup Maintenance Check other b Select the appropriate part name from the list by using the Up Scroll and Down Scroll buttons c Select Reset Item Life based on 5 coverage Auto Reset Replaceable By Black Standard Toner...

Page 59: ...lures due to contamination are less likely to occur Clean the printer with a soft lint free cloth dipped in a mild detergent Do not touch the transfer roller when cleaning the inside of the printer Grease and oils from the skin will contaminate the surface and reduce print quality To clean the laser open and close Door A a few times Please refer to the User Guide for more cleaning instructions ...

Page 60: ...ssemble the ITB The alignment of the home sensor is critical and is set up in the factory Incorrect re assembly will cause print quality degradation 3 Imaging Unit OPC drum If the imaging unit is exposed to direct sunlight for a long time the parameters and response of the electrostatic surface are changed causing image transfer and print quality issues Caution There is no protective shutter on th...

Page 61: ...TION SPEC S1 SCREW MACHINE 2 6 4 GOLD S2 SCREW TAPPING 4 15 GOLD S3 SCREW TAPPING 3 8 GOLD S4 SCREW TAPTITE 2 6 6 GOLD S5 SCREW TAPTITE 3 8 BLACK S6 SCREW TAPTITE 2 10 GOLD S7 SCREW TAPTITE 3 6 GOLD S8 SCREW TAPTITE 3 10 SILVER S9 SCREW TAPTITE 3 6 GOLD S10 SCREW ASS Y MACH 3 6 GOLD NO DESCRIPTION SPEC S11 SCREW TAPTITE 3 6 GOLD S12 SCREW TAPTITE 3 8 BLACK S13 SCREW MACHINE 3 8 SILVER S14 SCREW TA...

Page 62: ... consumable parts toner cartridge transfer belt and imaging unit Orientation of the Printer Doors 1 Pull the side handle to open the DEVE cover Door A and then press down firmly until the toner cartridges are ejected Note Before opening the exit cover completely open the DEVE cover 90o to the main frame ejecting the toner cartridges 2 Removing a toner cartridge K Y M and C ...

Page 63: ...Disassembly Service Manual 6 7 Caution Do not damage the rollers Keep the toner cartridges on a flat surface 3 Open the exit cover by pressing the cover open button Exit Cover Door B DEVE Cover Door A ...

Page 64: ...le provided Caution Ensure the drum surface is not scratched or damaged while removing from the printer or after placing it on a flat surface Do not touch the surface of the drum Exposing the drum surface to direct light for more than 5 minutes will damage the drum cover it with paper as shown below Transfer Belt Lever Lever Imaging Unit OPC Drum Paper ...

Page 65: ...he Waste Toner Cartridge PL 9 1 57 1 Push in the top corners of the front cover 2 Lift the latch at the top of the waste toner cartridge and pull the top edge forward then lift the cartridge out Note Do not spill toner from the waste toner cartridge ...

Page 66: ...Disassembly 6 10 3 Remove the toner caps and fit them to the inlets as shown below Toner Cap ...

Page 67: ...over PL 9 1 17 and Front Cover PL 9 1 15 1 Remove Tray 1 2 Open DEVE Cover Door A Exit Cover Door B and Duplex Door C 3 Remove 2 screws 3 10 silver from the top cover DEVE Cover Door A Exit Cover Door B Duplex Cover Door C Top Cover Screw Screw ...

Page 68: ...s at the base of the cover and remove as shown 5 Open the front cover 6 Remove 7 screws 3 10 silver located inside the front cover Note To access the bottom right front screw tray 1 needs to be removed from the printer 7 Remove 2 screws 3 10 silver located on the top of the front cover ...

Page 69: ...ervice Manual 6 13 8 Close the front cover door 9 Push the cover down and using a flathead screwdriver remove the cover from the posts on the bottom to release it from the printer 10 Remove the front cover Post Post ...

Page 70: ...9 2 19 1 Remove the front cover 6 4 1 2 Remove 3 A 3 8 gold 3 Disconnect the wiring harness connector 4 Rotate the control panel to release it from the tabs and remove the control panel from the printer Screw Screw Screw A A A A A A Connector ...

Page 71: ...ver Refer to 6 3 3 2 Remove the top cover Refer to 6 4 1 3 Remove 10 screws A Top 2 EA 3 10 Silver B Side 3 EA 3 10 Silver C Bottom 3 EA 4 10 Silver D Rear 2 EA 3 10 Silver E Side 2 EA 3 6 Gold Only for the DN Model 4 Remove the rear cover Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw A D C B A D C B ...

Page 72: ... 4 3 2 Open Door C 3 Remove the top 2 hinge screws 3 10 silver on either side of each hinge rail 4 Disconnect the links from the door 5 Holding the door at a 90o angle snap the front hinge out Slide the door towards the front of the printer and remove it Screw Duplex Assembly A A B B Screws ...

Page 73: ...ver Assembly Door C 6 4 4a 2 Release the 4 hooks on the right and left side of the duplex unit with a flat blade screwdriver 3 Remove the duplex assembly from the door 4 Remove the transfer roller by turning the bushing on each end of the roller Duplex Assembly Hook Hook Hook Hook Duplex Assembly Transfer Roller ...

Page 74: ...ore removing it 1 Open the DEVE cover Door A Note Before opening the exit cover completely open the DEVE cover until it is at a 90o angle to the main frame and the toner cartridges are ejected 2 Open the exit cover Door B 3 Remove the 4 thumbscrews 4 Remove the fuser by holding both sides and pulling straight up and out of the priner Screw Screw Screw Screw ...

Page 75: ...Disassembly Service Manual 6 19 6 4 5b Fuser Base Cover PL 9 13 29 1 Remove the fuser 6 4 5a 2 Remove 3 screws 3 10 silver 3 Lift the base cover off Screws ...

Page 76: ... 5 0 1 Open the duplex cover Door C 2 With the exit cover closed remove the E ring and the hinge pin Caution Do not lose the hinge pins Note The diagram shows the door open and covers off for reference only 3 Remove the exit cover E Ring Hinge Pin ...

Page 77: ... PL 9 1 19 1 Remove the rear cover 6 4 3 2 Remove 5 screws 3 6 machine gold from the main board shield 3 Remove 2 screws 3 10 machine silver connected to the parallel port and then remove the main board shield Main PBA Bracket Screw Screw Screw Screw Screw Screw Screw Screw ...

Page 78: ...ews 3 10 silver from the harness guide and free the harness then remove the guide 6 Press the top of the LVPS cage towards door C and tilt it out to access and disconnect the 4 harnesses from the LVPS 7 Remove the LVPS Screw Screw Screw LVPS C A Screw B B C A Harness Guide Screw CON4 CON3 CON4 CON4 CON3 CON3 CON4 CON3 CON1 CON1 Fuse CON2 CON2 ...

Page 79: ...ect all harness connected to the main board 3 Remove 5 screws 3 6 machine screw gold and then remove the main board NVRam Chip Screw Screw Screw Screw Screw Main Board USB NPC Parallel Port CN26 CN27 CN28 CN29 CN30 CN30 CN32 CN33 T2 HOME BLDC1 FSR_ROLL FUSER_FAN SMPS MP EMPT MP SOL FEED CN25 PICK_UP CN23 CLT_FEED CN21 EMPT CN9 CN1 CN16 SCF CN12 LSU CN6 OPC KEY CN5 DEVE_DRIVER DEVE_DRIVER CN14 LSU ...

Page 80: ... 9 1 27 1 Remove the top cover 6 4 1 2 Remove the rear cover 6 4 3 3 Remove the main board shield 6 4 7 4 Remove 3 screws 3 10 silver 5 Disconnect and free the harness from the main board and then remove the fuser fan Fuser Fan Screw Screw Screw ...

Page 81: ...rness guides Two harnesses need to be freed from the bottom of the bracket 6 Remove the LVPS cover bracket 7 Look inside the imaging unit cavity and locate the transfer roller T2 cam Note Place a piece of paper below the transfer roller T2 cam to avoid dropping the split ring washer into the drive gears 8 Remove the split washer and then remove the transfer roller cam Bracket Cover LVPS Cam Drive ...

Page 82: ...ter removing the imaging unit Note Take care that the pin is not lost as you remove the gear 10 Disconnect CN 23 24 27 and 32 11 Remove 5 screws 3 10 silver and then take out the main drive assembly On Re assembly 1 Be sure to reconnect the grounding wire Gear Drive Pin Drive Washer Plain Screw Screw Screw Screw Screw Screw ...

Page 83: ...rd shield 6 4 7b 4 Remove and free the CN7 harness from the main board 5 Remove 1 harness and 4 high voltage harnesses from the HVPS Caution Do not swap the HVPS wires they are the same color size and shape Note the wire connectors and connection points for T1 and T2 6 Free the white wiring harness through the channel in the chassis SUPPLY T1 T2 CHARGER CN1 to Deve Driver CN2 to Deve OEM USB Paral...

Page 84: ...Disassembly 6 28 7 Remove 5 screws 3 6 machine gold and then remove the HVPS Screw Screw Screw Screw Screw ...

Page 85: ...chine screw gold Top Right 2 EA 3 10 silver Bottom 1 EA 4 10 silver Note The black harness guide will fall off 4 Remove the ground harness and the harness guide bracket by removing 3 screws Top 2 EA 3 6 machine screw gold Bottom 1 EA 4 10 silver Harness Guide Main Board Bracket Screw Screw 3 x 6 Gold 4x 10 White 3x 10 White Screw Screw Screw Guide Harness Bracket Screw Screw Screw 4 x 10 White Scr...

Page 86: ...5 Disconnect the harness from the DEVE Motor 6 Remove 4 harnesses connected to the DEVE drive board then remove the DEVE drive assembly 7 Remove 5 screws 3 10 silver from the DEVE drive assembly Screw Screw Screw Screw ...

Page 87: ...en servicing this assembly 1 Remove the rear cover 6 4 3 2 Remove the main board 6 4 7b 3 Remove the main board shield 6 4 7b 4 Remove the main board bracket steps 1 and 2 from 6 4 11 5 Free the wiring from the black harness guide 6 Remove the screw 3 10 silver from the guide and remove it 7 Remove the screw 3 10 silver and then take out the DEVE cover open S W DEVE Board Deve Cover Open S W Screw...

Page 88: ...correctly Start with CN8 which corresponds to the bottom clutch assembly then work up to CN4 CN9 and CN5 10 Remove the 4 high voltage terminals to ensure they don t become damaged or lost Caution Do not lose or damage the terminal springs Screw Screw Screw Screw Screw Screw SUPPLY CN1 CN2 SOL 2ND CN7 SOL 3RD CN1 BLCD_DEV CN10 SOL_T1_CLN CN6 SOL_1ST CN3 SOL_4TH CN5 CLT_4TH CN9 CLT_3RD CN4 CLT 2ND C...

Page 89: ... 33 T1 Clean 1 Remove the rear cover 6 4 3 2 Remove the main board shield 6 4 7b 3 Remove 4 screws 3 6 gold and then remove the DEVE drive motor 4 Unplug 1 harness from the DEVE drive board 5 Release the locking tab from the shaft 6 Remove the solenoid Screw Screw Screw Screw Clutch Cam Solenoid ...

Page 90: ...nd the exit cover Door B 5 Remove 2 screws 4 10 silver from the laser unit cover and 2 clips located next to the DEVE cover hinge A 6 Remove the laser unit cover 7 Remove the waste auger tube 8 Remove 1 screw 4 10 silver and then remove the lamp cover B 9 Remove the 2 clips and lift the eraser lamp assembly and disconnect the harness and then remove the erase lamp Screw Screw Screw A B A B Erase L...

Page 91: ...ing unit protect from light 6 3 3 2 Remove the front cover and top cover 6 4 1 3 Remove the laser unit cover Steps 1 3 of 6 4 14 4 Remove 3 screws 4 15 silver from the hinge bracket on the right of the DEVE cover 5 Release the brush arms from the laser housing and pull the brush out of the printer DEVE Cover Brush Arm 3 Screws ...

Page 92: ...Disassembly 6 36 6 4 15 DEVE Cover Door A PL 9 1 18 1 Remove the Laser Brush 6 4 15a 2 Remove the DEVE cover by pulling it in the direction of the arrows Deve Cover LSU Cleaner ...

Page 93: ...Remove the transfer unit and imaging unit protect from light and damage 6 3 3 2 Remove the DEVE cover Door A 6 4 15 3 Remove the Laser Unit Brush 6 4 15 1 4 Remove 4 screws 4 10 silver 5 Remove 1 screw 3 8 yellow Screw Screw Screw Screw Screw LSU Ground LSU Ground ...

Page 94: ...Disassembly 6 38 6 Disconnect 2 harnesses and remove the laser unit Harness Harness ...

Page 95: ... from the HVPS and free it from the channel 3 Disconnect the harness CN2 from the DEVE OEM board 4 2 Remove the 6 screws 3 8 black and remove the Board 5 Remove the 12 terminals so they dont get lost On Reassembly Caution On reassembly ensure the springs are seated correctly and not damaged or bent Deve OEM PBA Screw Harness Screw Screw Screw Screw Screw Terminals ...

Page 96: ...d toner 2 Disconnect harness CN2 from the DEVE OEM Board 3 Remove 6 screws 3 10 silver Upper part 4 screws Lower part 2 screws Caution Do not damage the foam gaskets located behind the auger tube and dust cover 4 Reach into the drum cavity and lightly depress the waste toner receiver Holding the toner receiver down gently pull the waste toner assembly away from the printer Once the assembly is rel...

Page 97: ...e printer towards you but do not disconnect it Caution Be careful not to spill waste toner Pay attention to the position of the foam gasket as it can be easily damaged 8 Route the wiring harness through the channel to free it from the chassis 9 Remove 1 screw 3 10 Silver from the toner waste cartridge full sensor Note Note the orientation of the sensor for reassembly 10 Release the sensor assembly...

Page 98: ...e wrap to loosen the sensor and solenoid harness on the rear of the printer 9 Remove the 4 screws 3 10 Silver securing the asembly to the base 10 Slide the right side of the printer 3 to 4 inches over the edge of the table to give access to the underside Caution Do not tilt the printer excessively or waste toner will spill 11 Reach up underneath to locate the locking tabs which secure the MPT to t...

Page 99: ...ual 6 43 6 4 19 cont d MPT Feed Roller 1 Place the MPT assembly on a flat surface and remove the e ring and washer securing the pick roller shaft to the assembly 2 Slide the shaft to the right to free the roller and remove it ...

Page 100: ... facing out The hole through the roller is round on one end and D shaped on the other The D shaped end needs to face the left The black plastic bearing that the roller shaft fits into is not attached to the printer and is easily lost It has a small key that fits into a slot in the MPT assembly Caution Do not pinch the black washer in the e ring slot ...

Page 101: ... Waste Toner Auger Assembly 6 4 18 11 Remove the Main Drive 12 At the end of the erase lamp remove the 1 black screw 3 8 from the grounding strap 13 Disconnect all wiring harnesses from the lower portion of the chassis 14 Cut the two tie wraps securing the harnesses together Caution Be sure the harnesses are all routed out of the way so that on reassembly the harnesses do not get damaged Use care ...

Page 102: ...ently pull out on the outer bushing s locking tab where the gear was to free it from the chassis Align the tab in the bushing with the slot in the base and slide it toward the back of the printer to free it 5 Remove 3 screws type 6 Free the wiring harnesses from the channel 7 Remove the assembly from the base frame On re assembly Note Ensure the mylar shield is in front of the pick assembly before...

Page 103: ...inner and the outer 9 Gently pull out on the outer bushing s locking tab to free it from the chassis Rotate the bushing 90o counter clockwise and remove it 10 Gently free the locking tab on the inner white plastic bushing from the vlack housing and rotate it 90o clockwise towards the bottom of the printer until the tabs can slide through the slot in the housing 11 Flex the shaft and slide the whit...

Page 104: ...ect from light 6 3 3 2 Remove the Top Cover 6 4 1 3 Remove the Rear Cover 6 4 3 4 Remove the LVPS and LVPS Cover 6 4 7a 5 Remove the LVPS inner cover by lifting it out of the printer it is not held by screws 6 Remove the 1 screw securing the solenoid to the base 7 Disconnect the harness CN25 from the main board and remove the solenoid ...

Page 105: ... 6 Remove the DEVE Cover Door A 6 4 15 7 Remove the Laser Cover 6 4 15 1 8 Remove the DEVE Drive Assembly 6 4 11 9 Remove the Erase Lamp 6 4 14 10 Remove the Waste Toner Auger Assembly 6 4 18 11 Remove the Main Drive 12 Remove all 7 base screws 1 3 8 black and 6 4 10 silver and gently lift the rear right of the frame enough to feed the harness between the base and the frame 13 Remove 3 screws secu...

Page 106: ...e roller off the shaft using a small flat blade screwdriver On re assembly 1 When replacing the roller onto the shaft depress the 2 white rollers one behind and one below to allow clearance for the black roller 2 Wedge a small screwdriver behind the large white gear to prevent the shaft from moving when reinstalling the roller 3 Be careful not to damage the clear plastic paper guide It should fit ...

Page 107: ...ful not to lose the white bushing and black plastic washer when removing the bracket 4 This roller is a press fit roller so gently work the roller off the shaft using a small flat blade screwdriver Be careful not to lose the black plastic washer behind the roller On re assembly Note When replacing the roller onto the shaft depress the white roller behind the mid roller to allow clearance for the b...

Page 108: ...crews type securing the laser cover and slide it out of the way 7 Remove the single screw and the erase lamp cover 8 Disconnect CN33 wiring harness from the main board and free the harness 9 Remove the tape securing the wiring to the metal chassis frame 10 Free the wiring through the middle of the printer 11 Remove the sensor On re assembly Caution Pay attention to the wire routing Be careful not ...

Page 109: ...Cover Base 6 4 5 and 6 4 5 1 5 Remove the LVPS and LVPS Cover 6 4 7 6 Remove the Main Drive Assembly 6 4 9 7 Disconnect CN19 wiring harness from the main board 8 Remove the 1 screw securing the sensor to the front frame 9 Feed the harness through the channel and remove the sensor from the front frame On re assembly Caution Be careful not to pinch or damage the wiring when reinstalling the main dri...

Page 110: ...Disassembly 6 54 6 4 29 500 Sheet Feeder PL 9 1 44 1 Turn the printer off and remove all cables 2 Using 2 people lift the printer off the 500 Sheet Feeder Tray 2 Sensor Contacts Door D Front ...

Page 111: ...Paper path 7 Maintenance and Diagnostics DEV Black DEV Yellow Pick up Roller DEV Magenta DEV Cyan CASSETTE Feeder DUPLEX FuserUnit EXITAss y MPF Path DuplexPath DuplexPath M P F M P T DEV Black DEV Yellow Imaging Unit Imaging Unit DEV Magenta DEV Cyan SCF Tray 2 Tray 1 Transfer Belt Transfer Belt Feeder DUPLEX FuserUnit EXITUnit SCF Path Transfer Roller Exit Sensor Paper Pick Up Roller Paper Empty...

Page 112: ...d sensor the feed sensor doesn t turn off fails to detect the trailing edge of the paper in time After the leading edge of the paper has passed the feed sensor it doesn t reach the exit sensor in time Exit sensor is faulty and does not detect paper 3 Jam at B C Jam in exit area After the leading edge of the paper has passed the exit sensor the trailing edge of the paper has not passed the exit sen...

Page 113: ...y ejected to the exit tray If the duplex solenoid is operating properly paper is fed back into the printer If the leading edge of the paper does not reach the feed sensor in time then a Jam at C is displayed on the control panel This can be cause by paper being jammed in the duplex path area 5 Jam at MPT Paper could not be picked from the MPT After picking the paper paper feeds but doesn t reach t...

Page 114: ...ling the paper backwards can damage clutches in the printer If at all possible remove the paper as a single sheet If the paper tears ensure ALL paper fragments are removed Any fragments left inside the machine can cause it to jam again 7 2 1 Factors that Cause Paper to Jam Unsupported media is used Too much paper is loaded in the tray Paper is not loaded correctly in the tray Duplex cover opened w...

Page 115: ...you see Demo Page 4 Press the OK button A demo page prints out 7 3 2 Printing a Configuration Page Print a configuration page to make sure that the printer is operating correctly 1 Press the Menu button on the control panel until you see Information on the display 2 Press the OK button 3 Press the Scroll button until you see Configuration Page 4 Press the OK button A configuration page prints out ...

Page 116: ... Ready mode press the Menu button on the control panel until you see Maintenance then press OK 2 Press the Scroll button to access the Check Others menu then press OK 3 Press the Scroll button until the item you want to check displays 4 Press the OK button the display will give you the results for the item you selected 5 Pressing the Scroll button displays either Image Count or Reset 6 Choose Rese...

Page 117: ... to off line Offline The printer is off line If you press On Line Continue the printer switches to on line Processing The printer is printing If you want to cancel printing press Cancel Power Saver The printer is in power saver mode using less power When a print job is received or any button is pressed the printer will switch on line and return to Ready Use the control panel to change the power sa...

Page 118: ...cannot print The printer is in power saver mode When data is received it switches to on line Orange On The printer stops printing due to an error Check the display message Blinking A minor error has occured and the printer is waiting for the error to be cleared Check the display message When the problem is cleared the printer resumes printing To ignore errors of this type press this button Press M...

Page 119: ... Color All Color Page Cyan Solid Magenta Solid Yellow Solid Black Solid Configure TCP Enable AppleTalk Reset Network Reset Defaults Off Long Edge Short Edge CMYK Default Manual Adjust 30 Minutes 45 Minutes 60 Minutes 120 Minutes Imaging Unit Transfer Belt Fuser Transfer Roll MPT Roller Tray 1 Roller Tray 2 Roller Top Margin Left Margin Short Binding Long Binding Off Auto Run Now Yellow Magenta Cya...

Page 120: ...ts A damaged imaging unit drum caused by over exposure to light may recover after 24 hours Part Defective Image Typical Defect Imaging Unit Drum same position on each page White spot on black image or black spots Imaging Unit Charge Roller 44 mm Black spots Toner Supply Roller 17 mm Light or dark horizontal banding Toner Developer Roller 29 mm Horizontal image band Transfer Belt T1 Roller 39 mm Bl...

Page 121: ...hen Press access key is displayed press the Cancel key twice e You are now in EDC mode NOTE There are a number of other test modes Only EDC Test and Panel Tests should be used by service technicians all other functions are for factory use only 7 6 1 2 Functions of the Buttons While in EDC Mode 7 6 1 3 LCD Functions and Directions Upper line messages mainly show the current test menu or sub menu it...

Page 122: ...PT Pick up Tray 1 Pick up Tray 2 Pick up Transfer Roller LSU FUSER TEST LSU Test Laser Diode Fuser SOLENOID TEST Y Clutch M Clutch C Clutch K Clutch Y Solenoid M Solenoid C Solenoid K Solenoid Feed Clutch T2 Clutch Transfer Roller ITB Clutch Transfer Belt Duplex Solenoid Tray 1 Clutch MPT Clutch Tray 2 Clutch SENSOR TEST Feed Sensor Exit Sensor Waste Box Sensor Side Cover Tray 1 Empty Sensor MPT S...

Page 123: ...est d Press the OK button to run the test The test is stopped by pressing the Back button e Pressing the Back button when the test is already stopped will return to Step C above f Pressing the Back button again will return to the EDC main menu Menu Item Description Test Results Main Motor Operates main motor Success or Failed Dev Motor Operates the developer motor Success or Failed Fan Motor Opera...

Page 124: ...or Off M Clutch Operates the magenta developer clutch On or Off C Clutch Operates the cyan developer clutch On or Off K Clutch Operates the black developer clutch On or Off Y Solenoid Operates the yellow developer solenoid On or off M Solenoid Operates the magenta developer solenoid On or Off C Solenoid Operates the cyan developer solenoid On or Off K Solenoid Operates the black developer solenoid...

Page 125: ...n menu Menu Item Description Test Results Feed Sensor Displays feed sensor status With Paper or Without Paper Exit Sensor Displays exit sensor status With Paper or Without Paper Waste Box Sensor Displays waste toner cartridge sensor Not installed when full or not installed Installed when empty or installed Side Cover Left or right cover sensor status Cover opened or Cover closed is dispayed Tray 1...

Page 126: ...e OK button e Press the Scroll button select a tray f Press the OK button g Press the Scroll button until you see Select Pattern is displayed h Press the OK button i Press the Scroll button to select the pattern either or j Press the OK button k Press the Scroll button until you see Print Pattern is displayed l Press the OK button to print m Pressing the Back button twice will return to the EDC ma...

Page 127: ...ressing the Back button again will return to the EDC main menu The allowed tolerance is commonly 3 this is the value displayed For Dev AC it is the value of Vpp T2 reverse biase tolerance of 20 Warning HIGH VOLTAGE Do not probe these voltages to confirm output Follow the troubleshooting procedures in Section 8 to isolate problems to the HVPS board The DPT test is not for service use factory use on...

Page 128: ...s on Regi Set Always identify the lead edge of the paper This will be your reference point Always check the same area on the page as your reference point From the lead edge of the printed page the left lower corner is the best place to monitor your adjustment This process will only adjust the colors across the long edge there is no adjustment for short edge A negative adjustment will move away fro...

Page 129: ...nction c Use the Scroll button to move through the menu items Off turns TRC off Auto is the default setting Run Now will perform on the next print a color measurement and adjust according to the TRC d Press the OK button to select this function e From the main menu in customer mode go to Color then Custom Color f Press the OK button to select this function g Press OK again to select CMYK h Use the...

Page 130: ...Maintenance and Diagnostics 7 20 ...

Page 131: ...nter obtain a detailed description of the problem from the customer 8 Troubleshooting Control Panel ON See 8 1 1 Basic Check List Print Print quality is normal END Ready or Power Saver Indicate Error Message Power On No Power Control Panel Main Board See 8 5 Error Message See 8 2 Print Quality Troubleshooting ...

Page 132: ...control panel wiring harness c Is there an error message on the control panel Refer to section 8 4 or 8 5 3 Check the paper path a Is there a Paper Jam Remove any paper fragments caught in the paper path Refer to section 8 3 b Paper Jam occurs repeatedly at a specific point in the paper path Check the printers internal paper path and inspect the region where the jam occurs Check for paper fragment...

Page 133: ...unding area are within specification If necessary move the printer c Ensure that the printer is positioned away from any air conditioning or other heating or cooling equipment Also ensure that it is not positioned in a direct draft from any air conditioning fan or open window If necessary move the printer d Ensure the printer is not positioned in direct sunlight If it is unavoidable use a curtain ...

Page 134: ...erate even at their end of life but should be replaced as soon as possible to avoid print quality issues Note All consumable life counts are reset to zero automatically after being replaced with the exception of the fuser and transfer roller These must be reset through the control panel The printer calculates the working time and quantity of output for each component and saves this information ...

Page 135: ...ransfer belt contacts are dirty or not making good contact or there is a faulty transfer belt Check and clean the transfer belt contacts Re seat the transfer belt Replace the transfer belt Laser cable harness plugs not seated properly or faulty laser unit Verify the connectors on the laser unit and main board are properly seated CN12 Replace the laser unit or harness as required Toner transfer pro...

Page 136: ...s contaminated Run the fuser cleaning page up to 5 times Replace the fuser Are the spots a repeating defect See the topic Evenly repeating defect Example Possible Cause Sequence of Repair Actions Paper path is contaminated Open covers fully and clean the paper path Transfer belt is contaminated Clean or replace the transfer belt Pressure roller in the fuser is contaminated Run the fuser cleaning p...

Page 137: ... Cause Sequence of Repair Actions Developing process is contaminated Replace the toner cartridge Replace the imaging unit Transfer belt is damaged or dirty Clean or replace the transfer belt Fuser is damaged or dirty Run the fuser cleaning page up to 5 times Replace the fuser if necessary Cover glass on the laser unit is damaged or dirty Clean the cover glass on the laser unit Replace the laser if...

Page 138: ...e roller comes properly into contact when the solenoid operates Example Possible Cause Sequence of Repair Actions The toner cartridge for the problem color is low or at it s end of life Check the life of the toner cartridge Replace if necessary The toner cartridge sensor is bad Check or replace the toner cartridge The paper path is blocked or damaged Check for the correct positioning of the paper ...

Page 139: ...plex printing Replace the duplex unit Example Possible Cause Sequence of Repair Actions Check the distance of the repeating defect to the corresponding unit Refer to the table in section 7 5 of this manual and replace the corresponding unit if necessary Is the defect is within 1 2 mm Replace the laser Is the defect in an irregular pattern Replace the imaging unit Example Possible Cause Sequence of...

Page 140: ...k the feed clutch and tray clutch pick solenoid in EDC mode Replace any defective parts Check if the friction pad is loose or missing in the tray Replace the tray Check the surface of the pick roller Is it dirty or damaged Clean or replace the pick roller Check the feed sensor in EDC mode when the paper feeds into the printer Replace the actuator sensor or main board Possible Cause Repair Actions ...

Page 141: ...erly Check for debris or caught wiring The paper is wrapped in the fuser Accordion jams occur Fuser temperature may increase If the heat roller or pressure roller may get contaminated by toner Replace the fuser There are accordion type ripples inside the fuser Replace the fuser Check the condition and operation of the exit assembly and replace as necessary Check the exit sensor in EDC mode Replace...

Page 142: ...the friction pad or replace the tray The paper is curled Use approved fresh clean paper The paper guides are not adjusted or the paper is loaded on top of the tabs Adjust the paper guide and load paper under the tabs The paper is charged with static electricity Remove the static electricity before loading the paper Checks and Causes Repair Actions The heat roller is contaminated Background toner H...

Page 143: ... and Causes Repair Actions Check the continuity of the thermostat AC wire and heat lamp Check the continuity of the thermistor and thermistor harness contacts Replace the fuser if any of these circuits are open Check the fuser for any evidence of damage due to overheating or melting Replace the fuser Checks and Causes Repair Actions Check the laser connetor CN12 to the main board Reseat the connec...

Page 144: ... and Causes Repair Actions Check for a broken or distorted paper empty sensor actuator Check that the actuator is not stuck Replace the paper empty sensor actuator Test the tray empty sensor and actuator in EDC mode Replace any defective part as necessary Check the sensor connectors and cable harness Ensure that a signal reaches the main board Replace the harness Checks and Causes Repair Actions C...

Page 145: ...ch as necessary Test the cover open actuator and switch in EDC mode Replace any defective parts If the error recurs replace the main board Checks and Causes Repair Actions Check if the motor harness CN27 or motor board is damaged Replace the motor or motor harness Test the motor using EDC mode Replace the main motor if defective If the error recurs replace the main board Checks and Causes Repair A...

Page 146: ...N12 and the laser Replace the laser Replace the main board Checks and Causes Repair Actions If 10 or less toner remains in any of the cartridges this message will be displayed Check the toners percent remaining using the control panel If the toner is low or empty replace toner cartridge Check the condition of the contacts on the DEVE_OEM Board Replace the DEVE OEM board Replace the main board Chec...

Page 147: ... fault increased torque in any one of the toner cartridges due to rollers sticking a power supply fault or a fault on the main board 1 Open the DEVE Cover and check each toner cartridge to ensure the rollers rotate Turn the rollers by hand and check how difficult it is to rotate the rollers Replace the toner cartridge if it seems excessively tight 2 Open the rear cover and check if the DEVE motor ...

Page 148: ... board 6 Replace the LVPS Fuser Error High Temperature The temperature of the fuser is higher than the printing temperature 1 Replace the fuser Caution You must replace the complete fuser assembly if a Fuser Error High Temp has occurred Do not replace the thermistor 2 Check the harness connected to the LVPS CN2 and fuser Reseat the harness or replace if defective 3 Replace the main board 4 Replace...

Page 149: ...ace the waste toner cartridge and unblock waste inlet feeds 2 Open the top cover and remove the transfer unit and imaging unit to see if the imaging unit waste toner outlet is blocked 3 Remove the front cover and check the waste motor harness CN2 DEVE_OEM to waste motor Reseat or replace if defective 4 Remove the HVPS cover and check the HVPS OEM harness CN2 to DEVE_OEM CN1 Reseat or replace if de...

Page 150: ...OEM resistor in the transfer belt 1 Open the top cover and then check that it is correctly locked in position Remove re install and re lock the transfer belt 2 Replace the transfer belt 3 If the fault continues after re seating the transfer belt check the voltage on Pin4 of CN10 on the main board Replace the harness if the voltage is not correct 4 Replace the main board Invalid Color Toner This is...

Page 151: ...e tray and after removing any trapped paper ensure that the tray is properly loaded not overfilled and that the guides are properly adjusted 3 Check the feed sensor actuator for proper operation or defects 4 Check the tray clutch pickup solenoid using EDC mode Replace if defective 5 If the error recurs check the condition of the cable harness to the main board 6 Replace the main board if the volta...

Page 152: ... actuator if damaged or defective 4 If the fault continues refer to section 8 3 3 for additional troubleshooting Load Manual Press Cont Key This is only displayed when printing in manual feed mode and the MPT tray is empty 1 Load a sheet of media into the MPT and press the On line continue button The button needs to be pressed for each page that needs to be printed Load Size in Tray The size of th...

Page 153: ...lict IP address confilict with the address of another device on the network 1 This only occurs when the optional network interface card is connected and an IP address conflict is detected Change the IP address Install Imaging Unit This occurs when the imaging unit is not correctly installed or seated properly 1 Verify the imaging unit is properly installed 2 Replace the imaging unit 3 Check the im...

Page 154: ...r Tray 2 is not installed properly 1 Turn off the printer and re insert Tray 2 Cover D Open Tray 2 cover is open 1 Open and close the Tray 2 cover properly 2 If the fault continues refer to section 8 3 6 for additional troubleshooting Waste Cartridge Full Not Installed Waste toner cartridge is full or not installed 1 Check the waste toner cartridge for proper installation 2 If it is full replace t...

Page 155: ... Assembly 9 8 Main Drive Assembly 9 9 Fuser Assembly 9 10 Paper Tray Tray 1 FCT 9 11 Paper Tray Tray 2 SCT 9 12 Optional 500 Sheet Feeder SCF 9 13 Main Frame 9 14 Front Frame Assembly 9 15 Rear Frame Assembly 9 16 Base Frame Assembly 9 17 MPT Assembly 9 18 Pickup Assembly 9 19 Feeder Assembly 9 20 Paper Guide Assembly 9 21 Transfer Belt Cam Assembly 9 22 Fuser Base Assembly 9 23 Xerox Kits and Acc...

Page 156: ...igh capacity 2 000 5 000 106R00678 106R00682 User replaceable Magenta Standard Toner Cartridge Magenta High capacity 2 000 5 000 106R00677 106R00681 User replaceable Imaging Unit 50 000 images 108R00593 User replaceable Transfer Belt 50 000 images 108R00594 User replaceable 500 Sheet Feeder N A 119650600 Waste Toner Cartridge 3 000 to 5 000 pages color 5 106R00683 User replaceable The Fuser and Tr...

Page 157: ...LD S7 SCREW TAPTITE 3 6 GOLD S8 SCREW TAPTITE 3 10 SILVER S9 SCREW TAPTITE 3 6 GOLD S10 SCREW ASS Y MACH 3 6 GOLD NO DESCRIPTION SPEC S11 SCREW TAPTITE 3 6 GOLD S12 SCREW TAPTITE 3 8 BLACK S13 SCREW MACHINE 3 8 SILVER S14 SCREW TAPTITE 4 10 SILVER S15 SCREW TAPTITE 3 6 GOLD S16 SCREW MACHINE 2 16 BLACK S17 SCREW TAPTITE 4 6 YELLOW S18 SCREW SPICIAL 3 10 BLACK S19 SCREW TAPTITE 4 6 SILVER S20 SCREW...

Page 158: ...56 1 56 2 S8 56 54 27 45 20 3 1 2 6 5 4 36 15 35 57 57 1 14 7 13 26 22 38 22 39 8 21 9 33 25 30 11 16 2 16 3 16 1 S8 19 2 S9 19 41 55 37 47 48 44 19 1 19 3 16 23 40 16 4 28 31 29 32 43 1 43 2 10 43 46 42 24 58 18 51 52 49 49 3 49 3 49 1 49 5 49 2 49 4 ...

Page 159: ...le Spare 10 116 1852 00 1 Main Controller Board 11 1 Main Frame 12 116 1853 00 1 Exit ASM 13 116 1928 00 1 Duplex ASM 14 116 1854 00 1 Paper Tray Tray 1 FCT 15 1 Front Cover 16 116 1855 00 1 Rear Cover ASM 16 1 1 Cover Rear 16 2 1 Cover Rear Deco 16 3 1 Cover Open Board 16 4 1 Label P Rear 16 S8 1 Screw 17 116 1856 00 1 Top Cover ASM 18 116 1857 00 1 DEVE Cover ASM 19 116 1859 00 116 1858 00 1 1 L...

Page 160: ...1 Shaft Laser Cleaner 49 3 1 E Ring Laser Cleaner 49 4 1 Plate Link Rear 49 5 1 Plate Link Front 50 1 DEVE Open Link 51 1 DEVE Open Link Guide 52 116 1865 00 1 Cover LSU Laser Cover 53 116 1885 00 1 Terminals 54 116 1566 00 1 Transfer Roller T2 Customer Replaceable Spare 55 1 Bracket LVPS SMPS Cover 56 1 Fuser Unit Duct 56 1 1 Fuser Duct Lower 56 2 1 Fuser Duct Upper 56 S8 1 Screw Taptite 57 1 Was...

Page 161: ...38 00 1 Front Cover Deco 9 116 1869 00 1 Front Cover Inner 10 116 1870 00 1 Front Cover 11 116 1871 00 2 Front Cover Latch 12 1 Cover OPE Frame 13 1 OPE Key 1 14 1 OPE Key 1 Cap 15 1 OPE Key 2 16 1 OPE Key 2 Cap 17 1 Label P Front Inner 18 1 Sub Panel Board 19 333 4414 00 1 Front Panel Assembly Control Panel S4 P O Screw Kit 2 Screw Taptite S5 P O Screw Kit 6 Screw Taptite S8 P O Screw Kit 4 Screw...

Page 162: ...Name and part description 0 116 1856 00 1 Top Cover ASM 1 1 Cover Top 2 1 Spring CS 3 1 Cover Top Button 5 2 Cover Top Opener 6 2 Cover Top Stacker 7 1 Stopper Stacker F 8 1 Stopper Stacker R 9 1 Lavel P Top S15 P O Screw Kit 2 Screw Taptite 6 5 3 0 2 9 1 7 S15 8 S15 4 ...

Page 163: ...EVE Cover ASM Door A 1 1 Spring TS 2 1 Cover DEV Lock Bar 3 1 Label P DEVE Cover 4 1 Cover Dup Locker F 5 1 Cover Dup Locker R 6 1 Cover DEVE 7 1 Cover DEVE Inner 8 8 Cover DEV Spring CAp 9 1 Cover DEVE Hinge 10 1 Cover Duplex Handle 11 8 Spring CS 12 1 DEVE Open Link S14 P O Screw Kit 10 Screw taptite 4 0 2 6 12 S14 S14 3 7 9 1 10 5 11 8 18 ...

Page 164: ...t Lock Cover 3 1 Cover Exit Bar 4 1 Cover Dup Locker F 5 1 Cover Dup Locker R 6 2 Spring TS 7 1 Cover Exit Guide 8 1 Cover Exit F Cap 0 5 6 2 4 6 1 7 8 10 9 13 12 3 S8 S19 S8 11 10 11 S8 11 11 8 11 9 11 21 11 1 11 4 11 S8 S8 11 13 11 14 11 15 11 16 11 19 11 20 11 S8 11 20 1 11 20 2 11 18 11 12 11 11 11 17 11 22 11 5 11 2 11 2 1 11 3 11 7 11 6 S19 S14 ...

Page 165: ...tistatic 11 11 1 Holder Ground Ball 11 12 1 Guide Exit Lower 11 13 4 Roller FD F 11 14 4 Roller FD R 11 15 4 Holder Exit 11 16 4 Spring ETC Exit Lower Idle 11 17 1 Roller Exit Idle 11 18 2 Roller Exit F_up 11 19 1 Ground Exit Plate 11 20 2 Unit Terminal L 11 20 1 1 Spring ETC HV Small 11 20 2 1 Shaft HV Large 11 21 3 Spring ETC Clutch 11 22 1 Sheet Exit Upper 11 S8 4 Screw Taptite 12 1 Label P Exi...

Page 166: ... 2 11 2 29 2 22 2 20 2 2 15 2 16 2 16 31 32 2 14 2 15 2 24 2 25 2 23 2 12 2 27 2 12 5 2 13 1 0 2 12 7 2 12 4 2 12 3 2 12 4 2 12 1 2 12 2 2 18 2 17 2 30 2 18 2 30 2 17 S8 S5 S8 S8 S8 2 12 8 2 12 6 1 9 1 10 1 8 S8 S8 1 1 1 7 1 5 1 4 1 3 1 12 1 12 2 1 12 1 1 12 2 1 12 5 1 12 3 1 12 6 1 12 7 1 12 4 1 2 1 6 1 11 1 11 ...

Page 167: ...PT 1 12 3 1 Guide Latch 1 12 4 1 Tray Cover MPT 1 12 5 1 Side Guide MPT 1 12 6 1 Tray Exit MPT 1 12 7 1 Label R Height MPT 2 116 1878 00 1 Duplex Unit 2 1 1 Bracket Guide A 2 2 1 Holder Saw 2 3 1 Plate Saw 2 4 1 Frame Duplex 2 5 2 Pulley Belt 2 6 1 Belt Timing 2 7 2 Gear Duplex Idler_Z25 2 8 1 Cover Belt 2 9 1 Bracket Ground TR 2 10 2 Spring ES 2 11 1 Gear MPT Dup Drive 2 12 1 Unit T2_Assy 2 12 1 ...

Page 168: ...Ground A 2 23 1 Bracket Ground D 2 24 1 Bracket Ground C 2 25 1 CBF Harness Control Panel Ground OPE 2 26 1 Bushing Feed 2 27 1 Guide Lower Duplex 2 28 P O Hardware Kit 1 Ring CS 2 29 1 Guide Feed 2 30 1 Poly Washer S5 P O Screw Kit 19 Screw Taptite S8 P O Screw Kit 19 Screw Taptite No Part number Qty Part Name and part description ...

Page 169: ... Drive ASM 1 1 Bracket DEVE Front 2 4 Clutch Spring DEVE 3 4 Shaft DEVE Clutch 4 12 Bushing D6 L4 5 P O Hardware Kit 12 E ring 6 4 Shaft DEVE Drive 7 4 Washer plain 8 4 Gear DEVE DRive 2_Z20 9 1 Gear Idle Z51 10 1 Harness Guide 11 1 Gear ITB Clean RDCN 12 1 Gear DEVE RDCN 9 11 13 13 18 1 5 8 17 10 12 13 0 7 14 6 3 2 4 4 15 19 5 4 20 5 16 S17 S11 18 ...

Page 170: ...E Idle_Z53 15 1 Bracket DEVE Rear 16 116 1880 00 1 Motor BLDC DEVE DEVE Motor 17 4 Washer Plain 18 12 PIN ADF 19 4 Gear DEVE Drive 1_Z25 20 4 Gear DEVE Clutch 2_Z33 S11 4 Screw Taptite S17 5 Screw Taptite No Part number Qty Part Name and part description ...

Page 171: ... Main Drive Main Motor 2 1 Duplex Solenoid 3 116 1934 00 1 Clutch Cam Solenoid 4 1 Clutch Electric Feed 5 3 Busing 8 5 6 6 Bushing D6 L4 7 P O Hardware Kit 1 Spring ETC Solenoid DP 8 1 Gear Feed Drive_Z37 9 1 Gear Fuser Drive 1_Z47 10 1 Gear Fuser Drive 2_Z30 28 38 16 33 9 4 11 12 12 17 18 12 31 32 3 6 29 22 23 25 24 10 20 14 8 35 37 15 13 26 42 42 21 5 2 36 30 27 19 7 0 1 S17 S11 S11 ...

Page 172: ...d Drive 22 1 Shaft Fuser Drive 23 1 Shaft ITB Transfer Belt Drive 24 1 Shaft OPC Imaging Unit Drive 25 1 Shaft T2 Cam 26 1 Shaft T2 Drive 27 1 Gear Exit U ID 28 1 Bracket Main Front 29 1 Bracket Main Rear 30 1 Link Solenoid 31 1 Hub Clutch 32 1 Clutch 33 3 Washer Plain 34 3 Washer Plain 35 3 Washer Plain 36 P O Hardware Kit 1 C Ring 37 1 E Ring 38 2 ICT PIN ADF S11 P O Screw Kit 6 Screw Taptite S1...

Page 173: ...mbly 1 2 Roller Heat 2 2 Bearing Fuser F 3 2 Bearing Fuser Gear 4 2 Gear Fuser Z35 5 2 Spring ETC PR 6 1 Fuser Upper 7 1 Fuser Lower 8 1 Ground Fuser 9 1 NPR Electrode AC Wire 12 2 Thermostat 13 1 NPR Electrode F 14 1 NPR Electrode PR 15 1 NPR Electrode AC Plate 21 27 23 2 0 5 8 6 5 7 12 15 28 22 28 S10 S2 S2 9 25 24 14 16 20 34 34 26 30 1 3 4 18 19 17 34 34 13 S10 12 29 31 35 33 32 ...

Page 174: ...en Lamp 300w 110V 220V 23 1 Halogen Lamp 500W 110V 220V 24 1 Actuator Exit 25 1 Spring ETC Actuator 26 1 Guide Output 27 1 Thermistor NTC 28 4 Nut Hexagon 30 1 Guide Input 31 1 Label P Fuser 110V 220V 32 1 CBF Harness Fuser 33 1 Frame Drawer Connector 34 4 Cover Dime Screw 35 2 Screw Taptite S10 P O Screw Kit 10 Screw Assembly Machine S8 P O Screw Kit 13 Screw Taptite No Part number Qty Part Name ...

Page 175: ...ray Tray 1 FCT 1 1 Frame Cassette 2 1 Cover Cassette 3 1 Guide Side CST 4 1 Guide Front CST 5 1 Guide Rear 6 1 Plate K UP 7 1 Finger 8 1 Spring Plate Guide 9 1 Guide Plate Paper 10 2 Spring 11 1 Spring Locker 12 1 Locker Plate 13 2 RPR Pad CST 14 1 Label R Height Xerox 15 1 Label P Instruction S8 P O Screw Kit 2 Screw_Taptite 8 0 3 15 9 7 4 1 2 12 S8 14 5 11 13 10 6 ...

Page 176: ... Cover Cassette 3 1 Guide Side CST 4 1 Guide Front CST 5 1 Guide Rear 6 1 Plate K UP 7 1 Finger 8 1 Spring Plate Guide 9 1 Guide Plate Paper 10 4 Spring CS 11 1 Spring Locker Plate 12 1 Locker Plate 14 1 Side Guide 15 2 RPR Pad CST 16 1 Label P Instruction 17 1 Label R Height CST 18 1 Label P LTR A4 19 1 Label P Load CST S8 4 Screw_Taptite 14 15 8 10 0 3 17 18 9 7 11 4 6 1 2 12 S8 S8 16 5 ...

Page 177: ...and part description 0 119 6506 00 1 500 Sheet Feeder 1 1 HOU Motor 1 1 1 Ground_Roller 1 2 P O Hardware Kit 4 E ring 11 3 0 1 6 S8 S5 S8 S8 S8 S8 S8 S9 S8 S5 S5 9 12 S5 4 6 10 7 5 2 9 19 17 16 8 14 3 3 1 4 1 S9 1 3 1 2 2 1 2 5 2 6 2 7 2 3 2 4 2 2 2 8 2 S9 1 1 1 9 3 1 3 4 3 8 3 12 3 11 3 8 3 10 3 6 3 5 3 9 3 13 3 7 3 8 3 2 1 5 1 8 1 6 1 7 ...

Page 178: ... Label P Jam S5 4 Screw Taptite 3 1 HOU Guide Upper SCF 3 1 1 E ring 3 2 1 Spring Pickup 3 3 1 Gear Pickup 3 4 1 Gear Feed 3 5 1 Actuator Empty 3 6 1 Shaft Pickup 3 7 1 Guide Upper 3 8 4 Bearing Shaft 3 9 1 Bushing P U MPT 3 10 2 Rubber Pickup 3 11 1 Roller Feed 3 12 1 Board Sub SCF Cover Sensor 3 13 1 Board Sub SCF P_Empty Sensor 4 2 Foot ML80 5 1 Cam Catch 6 1 Plate Ground A 7 1 Plate Locker L 8...

Page 179: ...List Service Manual 9 25 16 1 Harness Driver Ground 17 1 Harness SCF_8P 18 1 Board SUB SCF S5 P O Screw Kit 8 Screw Taptite S8 P O Screw Kit 26 Screw Taptite No Part number Qty Part Name and part description ...

Page 180: ...18 27 25 28 5 2 5 3 5 1 3 3 3 6 3 7 3 2 3 1 11 10 24 9 12 2 31 3 5 3 4 1 1 18 1 3 1 17 1 10 1 14 1 15 1 20 1 11 1 4 1 8 1 3 1 5 1 13 1 19 1 16 1 12 1 7 1 6 1 9 1 1 2 1 1 3 S1 1 1 4 1 1 1 1 1 1 1 5 1 2 13 17 3 17 7 17 8 17 9 17 4 17 1 17 2 17 5 17 16 17 6 19 20 32 ...

Page 181: ...1 Duct M Waste Lifter 1 11 1 Duct M Waste Toner Inlet 1 1 12 1 Duct M Waste Toner Inlet 2 1 13 1 Pipe Waste Transfer 1 14 1 Sponge Waste Lifter 1 1 15 1 Sponge Waste Lifter 2 1 16 1 Sponge Waste Duct OPC 1 17 1 Sponge Waste Cover 1 18 116 1957 00 1 E Ring also in hardware kit 1 19 1 Spring CS 1 20 2 Spring CS 1 S8 6 Screw Taptite 2 1 Holder Eraser 3 1 LSU Guide Bracket 3 1 1 Bracket LSU 3 2 1 LSU ...

Page 182: ...ptite 17 S8 P O Screw Kit 1 Screw Taptite 18 2 Spring Clutch 19 116 1949 00 1 CBF Harness Waste Motor 20 116 1866 00 1 SUB DEVE Drive Board 21 1 Harness Main FSR Roll 22 116 1941 00 1 CBF Harness Main Eraser 23 1 Ground Fuser Frame 24 1 Sheet Eraser Lamp 25 1 Gear Fuser DRV Outer 26 1 Gear DP Idle 27 2 Gear Exit Idle Z17 28 1 Ground Paper Guide 29 1 Cover Fuser Base 30 1 Cover Harness Fuser 31 1 L...

Page 183: ...t Name and part description 0 1 Frame Front 1 116 1879 00 1 Waste Toner Sensor 1 1 P O Hardware Kit 1 Ring CS 1 2 1 Holder M Waste Toner Sensor 11 14 6 38 33 4 31 10 12 25 26 8 4 30 36 3 22 17 1 18 21 13 19 7 9 27 37 39 24 2 2 1 2 2 3 3 3 2 3 4 3 6 3 7 3 5 3 5 3 1 2 3 1 1 1 2 1 4 1 3 16 20 29 28 23 34 15 5 ...

Page 184: ... 8 116 1885 00 12 Terminals 9 1 Ground HVPS Laser 10 1 Link Lock OPC F 11 1 Lever Transfer Belt Lock Front 12 1 Label R Color Bar 13 1 Harness Bushing Ground 14 1 Bracket Guide HVPS R 15 1 Bracket Exit Hinge F 16 1 Transfer Belt Hinge Ground 17 1 Transfer Belt Guide Tortion 18 1 OPC Guide Tortion 19 1 OPC Transfer Belt Bround 20 1 OPC Lock Front 21 1 OPC Laser Ground 22 1 Shutter Tortion 23 1 Fram...

Page 185: ...ual 9 31 38 1 Spring Transfer Belt Lock ITB 39 1 Spring Toner Duct Housing S5 P O Screw Kit 6 Screw Taptite S7 P O Screw Kit 6 Screw Taptite S8 P O Screw Kit 26 Screw Taptite No Part number Qty Part Name and part description ...

Page 186: ...st 9 32 9 15 Rear Frame Assembly 36A S8 S8 S5 S8 1 28 25 10 3 34 23 24 12 12 1 15 31 18 33 9 S8 S8 21 11 32 20 26 29 S5 S8 S8 35 22 S5 6 36A 2 S5 19 4 34 36 12 1 S9 30 5 38 14 16 7 13 1 S8 S8 17 8 36A 36B 36B 1 ...

Page 187: ... 1 Gear T2 RDCN Z32 Z23 15 1 Lever Transfer Unit Lock Rear 16 1 Bracket Laser R 17 1 Bracket Guide HVPS F 18 1 Bracket Lock Transfer Belt 19 1 Bracket Exit Hinge R 20 1 Plate Fuser 21 1 Plate Lock Transfer Belt 22 1 Plate OPC HV 23 1 Plate T1 24 1 Plate T2 25 1 Ground HVPS 26 1 Ground Main 27 1 Frame Rear 28 1 Cover T1 HV 29 1 Cover T2 HV 30 1 Guide Lock Imaging Unit 31 1 Link Lock Imaging Unit 32...

Page 188: ...Parts List 9 34 9 16 Base Frame Assembly 16 15 14 23 13 6 12 8 3 3 7 4 5 19 10 9 20 18 22 17 1 2 24 25 26 11 21 ...

Page 189: ...rew Cover Locking Cap 9 1 Cover M Base Bar 10 1 Cam Catch 11 1 Gear Pickup 12 1 Bracket Base Bar 13 1 Channel Frame Base 14 1 Bracket DEVE Hinge F 15 1 Bracket DEVE Hinge R 16 1 Bracket Power 17 1 Sheet Guide Paper 18 1 Frame Base 19 1 Guide Tray 2 SCF Paper 20 1 Paper Guide 21 116 1959 00 1 Bearing 22 116 1892 00 1 Solenoid Pickup 23 116 1893 00 1 Temp Sensor 24 1 Washer Plain 25 1 Laser Harness ...

Page 190: ...Parts List 9 36 9 17 MPT Assembly 15 19 20 13 4 17 17 18 24 1 18 11 3 7 23 1 S5 6 2 S9 9 14 22 10 21 8 5 16 12 0 ...

Page 191: ...T 8 1 Roller Cam MPT 9 116 1895 00 1 Actuator MPT Empty 10 1 MPT Adjuster 11 1 MPT Cam Pickup 12 1 MPT Frame 13 1 MPT Holder Pad 14 1 MPT Holder Sensor 15 116 1945 00 1 PMO Housing Pickup MPT 16 116 1946 00 1 PMO Lift Plate MPT 17 2 MPT Idle Pickup 18 116 1947 00 2 Bushing 19 116 1948 00 1 Pick Roller MPT 20 1 Pad MPT PLUS 21 1 Pad Lift Up MPT 22 116 1896 00 1 MPT Empty Sensor 23 1 Gear P U MPT 24...

Page 192: ... Tray 1 Pickup ASM 1 1 Pickup Spring 2 1 Ground Feed 3 1 Guide Input 4 1 Cap Connector L 5 1 Cap Connector U 6 116 1897 00 1 Actuator Tray 1 Empty 7 1 Pickup Shaft 8 1 Guide Paper 9 116 1898 00 1 Tray 1 Empty Sensor 10 1 Bearing Shaft 11 116 1947 00 1 Bushing 12 116 1951 00 2 Pick Rollers Tray 1 7 1 5 12 11 2 0 8 3 6 4 10 9 ...

Page 193: ...number Qty Part Name and part description 0 1 Feed Unit 1 1 Holder Pinch C3 1 1 1 Holder Pinch C3 1 2 1 Roller Feed L 1 3 1 Feed Idler Shaft 1 0 5 S8 5 6 7 8 8 9 10 12 11 1 1 22 S8 S8 23 1 2 14 3 1 25 8 11 15 13 4 3 2 2 1 8 8 19 21 16 17 18 11 5 5 5 20 1 3 2 3 24 2 2 3 5 3 4 3 2 3 3 ...

Page 194: ...Bracket Feed Mid 8 6 Washer Plain 9 116 1890 00 1 Roller Feed Mid 10 1 Shaft Feed Mid 11 3 Bushing Pickup MPT 12 1 Ground Pickup Plate 13 116 1900 00 1 Roller Feed 14 1 Shaft Feed 15 1 Gear MPT DUP Drive 16 1 Pulley Feed L 17 1 Gelt Timing Gear 18 1 Gear Feed 19 1 Pulley Feed S 20 1 Bracket Feed 21 1 Pulley Idle 22 P O Hardware Kit 1 Ring CS 23 1 Spring Feed MID 24 1 Spring Feed MID A 25 1 Spring ...

Page 195: ...t Name and part description 0 1 Paper Guide 1 116 1901 00 1 Feed Sensor Cover 2 116 1902 00 1 Feed Sensor 3 116 1903 00 1 Feed Sensor Actuator 4 1 Paper Guide Bracket 5 116 1952 00 2 Sheet Paper Guide 6 116 1953 00 1 Guide Paper Path 7 1 Actuator Spring S9 P O Screw Kit 5 Screw Taptite 4 0 6 S9 3 7 1 2 5 5 ...

Page 196: ...Parts List 9 42 9 21 Transfer Belt Cam Assembly S18 9 0 8 S8 7 6 5 10 1 2 14 3 12 13 S8 11 4 ...

Page 197: ...Erase Lamp PTL 3 116 1905 00 1 PTL Path 4 1 Shaft Transfer Belt Cleaning Cam 5 1 Transfer Belt Cleaning Cam 6 1 Bushing D6 L4 7 P O Hardware Kit 1 E Ring 8 1 Transfer Belt Cam Upper 9 1 Harness Set Drawer 10 1 Cover Cam Shaft 11 1 Guide Erase Lamp Spring 12 P O Hardware Kit 1 Erase Lamp Spring 13 P O Hardware Kit 1 Ring CS 14 116 1955 00 1 Temp Sensor S9 P O Screw Kit 5 Screw Taptite S18 P O Screw...

Page 198: ... Fuser Base Assembly Fuser Base Assembly 9 22 No Part number Qty Part Name and part description 0 1 Fuser Base 1 1 Fuser Base 2 116 1907 00 1 Housing Switch AC 3 116 1906 00 1 Switch AC S8 P O Screw Kit 2 Screw 2 S8 1 3 0 ...

Page 199: ...Network Interface Board DN Model Only 116 1916 00 128 Mbytes 16M x 64 PC133 Memory DIMM Phaser 3540 Laser Printer 097S03136 World Kit 061450400 Printer Repackaging Kit 065062600 Description Part Number Cord Power Standard 115V 161 0066 00 Cord Power Euro 220V 161 0066 09 Cord Power UK 240V 161 0066 10 Cord Power Aust 240V 161 0066 11 Cord Power Swiss 220V 161 0154 00 Cord Power Danish 250V 161 024...

Page 200: ...Parts List 9 46 ...

Page 201: ...net DN Only 32bit LSU 8 16bit HVPS PWM c on trol For Engineering Use Only Analog MUX TEMP 2 EA Fusing Temp HVPS x 3 CTD OPC key Waste Toner Waste Auger Total 10 input 5pin UART UART 32bit 16bit 60MHz Parallel Port USB 2 0 Flas h Memory 2MB SDRAM 64MB Option Memory Mot ors SPGPm EEPROM LPEC1 Color ASIC ...

Page 202: ... n N P C_ I NT Flash Memory AM29LV160 2 2MB SDRAM K4S561632 2 64MB EEPROM 93C86L 2 KBytes SDRAM DIMM Option 32MB 64MB 128MB D 31 16 A 15 3 A 21 2 D 31 0 SA 12 0 SD 31 0 SD 31 0 SA 12 0 CS SK DI DO PD 7 0 nRD nWR nCS_LPEC nRESET Crystal 12 00M A 9 2 SPGPm ARM946ES Embedded Main Control Board nVDO OSC 19 9M Engine Control ASIC LPEC1 U S B FUSER Heater Thermostat Thermistor Erase Lamp Lower Erase Lam...

Page 203: ...Parallel Port IEEE 1284 Ethernet NPC Imaging Unit Erase Lamp Lower Erase Lamp Upper PTL CN1 CN1 Tray 2 Sensor Paper Empty Sensor MPT_Empty Sensor Feed Clutch Feed Solenoid Pick up Solenoid MPT Solenoid Duplex Sensor Exit Transfer Belt Sensor Waste Sensor Temp 1 Sensor Temp 2 CN25 CN3 CN2 CN4 CN9 CN6 CN13 CN13 CN8 CN11 CN12 CN26 CN16 CN21 CN31 CN33 CN23 CN32 CN24 CN19 CN10 CN17 CN15 Solenoid T2 hom...

Page 204: ...t Pin Signal Name Dir Pin Signal Name 1 AN_FUSER1_OUT 2 AN_FUSER1_OUT2 5 Main BD CN14 Switch Left cover Pin Sig nal Name Dir Pin Sig nal Name 1 5V 2 5VL 6 Main BD CN7 HVPS CN1 1 Pin Sig nal Name Dir Pin Sig nal Name 2 24VF 1 24V 4 AGND 3 GND 6 PWM_AC_VPP 5 AC_Vpp_PWM 8 PWM_T2 7 T2_PWM 10 PWM_CHARGE 9 CHARGE_PWM 12 ENB_DEVE_AC 11 DEV_REM_PWM 14 A_READ_T1 13 T1_READ 16 nWST_AGT 15 nWST_AGT 18 5VL 17...

Page 205: ...eve Cartridge 3rd Y Pin Signal Name Dir Pin Signal Name V7 SDA_CRUM V8 DGND V9 SCL3_CRUM 9 d Deve OEM Key Deve Cartridge 4tH K Pin Signal Name Dir Pin Signal Name V10 SDA_CRUM V11 DGND V12 SCL4_CRUM 10 Main BD CN5 Deve Drive CN1 Pin Signal Name Dir Pin Signal Name 1 AGND 2 AGND 2 24VF 1 24V 3 AGND 4 AGND 4 24VF 3 24V 5 AGND 6 AGND 6 24VF 5 24V 7 DGND 8 DGND 8 5V 7 5V 9 nSOL_DEVE_1ST 10 nSOL_DEVE_1...

Page 206: ... NC 3 AGND 13b Deve Drive CN4 Clutch Deve 2nd Pin Signal Name Dir Pin Signal Name 1 nCLT_DEV_2ND 2 NC 3 AGND 13c Deve Drive CN9 Clutch Deve 3rd Pin Signal Name Dir Pin Signal Name 1 nCLT_DEV_3RD 2 NC 3 AGND 13d Deve Drive CN5 Clutch Dev e 4th Pin Signal Name Dir Pin Signal Name 1 nCLT_DEV_4TH 2 NC 3 AGND 14 Deve Drive CN10 Solenoid T1 clean Pin Signal Name Dir Pin Signal Name 1 nSOL_T1_CLN 2 NC 3 ...

Page 207: ...nal Name Dir Pin Signal Name 19 DGND 20 DGND 21 DGND 22 DGND 23 DGND 24 DGND 25 DGND 26 DGND 27 DGND 28 DGND 29 DGND 30 DGND 31 nINIT 32 nFAULT 33 NC 34 NC 35 NC 36 nSELECTIN 18 Main BD CN2 USB Port Pin Signal Name Dir Pin Signal Name 1 VBUS_2270 VBUS 2 DN D D 3 DP 4 DGND AGND 5 AGND FGND 6 AGND FGND 19 Main BD CN4 Control Panel CN2 Pin Signal Name Dir Pin Signal Name 1 DGND 1 DGND 2 5V 2 VCC 3 PA...

Page 208: ...2 A_ADDR 13 32 XPAddr 11 33 DATA 17 33 XPData 17 34 A_ADDR 12 34 XPAddr 10 35 DATA 16 35 XPData 16 36 A_ADDR 11 36 XPAddr 9 37 A_ADDR 6 37 XPAddr 4 38 A_ADDR 10 38 XPAddr 8 39 nNPC_RST 39 nRESET_P 40 A_ADDR 9 40 XPAddr 7 41 nWAIT 41 nXPWAIT 42 A_ADDR 8 42 XPAddr 6 43 NC 43 NC 44 A_ADDR 7 44 XPAddr 5 45 NC 45 NC 46 NC 46 NC 47 NC 47 NC 48 DGND 48 GND 49 NC 49 NC 50 nRD 50 nXPRE 51 nWR 51 nXPWE 52 D...

Page 209: ... 2 nSOL_MP 3 NC 29 Main BD CN24 Solenoid Duplex Pin Signal Name Dir Pin Signal Name 1 24VF 2 nSOL_DUP 30 Main BD CN26 Solenoid T2 home Pin Signal Name Dir Pin Signal Name 1 3 3V 1 2 NC 2 3 nSOL_T2 3 31 Main BD CN17 Sensor Waste Toner CN1 TX CN1 RX Pin Signal Name Dir Pin Signal Name 1 3 3V 1 2 DGND 2 3 nS_TONER_RX 1 4 DGND 2 5 NC 32 Main BD CN15 Sensor Temp 1 Pin Signal Name Dir Pin Signal Name 1 ...

Page 210: ...DY_LSU 2 READY 10 nSTART_LSU 3 START 11 AGND 4 GND 12 24V 5 VCC 35 Main BD CN11 PTL CN1 Pin Sig nal Name Dir Pin Sig nal Name 1 5V 1 2 EN_ERASER 2 36 Main BD CN8 ERASER CN1 Pin Sig nal Name Dir Pin Sig nal Name 1 5VL 1 2 EN_ERASER 2 37 Main BD CN6 Imaging Unit OPC Pin Sig nal Name Dir Pin Sig nal Name 1 A_OPC_KEY 2 DGND 38 Main BD CN13 Sensor Temp 2 Pin Sig nal Name Dir Pin Sig nal Name 1 A_TEMP2 ...

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