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Phaser® 3500
laser printer
Service
Manual
Copyright © 2005 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc. XEROX®, The Document Company®, the stylized X®, CentreWare®, infoSMART®, Made For Each Other®, Phaser®, PhaserSMART®, and Walk-UpTM are trademarks of Xerox Corporation in the United States and/or other countries. Adobe® Reader®, Illustrator®, PageMaker®, Photoshop®, PostScript®, ATM®, Adobe Brilliant® Screens, Adobe Garamond®, Adobe JensonTM, Birch®, Carta®, IntelliSelect®, Mythos®, Quake®, and Tekton® are trademarks of Adobe Systems Incorporated in the 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 Corporation in the United States and/or other countries. Windows®, Windows NT®, and Wingdings® are trademarks of Microsoft Corporation in the United States and/or other countries. Novell®, NetWare®, NDPS®, NDS®, Novell Directory Services® , IPXTM , and Novell Distributed Print ServicesTMare trademarks of Novell, Incorporated in the United States and/or other countries. Sun® and Sun Microsystems® are trademarks of Sun Microsystems, Incorporated in the United States and/or other countries. UNIX® is a trademark in the United States and other countries, licensed exclusively through X/Open Company Limited. As an ENERGY STAR® partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.
Warning: The following 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 2005
071-0877-00
Service Terms
Cautions, Notes, and Warnings
Note: A note indicates 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 statement indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in damage to, or destruction of, equipment. Warning: A warning statement indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in injury or loss of life.
Product Terms
Caution: A personal injury hazard exists that may not be apparent. For example, a panel may cover the hazardous area. Warning: A personal injury hazard exists in the area where you see the sign.
Phaser® 3500 Laser Printer Service Manual ii
Symbols Marked on the Product
DANGER high voltage.
Protective ground (earth) symbol.
Hot surface on or in the printer. Use caution to avoid personal injury.
0
The surface is hot while the printer is running. After turning off the power, wait 30 minutes.
30 min.
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.
Phaser® 3500 Laser Printer Service Manual iii
Power Safety Precautions
Power Source
For 110 VAC printers, do not apply more than 140 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 VAC printers, do not apply more than 264 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord. This manual assumes that the reader is a qualified service technician. Plug the three-wire power cord (with grounding prong) into a grounded AC outlet only. If necessary, contact a licensed electrician to install a properly grounded outlet. If the product loses its ground connection, contact with conductive parts may cause an electrical shock.
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 power down the printer during an emergency. Disconnect the power plug by pulling the plug, not the cord. Disconnect the power cord in the following cases:
if the power cord or plug is frayed or otherwise damaged, if any liquid or foreign material is spilled into the case, if the printer is exposed to any excess moisture, if the printer is dropped or damaged, if you suspect that the product needs servicing or repair, whenever you clean the product.
Phaser® 3500 Laser Printer Service Manual iv
Electrostatic Discharge (ESD) Precautions
Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic Discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated Circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity. Be sure the power to the chassis or circuit board is off, and observe all other safety precautions.
Before handling any semiconductor components assemblies, drain the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit 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, as they can generate electrical charges that may damage some devices. Do not remove a static sensitive replacement component or electrical sub-assembly from its protective package until you are ready to install it. Before removing the protective 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. Simple motions such as your clothes brushing together or lifting a foot from a carpeted floor can generate enough static electricity to damage a static sensitive device Handle IC's and EPROM's carefully to avoid bending pins. Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCB's).
Phaser® 3500 Laser Printer Service Manual v
Service Safety Summary
General Guidelines
Note: The material presented here is intended as a safety reminder for qualified service personnel. Refer also to the preceding Power Safety Precautions.
Avoid servicing alone
Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present.
Use care when servicing with power
Dangerous voltages may exist at several points in this product. To avoid personal injury, do not touch exposed connections and components while power is on. Disconnect power before removing the power supply shield or replacing components.
Do not wear jewelry
Remove jewelry prior to servicing. Rings, necklaces and other metallic objects could come into contact with dangerous voltages and currents.
Power Source
This product is intended to operate from a power source that will not apply more then 264 volts rms for a 220 volt AC outlet or 140 volts rms for a 110 volt AC outlet between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.
Warning Labels Read and obey all posted warning labels. Warning labels are displayed on potentially dangerous printer components. As you service the printer, check to make certain that all warning labels remain in place. Safety Interlocks
Make sure all covers and the printer's control panel are in place and all interlock switches are functioning correctly after you have completed a printer service call. If you bypass an interlock switch during a service call, use extreme caution when working on or around the printer.
CLASS 1 LASER PRODUCT
The Phaser 3500 Laser Printer is certified to comply with Laser Product Performance Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser Product. This means that this is a class of laser product that does not emit hazardous laser radiation; this is possible only because the laser beam is totally enclosed during all modes of customer operation. The laser is not hazardous during servicing if you follow the procedures specified in the manual.
Phaser® 3500 Laser Printer Service Manual vi
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 printer with power applied, be aware of the potential for electrical shock. Warning: Turning the power off by using the On/Off switch does not completely de-energize 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. Warning: Do not touch any electrical component unless you are instructed to do so by a service procedure.Servicing Mechanical Components Caution: When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears. Warning: Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running. Warning: This printer uses heat to fuse the toner image to media. The Fuser Assembly is VERY HOT. Turn the printer power off and wait at least 5 minutes for the Fuser to cool before you attempt to service the Fuser Assembly or adjacent components.
Regulatory Specifications
Regulatory Specifications for this printer can be found in the User Guide and on the Xerox Website.
Phaser® 3500 Laser Printer Service Manual vii
Contents
Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Cautions, Notes, and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Product Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Disconnecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi CLASS 1 LASER PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Servicing Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
1
Service Call Procedures
1-2 1-3 1-3 1-3
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Preventive Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Repair Analysis Procedures
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Accessing Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Entering Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Service Diagnostics Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Service Diagnostic Control Panel Button Descriptions . . . . . . . . . . . . . . . . . 2-5 Troubleshooting Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Jam At Tray [1] [2] [3] (Jam 0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Jam At Top (Jam 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Jam At Exit (Jam 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Jam At Rear (Duplex Jam 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Jam At Duplex (Duplex Jam 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge, Replace Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Close Fuser Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Close Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Fuser Failure, Engine Fuser Low Heat Error, or Engine Fuser Over Heat Error . . . 2-15 Laser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Output Tray Is Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Phaser® 3500 Laser Printer Service Manual viii
Contents General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Control Panel Display after Power Is Turned ON . . . . . . . . . . . . . . . . . Control Panel LED is On, Control Panel Display Is Blank . . . . . . . . . . . . . Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taking Voltage Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 2-17 2-17 2-17 2-18 2-18
3
Image-Quality Troubleshooting
Image-Quality Problems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Repeating Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Repeating Defects Measurement Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Control Panel (Internal) Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Deletions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Registration and Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Skips or Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Image-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 No Image/Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Light Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Dark Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Ghosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Non-Uniform Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Black Spots/Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Spot or Vertical Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Character Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Unfused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Skips/Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 OHP Print Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
4
Repairs and Adjustments
4-2 4-2 4-3 4-3 4-3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Phaser® 3500 Laser Printer Service Manual ix
Contents Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Control Panel and LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Open Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Tray 1 (MPT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Tray 1 Knock-Up Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Tray 1 Pick-Up Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Transfer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Tray 1 Separator (Holder) Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Feed2 Idle Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Registration Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 PTL Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Main Drive Assembly and Registration (Feed) Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Feed Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Tray 1 Pick-Up Assembly and Pick Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Tray 1 Pick Roller Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Pick Roller and Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Tray 2 Pick-Up Assembly and Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Feed 2 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Developer Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Connector Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Tray 1 (MPT) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Main Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Exit Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Exit and Duplex Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 Exit Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Tray Full Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Duplex Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Laser (LSU) Assembly and Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 LSU Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Left Side Cooling Supply Fan and Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Toner Sensor Board and CRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Cover Open Board and Harness Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 Main Board and Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47 Power Supply and Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 Fuser Gear Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 Paper Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Phaser® 3500 Laser Printer Service Manual x
Contents
5
Parts List
Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 PL 8.1 Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 PL 8.1 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 PL 8.2 Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 PL 8.2 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 PL 8.3 Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 PL 8.3 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 PL 8.4 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 PL 8.4 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 PL 8.9 Tray 2 Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 PL 8.9 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 PL 8.10 Tray 3 Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 PL 8.10 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 PL 8.11 Duplex Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 PL 8.11 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
6
General Information and Specifications
6-2 6-2 6-3 6-4 6-4 6-4 6-5 6-5 6-5 6-6 6-6 6-7 6-7 6-8 6-8 6-9
Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Options and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consumable and Service Part Life Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Location and Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Wiring Data
Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Phaser® 3500 Laser Printer Service Manual xi
Contents
8
Theory of Operation
Overview of the Phaser 3500 Laser Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Summary of the Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Printer Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Duplex Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Paper Feed Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Paper Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Paper Feed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Major Assemblies and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Laser Scan Unit (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Sensor Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Paper Empty Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Tray 1 Paper Empty Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Registration Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Fuser Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Cover Open Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Duplex Unit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Printer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Image Processor Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Print Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Paper Size Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Paper Pick Auto-Select. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Toner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Laser Light Intensity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Fuser Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Phaser® 3500 Laser Printer Service Manual xii
Service Call Procedures
This section includes the following:
Servicing Instructions on page 1-2 Service Preventive Maintenance Procedure on page 1-3
Phaser® 3500 Laser Printer Service Manual 2-1
Service Call Procedures
Servicing Instructions
The service flowchart is an overview of the path a service technician should take, using this manual, to service the print engine and options.
Step 1: Identify the Problem
1. Verify the problem reported and check for any error codes and write them down. 2. Print normal customer prints and service test prints and look for any of the following: any image quality problems in the test prints. any mechanical or electrical abnormalities present. any unusual noise or smell coming from the printer. 3. View the fault and jam histories and look at the total print count for the printer. 4. Verify the AC input power supply is within proper specifications by measuring the voltage at the electric outlet while the printer is running.
Step 2: Inspect and Clean the Printer
5. Switch OFF printer power and disconnect the AC power cord from the wall outlet. 6. Verify the power cord is free from damage or short circuit and is connected properly. 7. Remove the Print Cartridge and protect it from light, then inspect the printer interior and remove any foreign matter, obstructions, or loose toner. 8. Inspect the interior of the printer for damaged wires, loose connections, toner leakage, and damaged or obviously worn parts. Do not use solvents or chemical cleaners to clean the printer interior. Do not use any type of oil or lubricant on printer parts. Use only an approved toner vacuum. 9. Clean all rubber rollers with a lint-free cloth, dampened slightly with cold water. 10. Replace any service items that have reached their 150,000 end-of-life.
Step 3: Find the Cause of the Problem
11. Use the Repair Analysis Procedures to find the cause of the problem. 12. Use Diagnostics to check printer and optional components. 13. Use the Wiring Diagrams to locate test points. 14. Take voltage readings at various test points as instructed in the appropriate troubleshooting procedure.
Step 4: Correct the Problem
15. Use the Parts List to locate a part number. 16. Use the Repair and Adjustments Procedures to replace the part.
Step 5: Final Checkout
17. Test the printer to be sure you have corrected the initial problem and there are no additional problems present.
Phaser® 3500 Laser Printer Service Manual 1-2
Service Call Procedures
Service Preventive Maintenance Procedure
Perform the following procedures whenever you check, service, or repair a printer. Cleaning the printer, as outlined in the following steps, assures proper operation of the printer and reduces the probability of having to service the printer in the future. The frequency of use and the type of paper a customer prints on determines how critical and how often cleaning the machine is necessary. Record the number of sheets printed.
Recommended Tools
Toner vacuum cleaner Clean water Clean, dry, lint-free cloth Black light protective bag
Cleaning
Never apply alcohol to any parts in the printer. Never use a damp cloth to clean up toner. If you remove the Print Cartridge, place it in a light protective bag. Exposure to light can degrade its performance and result in early failure. Record number of sheets printed. Print several sheets of paper to check for problems or defects. Print several cleaning sheets to clear up image-quality problems. Turn off the printer. Remove any debris or foreign objects. Remove any loose toner from the interior of the printer using a Type II toner vacuum only. Remove and clean the paper trays. Clean pick rollers with a slightly damp, lint-free cloth.
1. 2. 3. 4. 5. 6. 7. 8.
Phaser® 3500 Laser Printer Service Manual 1-3
Repair Analysis Procedures
This section includes the following:
Introduction on page 2-2 Service Diagnostics on page 2-4 Troubleshooting Error Messages on page 2-10 General Troubleshooting on page 2-17 Power Supply Troubleshooting on page 2-18
Phaser® 3500 Laser Printer Service Manual 2-1
Repair Analysis Procedures
Introduction
This section covers troubleshooting procedures for the Phaser 3500 Laser Printer. When an error first occurs, record the error message and code and then cycle power to the printer to see if the error recurs. Be sure to follow the Service Call Procedures on page 1-1 before servicing the printer. To troubleshoot image-quality problems, see image-quality Troubleshooting on page 3-1.
Accessing Fault History
Any code associated with an error message or jam can be viewed by displaying the Fault History or Jam History on the Control Panel. 1. View the printer's fault history on the Control Panel. a. Go to Troubleshooting --> Service Tools --> Fault History or Jam History. If the printer is connected to a network and has a TCP/IP address, you can view the printer's web page using a web browser. b. Open a web browser. c. Enter the printer's IP address as the URL. d. Select the Troubleshoot link and the fault history will be displayed.
Fault History Code 41 44 5A 53 55 56 57 58
Printer Error Message Insufficient Memory Output Tray Is Full Laser Failure Replace Print Cartridge Invalid Print Cartridge Fuser Failure/Open Fuser Error Fuser Failure/Low Heat Error Fuser Failure/Over Heat Error
Jam History Code 01 02 03 04 05
Jam Error Message Jam At Tray 1, 2, or 3 (Jam 0) Jam At Top (Jam 1) Jam At Exit (Jam 2) Jam At Rear (Duplex Jam 1) Jam At Duplex (Duplex Jam 2)
Phaser® 3500 Laser Printer Service Manual 2-2
Repair Analysis Procedures
Using the Troubleshooting Procedures
1. Each Step in a Troubleshooting Procedure instructs you to perform a certain action or procedure. The steps are to be followed sequentially until the problem is fixed or resolved. 2. The Actions and Questions box contains additional information and/or additional procedures you must follow to isolate the problem. 3. When a procedure instructs you to test a component using service diagnostics, see the Service Diagnostics Menu Map on page 2-5 for the detailed steps and functions for testing parts of the printer. 4. The action is followed by a question. If your response to the question is "Yes", then follow the instructions for a "Yes" reply. If your response to the question is "No", then follow the instructions for a "No" reply. 5. Troubleshooting Procedures may ask you to take voltage readings or test for continuity at certain test points within the printer. For detailed diagrams, see Section 7, Wiring Data on page 7-1 for complete information on test point locations and signal names. 6. Troubleshooting Procedures often ask you to replace a printer component, see Repairs and Adjustments on page 4-1 for detailed steps in removing and replacing all major components of the printer. Section 5, Parts List on page 5-1, details the location, quantity, and part number for all spared printer components.
Phaser® 3500 Laser Printer Service Manual 2-3
Repair Analysis Procedures
Service Diagnostics
The printer has built-in diagnostics to aid in troubleshooting problems. The Service Diagnostics Menu provides a means to test sensors, motors, switches, clutches, fans and solenoids. Diagnostics also contain built-in test prints, cleaning procedures, printer status and some NVRAM access. Service diagnostics are to be executed through the control panel by a certified service technician only. The printer must be rebooted to enter Service Diagnostics.
Entering Service Diagnostics
1. Turn the printer power OFF. 2. Hold down the OK button and turn the printer back ON. 3. Continue to hold the button until the following mesage is displayed on the Control Panel: "Diagnostic Mode" / "Press Menu Key", and then release the OK button. 4. Press the Menu button and use the Arrow buttons to scroll through the available functions (see the following Service Diagnostic Menu Map Table).
Phaser® 3500 Laser Printer Service Manual 2-4
Repair Analysis Procedures
Service Diagnostics Menu Map
Service Diagnostic Control Panel Button Descriptions
Button BACK Function Returns to the prior higher level menu structure, if available. Stops the actively running test. CANCEL MENU UP Terminates the current test. Cycles through all of the top level menu items. Scrolls up one menu item within a menu list. This control does not `wrap'. Used to increment values in tests requiring user input. DOWN Scrolls up one menu item within a menu list. This control does not `wrap'. Used to increment values in tests requiring user input. OK Enters the highlighted menu. Executes the current test item. Used to select the value entered by the user.
Main Menu Optins Interface
Sub Menu Tray 3 Interface Duplex Interface
Description/Function Tests the interface between the main controller and the Tray 3 interface board. Tests the interface between the main controller and the duplex interface board. Prints the test print page in simplex mode. The Control Panel will display the papers location during the print process. This process will print continuosly until stopped by the user.
Control Panel Display Tray 3 Interface: Pass /Fail :x.x.x Duplex Interface Pass/Fail :x.x.x Simplex Print Start -> Feed On -> Exit On
Test Pattern
Simplex
Duplex
Prints the test print page in 2-sided or duplex mode. This process will print continuosly until stopped by the user.
Duplex Print Start -> Feed On -> Exit On -> Duplex On
Motor/Fan
Main Motor
Main drive motor runs when the OK button is pressed and stops when the Cancel button is pressed.
Main Motor Running Test ON/OFF
Phaser® 3500 Laser Printer Service Manual 2-5
Repair Analysis Procedures
Main Menu
Sub Menu DEV Motor
Description/Function Developer motor runs when the OK button is pressed and stops when the Cancel button is pressed. Laser motor runs when the OK button is pressed and stops when the Cancel button is pressed. Duplex motor runs when the OK button is pressed and stops when the Cancel button is pressed. Tray 3 motor runs when the OK button is pressed and stops when the Cancel button is pressed. If Tray 3 is not installed, test does not run.
Control Panel Display DEV Motor Running Test ON/OFF Laser Motor Running Test ON/OFF Duplex Motor Running Test ON/OFF Tray 3 Motor Running Test ON/OFF Tray 3 Not Installed
Laser Motor
Duplex Motor
Tray 3 Motor (If installed)
Main Fan
Main fan runs when the OK button is pressed and stops when the Cancel button is pressed. SMPS fan runs when the OK button is pressed and stops when the Cancel button is pressed. Duplex fan runs when the OK button is pressed and stops when the Cancel button is pressed When the OK button is pressed the Tray 1 solenoid is turned on for 200ms, and then it automatically stops. When the OK button is pressed the Tray 2 solenoid is turned on for 200ms, and then it automatically stops. When the OK button is pressed the Tray 3 solenoid is turned on for 200ms, and then it automatically stops. When Tray 3 is not installed, this function does not work.
Main Fan Running Test ON/OFF SMPS Main Running Test ON/OFF Duplex Fan Running Test ON/OFF Tray 1 Solenoid ON/OFF
SMPS Fan
Duplex Fan
Solenoid/ Clutch
Tray 1 Solenoid
Tray 2 Solenoid
Tray 2 Solenoid ON/OFF
Tray 3 Solenoid
Tray 3 Solenoid ON/OFF
Tray 3 Not Installed
Phaser® 3500 Laser Printer Service Manual 2-6
Repair Analysis Procedures
Main Menu
Sub Menu Reg Clutch
Description/Function When the OK button is pressed, the registration clutch and main motor turn on for 200ms, and then they automatically stop. You can visually observe this test by removing the Top Cover and Print Cartridge.
Control Panel Display Reg Clutch ON/OFF
Duplex Solenoid
When the OK button is pressed, the duplex solenoid is turned on for 200ms, and then it automatically stops. When the OK button is pressed, the Tray 3 clutch and motor turn on for 200ms, and then they automatically stop. Place paper in the tray and compare the size with the control panel display. Pull out Tray 1 and manually toggle the actuator. Pull out Tray 2 and manually toggle the actuator. Pull out Tray 3 and manually toggle the actuator. When Tray 3 is not installed, this function does not work.
Duplex Solenoid ON/OFF
Tray 3 Clutch
Tray 3 Clutch ON/OFF
Sensors
Paper Size Sensor
Example: Tray2: Legal Tray3: Letter Tray 1 W/Out Paper or With Paper Tray 2 W/Out Paper or With Paper Tray 3 W/Out Paper or With Paper Tray 3 Not Installed Duplex Sensor W/Out Paper or With Paper
T1 NP Sensor T2 NP Sensor T3 NP Sensor
Duplex Sensor
With the rear cover open, push a piece of paper into the duplex path and watch the control panel display. Open the top cover and toggle the actuator. Open the top cover, remove the print cartridge, and then actuate the sensor Open the rear cover, and insert paper into the exit path. Actuate the output sensor.
Cover Open Sensor Feed Sensor Exit Sensor
Cover Open/Closed Feed Sensor W/Out Paper or With Paper Exit Sensor W/Out Paper or With Paper Out Bin Sensor Not Full/Full
Out Bin Sensor
Phaser® 3500 Laser Printer Service Manual 2-7
Repair Analysis Procedures
Main Menu
Sub Menu Tray 2 Out Sensor Tray 3 Out Sensor Fuser Door Sensor
Description/Function Remove Tray 2 from the printer. Remove Tray 3 from the printer. Open the rear cover and actuate the fuser door sensor. Developer Bias DC is applied when the OK button is pressed, and then goes off when the Cancel button is pressed. Developer Bias AC is applied when OK is pressed and goes off when Cancel is pressed. Charge Roller Voltage (+1200V) is supplied when OK is pressed and goes off when Cancel is pressed. Positive Transfer Voltage (+1200V) is supplied when OK is pressed and goes off when Cancel is pressed. [%d] is the value of the ADC. Negative Transfer Voltage (-800V) is supplied when OK is pressed and goes off when Cancel is pressed. Measure voltage with a DMM, if required. PTL turns on when OK is pressed and goes off when Cancel is pressed. Visual confirmation is possible with the cover open and the Print Cartridge removed. Laser Diode0 On is displayed when the laser diode is on. In the other case Laser Diode0 Off is displayed. Laser Diode1 On is displayed when the laser diode is on. In the other case Laser Diode0 Off is displayed.
Control Panel Display Tray 2 IN/OUT Tray 3 IN/OUT Fuser Door Sensor Closed/Opened Dev Bias DC ON/OFF
HVPS
Dev Bias DC
Dev Bias AC
Dev Bias AC ON/OFF
Charge Roll Voltage Transfer Roll (+)
Charge Roll ON/OFF
Transfer Roll (+) [%d] ON/OFF
Transfer Roll (-)
Transfer Roll (-) ON/OFF
Pretransfer Lamp (PTL)
Pre-transfer Lamp ON/OFF
Laser Scan Unit
Laser Diode_0
Laser Diode0 ON/OFF
Laser Diode_1
Laser Diode1 ON/OFF
Phaser® 3500 Laser Printer Service Manual 2-8
Repair Analysis Procedures
Main Menu
Sub Menu L Motor Ready
Description/Function This tests if the laser unit is ready and capable of printing, or at a stable polygon motor speed. When the Target Temp is displayed, INput the temperature you would like to set with the arrow buttons. Press the OK button. The target temperature and the real temperature will be displayed on the bottom line. Default is T:190 Note: You can adjust the temperature value while in diagnostics, however, once you exit the temperature will return to the default.
Control Panel Display Laser Ready Test Pass/Fail
Fuser
Fuser Temp.
Target/Current T: 190, C: XX
Read OPC Cycle
The total rotating number of the OPC drum is displayed on the bottom line of the control panel display when the process is on.
Total OPC-Cycle XXXX
Phaser® 3500 Laser Printer Service Manual 2-9
Repair Analysis Procedures
Troubleshooting Error Messages
Error Description Page page 2-11
Jam At Tray [1|2|3] (JAM 0) The leading edge of the paper doesn't pass the registration sensor or the sensor does not turn ON.
After paper pick, paper is not fed. After paper pick, paper enters the printer but does not reach the registration sensor in the specified time. After paper pick, the registration sensor turns ON and tries to pick again but the paper does not reach the registration senor in the specified time. page 2-11
Jam At Top (JAM 1) The paper is between the registration sensor and the exit sensor.
The leading edge of the paper passes the registration sensor but the trailing edge does not pass through the registration sensor in the specified time. (The registration sensor cannot be OFF). The leading edge of the paper passes the registration sensor, but the paper cannot reach the exit sensor in the specified time. (The exit sensor cannot be ON). page 2-12
Jam At Exit (JAM 2)
The trailing edge of the paper passes the registration sensor, but the paper does not pass the exit sensor in the specified time. page 2-12
Jam at Rear (Duplex JAM 1)
The trailing edge of the paper passes the exit sensor, but does not reach the duplex sensor in the specified amount of time. page 2-14
Jam at Duplex (Duplex JAM 2)
The leading edge of the paper passes the duplex sensor, but the leading edge of the paper does not reach the registration sensor in the specified time. page 2-14
Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge
A print cartridge is not detected. A non-Xerox print cartridge is installed. The toner sensor board is malfunctioning. page 2-14
Close Fuser Door
The fuser door sensor or actuator is malfunctioning or damaged. page 2-15
Close Top Cover.
Top cover is damaged Sensor or actuator is damaged. page 2-15
Fuser Failure, Engine Fuser Low Heat Error, Engine Overheat Error
Fuser is damaged or malfunctioning. page 2-15
Laser Failure
The laser unit is malfunctioning or damaged. page 2-16
Output Tray is Full
The outbin full sensor or actuator is malfunctioning or damaged.
Phaser® 3500 Laser Printer Service Manual 2-10
Repair Analysis Procedures
Jam At Tray [1] [2] [3] (Jam 0)
Step Actions and Questions 1. Check the side guides for the inoperative tray for damage or improper seating. 2. Are guides damaged or loose? Yes Replace the Tray. No Go to Step 2.
1.
2.
1. Check the surface of the pick-up rollers for dirt or damage. 2. Are the rollers dirty or damaged?
Clean rollers with a soft cloth very slightly dampened with water or replace if damaged. Go to Step 4. Repair or replace the actuator and/or sensor. Go to Step 6.
Go to Step 3.
3. 4.
1. Do the Registration Rollers turn freely? 1. Is the Registration/Feed Sensor Actuator damaged or binding? 1. Use service diagnostics to checkthe operation of the tray solenoids. 2. Do the tray solenoids operate correctly?
Replace Registration Assembly. Go to Step 5.
5.
Replace the inoperative solenoid.
6.
1. Use service diagnostics to check the operation of the Regi Clutch and Feed Clutch. 2. Do the clutches operate correctly?
Go to Step 7.
Replace the defective clutch.
7.
1. If paper feeds into the printer and the Jam error message appears, use service diagnostics to check the feed sensor operation. 2. Does the feed sensor operate correctly?
Replace the Main Board
Replace the defective sensor or actuator.
Jam At Top (Jam 1)
Step Actions and Questions 1. Clean the paper path of any obstructions, dirt or debris. 2. Did this correct the problem Yes Complete. No Go to Step 2.
1.
2.
1. Use service diagnostics to test the operation of the Registration roller and clutch. 2. Does the registration roller and clutch operate correctly?
Go to Step 3.
Replace the Registration Assembly.
Phaser® 3500 Laser Printer Service Manual 2-11
Repair Analysis Procedures
Step
Actions and Questions 1. Use service diagnostics to test the exit sensor. 2. Does the sensor operate correctly?
Yes Go to Step 4.
No Replace the exit sensor.
3.
4.
1. Replace the Fuser Assembly and retest. 2. Did this correct the problem?
Complete.
Replace the SMPS.
Jam At Exit (Jam 2)
Step Action and Questions 1. Is the Exit Sensor Actuator damaged or binding? 1. Inspect the Exit Roller Assembly. 2. Use service diagnostics to test the main drive to exit. 3. Is the exit roller damaged or binding? Yes Repair or replace the actuator and/or sensor. Replace the Exit Roller Assembly. No Go to Step 2.
1.
2.
Go to Step 3.
3.
1. Visually inspect the Fuser. 2. Is there paper wrapped around the Fuser rollers?
Remove obstruction and clean Fuser rollers. Go to Step 5.
Go to Step 4.
4.
1. Is the Fuser Assembly operational. 2. Do the Fuser gears rotates when the Main motor is on?
Replace the Fuser Assembly.
5.
1. Use the embedded diagnostics to check the Exit Sensor. 2. Is the sensor operational?
Replace Main Board.
Replace SMPS.
Jam At Rear (Duplex Jam 1)
Step Actions and Questions 1. Does paper jam after reversal but before reaching duplex sensor? 1. Replace Transport Roller Shaft Assembly. 2. Does problem recur? Yes Go to Step 2. Replace Duplex Assembly. No Go to Step 3. Complete
1. 2.
3.
1. Use service diagnostics to check the operation of the Duplex Sensor. 2. Does the sensor operate correctly?
Go to Step 4.
Replace the Duplex Sensor and/or Actuator.
Phaser® 3500 Laser Printer Service Manual 2-12
Repair Analysis Procedures
Step
Actions and Questions 1. Inspect the Duplex Assembly. Is any paper wrapped around the Duplex rollers? 1. Use service diagnostics to check the exit sensor. 2. Does the sensor operate correctly?
Yes Remove obstruction and clean rollers. Go to Step 6.
No Go to Step 5.
4.
5.
Replace the exit sensor and/or actuator. Go to Step 7.
6.
1. Inspect the exit and duplex roller assemblies. 2. Are the rollers damaged or binding?
Replace the exit or duplex roller as necessary. Replace the duplex assembly. Replace Main Board.
7. 8.
1. Inspect the duplex assembly for damage. 1. Does the Feed Roller Assembly operate properly without binding?
Go to Step 8. Replace the Feed Roller Assembly.
Phaser® 3500 Laser Printer Service Manual 2-13
Repair Analysis Procedures
Jam At Duplex (Duplex Jam 2)
Step Actions and Questions 1. Does the paper jam after reversal but before reaching the duplex sensor? 1. Use service diagnostics to test the duplex sensor. 2. Does the sensor operate correctly? Yes Replace the transport roller shaft. Go to Step 3. No Go to Step 2. Replace the duplex sensor.
1. 2.
3. 4.
1. Inspect the exit and duplex rollers for any signs of damage or binding. 1. Replace the Duplex Assembly. 2. Does the problem still occur?
Replace the problem roller. Replace the Main Board.
Go to Step 4. Replace the Power Supply Board.
Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge, Replace Print Cartridge
Step Action and Questions 1. Open the top cover and ensure that the Print Cartridge is properly seated. 2. Does the error clear after reseating the cartridge? Yes Complete No Go to Step 2.
1.
2.
1. Check the Print Cartridge for damage. 2. Does the cartridge contain toner and appear to be operating properly?
Go to Step 3.
Replace Print Cartridge.
3.
1. Reseat all harness connections to the Toner Sensor (CRUM) Board. 2. Does the error clear?
Complete
Go to Step 4.
4.
1. Check continuity between the Toner Sensor (CRUM) Board and CN6 on the Main Board. 2. Does the harness show continuity?
Replace the Toner Sensor Board.
Replace Harness.
Close Fuser Door
Step Action and Questions 1. Visually inspect the fuser door close tab for damage. 2. Is the tab broken? Yes Replace the Fuser. No Go to Step 2.
1.
Phaser® 3500 Laser Printer Service Manual 2-14
Repair Analysis Procedures
Step
Action and Questions 1. Verify the sensor and actuator on the Fuser is operating correctly.
Yes Replace the Main Board.
No Replace the Fuser. Replace the SMPS.
2.
Close Top Cover
Step Action and Questions 1. Visually inspec the top cover and the top cover actuator. 2. Is the top cover or actuator damaged? Yes Replace the Top Cover. No Go to Step 2.
1.
2.
1. Use diagnostics to test the cover open sensor. 2. Does the sensor function properly?
Replace the Main Board.
Replace the Sensor.
Fuser Failure, Engine Fuser Low Heat Error, or Engine Fuser Over Heat Error
Step Action and Questions 1. Does the error report Fuser Failure? 1. Check the thermistor. 2. Is the circuit open? Yes Go to Step 2. Replace the Fuser. No Go to Step 3. Replace the Main Board. Go to Step 4.
1. 2. 3.
1. Check the line voltages across the thermostats. 2. Are they open?
Replace the Fuser.
4.
1. Is the Fuser getting power?
Replace the Fuser.
Replace the SMPS. Replace the Main Board.
Laser Failure
Step Actions and Questions 1. Reseat the connections to the laser and visually inspect the laser unit for damage. 2. Did this correct the problem? Yes Complete No Go to Step 2.
1.
Phaser® 3500 Laser Printer Service Manual 2-15
Repair Analysis Procedures
Step
Actions and Questions 1. Use diagnostics to check the laser motor function. 2. Did the laser motor fail?
Yes Replace the Laser Unit.
No Replace the Main Board.
2.
Output Tray Is Full
Step Actions and Questions 1. Check the Output Tray sensor and actuator for obvious damage. 2. Is the actuator damaged? Yes Replace the actuator. No Go to Step 2.
1.
2.
1. Use diagnostics to test the output tray sensor. 2. Does the sensor operate correctly?
Replace the Main Board.
Replace the Output Tray Sensor.
Phaser® 3500 Laser Printer Service Manual 2-16
Repair Analysis Procedures
General Troubleshooting
The following procedures cover Control Panel and Start-up problems with the printer when no specific error code or Control Panel message is displayed.
Control Panel Troubleshooting
No Control Panel Display after Power Is Turned ON
1. Verify that power cord is securely plugged into both the printer and the grounded, three prong AC outlet with the appropriate power available. 2. Ensure that all covers are securely closed. 3. Verify the Top Cover, Print Cartridge, and Fuser interlocks are functional. 4. Verify voltages at the Main Board, see Power Supply Troubleshooting on page 2-18. 5. Replace the Power Supply Board. 6. Replace the Main Board. 7. Replace the Control Panel.
Control Panel LED is On, Control Panel Display Is Blank
1. Remove and reseat the Control Panel wiring to the Main Board. 2. Replace the Control Panel. 3. Replace the Main Board.
Phaser® 3500 Laser Printer Service Manual 2-17
Repair Analysis Procedures
Power Supply Troubleshooting
1. Check the voltage at the AC wall outlet, there should be approximately 110 VAC (or 220 VAC if the printer is a 220 V model) at the AC wall outlet? 2. Check the power cord for defects, damage, or a loose connection. 3. Check the AC switch harness for continuity. 4. Verify the Power Supply is operating correctly.
Taking Voltage Measurements
To locate connectors or test points, refer to Wiring Data on page 7-1 for more information. Unless otherwise specified, the following voltage tolerances are used within this section
Stated +3.3 VDC +5.0 VDC +24.0 VDC 0.0 VDC
Measured +3.135 to +3.465 VDC +4.75 to +5.25 VDC +21.6 to +26.4 VDC Less than +0.5 VDC
Phaser® 3500 Laser Printer Service Manual 2-18
Image-Quality Troubleshooting
This section covers the following:
Image-Quality Problems Overview on page 3-2 Control Panel (Internal) Test Print on page 3-4 Image-Quality Troubleshooting on page 3-7
Phaser® 3500 Laser Printer Service Manual 3-1
image-quality Troubleshooting
Image-Quality Problems Overview
Image-quality defects can be attributed to printer components, consumables, media, internal software, external software applications, and environmental conditions. To successfully troubleshoot image-quality problems, as many variables as possible must be eliminated. The following guidelines should be used before troubleshooting an image-quality problem:
Use an unopened ream of approved media for evaluating image-quality problems
Note: See the approved media list, Media and Tray Specifications on page 6-9, for media that has been tested and approved for use with the Phaser 3500 Laser Printer.
Generate the Control Panel (Internal) Test Print on page 3-4, and see if the imagequality problem still exists When analyzing a image-quality defect, first determine if the defect is repeating or random. Repeating defects can often be associated with a particular component. Inspect the surfaces of all rollers in the paper path for obvious defects.
Phaser® 3500 Laser Printer Service Manual 3-2
image-quality Troubleshooting
Repeating Defects
Some image-quality problems can be associated with specific assemblies, the most common problems and the associated assemblies are listed below. Also, see the specific image-quality troubleshooting procedure for more information.
Print Cartridge
Streaks Fine Lines Banding in Process Direction Uneven Density Voids Repeating Defects
Transfer Roller
Toner on the back side of the printed page (simplex mode) Light Prints Repeating Defects Spots on Image
Fuser
Hot or Cold Offsetting Repeating Defects Voids
Repeating Defects Measurement Table
Assembly Print Cartridge Component Developer Roller Drum Drum Charge Rollers Supply Roller Transfer Roller Fuser Assembly Transfer Roller Heat Roller Pressure Roller Distance between Defects 50 mm (1.97 in.) 94 mm (3.70 in.) 38 mm (1.50 in.) 42 mm (1.65 in.) 56 mm (2.20 in.) 126 mm (4.96 in.) 126 mm (4.96 in.) Typical Defect Horizontal image band White spots on black image or black spots on white Black spots Light or dark horizontal image bands Image ghost Black spots and image ghost Black spots on back
Phaser® 3500 Laser Printer Service Manual 3-3
image-quality Troubleshooting
Control Panel (Internal) Test Print
A test print is available to aid in determining the quality of output from the printer and to assist in troubleshooting image-quality problems. Each area of the test print is used for a imagequality parameter. The following pages explain each of the areas and the image-quality parameters. Follow these guidelines when generating the test print:
Use supported paper from a fresh, unopened ream Print five copies of the test print. Discard the first two prints and retain the remaining prints for image-quality analysis.
Deletions
Inspect the test print for the presence of deletions or unprinted spots. If these are found, see Spot or Vertical Deletions on page 3-10.
Fusing
Rub the image three times at the indicated points with a soft cloth or tissue. The toner should not lift off of the surface of the print. If the image smears or toner lifts off the image onto the cloth, see Unfused Image on page 3-11.
s3500-039
Phaser® 3500 Laser Printer Service Manual 3-4
image-quality Troubleshooting
Resolution
Observe the three resolution check points on several test prints.
Ensure that the 2 pixel horizontal, vertical, and diagonal lines are clear and continuous. The diagonal lines might appear to be narrower than the others. Characters in the text paragraphs should be uniform and equal in density. The halftone patches should be uniform in appearance.
If the image does not meet the criteria, see Non-Uniform Image on page 3-9 or Character Defects on page 3-10.
Registration and Skew
Fold the paper from two consecutive test prints in half (first side edge to side edge and then top edge to bottom edge). Observe the fold lines with reference to the crosshairs of the printed target. The fold line should be aligned perpendicular to the target crosshairs and should be within ±2.0 mm of the target crosshairs (each line on the target