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Manual - Printertec

1. Step Actions and Questions Yes No 1 1 Check the side guides for the Replace the Tray Go to Step 2 inoperative tray for damage or improper seating 2 Are guides damaged or loose 2 1 Check the surface of the pick up rollers Clean rollers with a Go to Step 3 for dirt or damage soft cloth very 2 Are the rollers dirty or damaged slightly dampened with water or replace if damaged 3 1 Do the Registration Rollers turn freely Go to Step 4 Replace Registration Assembly 4 1 Is the Registration Feed Sensor Repair or replacethe Go to Step 5 Actuator damaged or binding actuator and or sensor 5 1 Use service diagnostics to checkthe Go to Step 6 Replace the operation of the tray solenoids inoperative solenoid 2 Do the tray solenoids operate correctly 6 1 Use service diagnostics to check the Go to Step 7 Replace the operation of the Regi Clutch and Feed defective clutch Clutch 2 Do the clutches operate correctly 7 1 If paper feeds into the printer and the Replace the Main Replace the Jam error message appears use Board defective sensor or service diagnostics to check the feed actuator sensor operation 2 Does the feed sensor operate correctly Jam At Top Jam 1 operate correctly Step Actions and Questions Yes No 1 1 Clean the paper path of any Complete Go to Step 2 obstructions dirt or debris 2 Did this correct the problem 2 1 Use s
2. Phaser 3500 Laser Printer Service Manual 5 16 Parts List PL 8 4 Fuser Assembly Phaser 3500 Laser Printer Service Manual 5 17 Parts List PL 8 4 Parts List Table Fuser Assembly Item No Description Qty Part Number 1 ELA UNIT FUSER 110V 126N00242 ELA UNIT FUSER 220V 126N00243 1 1 COVER M FUSER UPPER 1 2 THERMOSTAT ELECTRODE P FU L 1 3 THERMISTOR 1 4 PMO GUIDE CLAW GREEN 1 5 SPRING TS 1 6 SPRING SEPARATION 1 7 MEC BRUSH ANTISTATIC 1 8 ELECTRODE P FU R 1 9 HOLDER M IDLE ROLLER 1 10 PMO ROLLER UPPER DP 1 11 HOLDER M LEVER L 1 12 HOLDER M LEVER R 1 13 ELECTRODE P SUPPORT 1 14 SCREW 1 15 SCREW 1 16 ROLLER HEAT 1 17 BALL BEARING 1 18 CAP M END 1 19 BUSH HR 1 20 GEAR M FUSER Z49 1 21 STOPPER SPACER 1 22 ELECTRODE FU 1 23 SPRING ETC GUIDE DEVE 1 24 CAP M ACTUATOR UP 1 25 COVER M REAR GUIDE UP 1 26 ELECTRODE P SU CARBON 1 27 IEX SHAFT IDLE F UP 1 28 HOLDER P SL CONNECTOR Phaser 3500 Laser Printer Service Manual 5 18 Fuser Assembly Continued Parts List Item No Description Qty Part Number 1 29 PEX ROLLER F UP 2 1 H ELA UNIT ASSY HEAT ROLL 2 MEA UNIT BRK GEAR FU 2 1 BRACKET P FUSER 2 2 GEAR IDLE 23 2 3 GEAR M IDLE 25 2
3. Printer Options and Supplies Options and Supplies Item 64 MB additional RAM memory 128 MB additional RAM memory 256 MB additional RAM memory Network Interface Card NIC Duplex Unit 500 Sheet Feeder Standard Capacity Print Cartridge 6 000 pages 5 area coverage High Capacity Print Cartridge 12 000 pages 5 area coverage Part Number 097S03389 097S03390 097S03391 097503386 097803387 097503385 106R01148 106R01 149 Phaser 3500 Laser Printer Service Manual 6 2 General Information and Specifications Consumable and Service Part Life Expectancy Consumable toner print cartridge usage is tracked by the CRUM and monitored by the Main Board in order to display the near end of life and end of life messages Life ratings are based on 5 coverage and an average 4 page job length Consumables Print Life Print Cartridge High Capacity 12 000 pages Standard Capacity 6 000 pages Service Parts Fuser Assembly 150 000 pages Transfer Roller 150 000 pages Feed Roller Kit 150 000 pages Retard Roller 150 000 pages Separator Pad 150 000 pages Note The service parts are not tracked with an NVRAM counter and there is no replace or low warnings associated with these service parts Phaser 3500 Laser Printer Service Manual 6 3 General Information and Specifications Parts of the Printer Front View Print Cartridge Output Tray Paper Outpu
4. 3500 051 Print Cartridge Fuser Assembly Paper transports Transfer Roller 1 Replace the Print Cartridge NOTE See Repeating Defects on page 3 3 for defect pitch 2 Inspect clean replace Fuser Assembly as necessary 3 Clean contamination from paper transports and exit rollers 4 Clean or replace the Transfer Roller Spot or Vertical Deletions Solid areas are marked with irregular white spots PRINTED IMAGE 3500 052 m Damp paper Foreign matter contamination of printer components Print Cartridge Transfer Roller 1 Replace paper 2 Check printer components for surface contamination or paper scraps Clean as required 3 If deletions repeat every 94 mm replace Print Cartridge NOTE See Repeating Defects on page 3 3 for defect pitch 4 Remove the Transfer Roller and clean dust off If deletions repeat every 56 mm replace Transfer Roller Horizontal Bands Dark bands appearing in the horizontal direction Print Cartridge Fuser Assembly Transfer Roller Incorrect high voltage outputs m Laser Assembly 1 Replace the Print Cartridge 2 Inspect clean replace Fuser Assembly as necessary 3 Inspect the Transfer Roller spring tension and bearing contacts 4 Replace Power Supply Board 5 Replace Laser Assembly Character Defects Garbled print missing repeating or scrambled characters are problems relating to font data or character
5. 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 m Toner vacuum cleaner m Clean water m Clean dry lint free cloth m Black light protective bag Cleaning m Never apply alcohol to any parts in the printer m Never use a damp cloth to clean up toner m 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 PNP SP SS PS Clean pick rollers with a slightly damp lint free cloth Phaser 3500 Laser Printer Service Manual 1 3 Repair Analysis Procedures This section includes the followin
6. 3500 Laser Printer Service Manual 4 9 Repairs and Adjustments Control Panel and LCD Display 1 Remove m Top Cover on page 4 8 2 Remove the 6 screws securing the LCD and control panel and remove from the top cover W 2 screws to the LCD Board W 4 screws on the key panel board Note DO NOT remove the 3 screws securing the plastic portion of the LCD display SS ys ey to Panel AT SUM DIN Wi aS 49 s3500 086 Phaser 3500 Laser Printer Service Manual 4 10 Repairs and Adjustments Open Cover 1 Remove m Covers on page 4 4 m Left Cover on page 4 5 m Top Cover on page 4 8 2 Remove the 2 screws and stoppers from the Open Cover 3 Remove the Open Cover from the Top Cover by flexing the 2 tabs as shown below 3500 087 3500 088 Phaser 3500 Laser Printer Service Manual 4 11 Repairs and Adjustments Tray 1 MPT Assembly 1 Open Tray 1 2 Unhook the 2 springs connecting the Knock up Plate to the Pick Up Rack Note DO NOT unhook the springs from the Pick Up Rack 3500 058 Note In the next step if you exert too much pressure you can break the tracks Phaser 3500 Laser Printer Service Manual 4 12 Repairs and Adjustments 3 Flex the left and right side tracks to disengage the Knock Up Plate from the Tray 1 Assembly Caution Tray 1 and the Knock Up Plate contain unsecured plastic parts that fall off
7. Assembly os gee eee ee REPLY IDEE UIS EST ea 4 12 Tray 1 Knock Up Plate 1 eno epe ERES Rte S ROS 4 14 Tray 1 Pick Up Racks 2e once ee eR e Rete RARE ees 4 15 Inner COVER 4 oso elas ee Demnusbibemve aeree rs r n 4 16 Transfer Roll z 22 226 hen bined Ree Euer TEES ERE whee i 4 17 Retard Assembly 654 4vb t deeb W rek etse Tos E ber ete serie ber obe da 405 4 18 Tray 1 Separator Holder Pad Assembly kk kk kK KK KK KK eee eee 4 19 Feed2 Idle Unit isos perri en Ser 2 as a 2 UP ee eee Tri PUER 4 20 Registration Assembly 2 5 0 0 2 cee nee eee re Re re rre 4 21 PLL Board si eu aee eb in Area e Ea A E RR eed h l 4 23 Main Drive Assembly and Registration Feed Clutch 0 0000005 4 24 Feed Clutch is 2 3 ehehvppecepyeeteeebseneeUegrbhlbauUprERSveeu e eee ae 4 24 Main Drive Assembly 0 0 0 KK KK KK KK KK KK KK kK KK KK KK KK KK kk k 4 25 Tray 1 Pick Up Assembly and Pick Rollers 0 2 0 cece KK KK KK KK KK KK KK KH 4 26 Tray 1 Pick Roller Only 5 2 bi KK KK KK KK ia one nu 4 26 Pick Roller and Shaft Removal W K KK KK KK KK KK KK KK KK eee 4 27 Tray 2 Pick Up Assembly and Rollers 0 0 0 kk kK KK KK KK KK KK KK KK KK KK KK KK K 4 29 Feed 2 Unites y pig bee Byer ree Sve ea e Wk 44 EQ 4 32 Developer Drive Assembly Wa kK KK KK KK KK KK KK KK KK KK KK KK KK KK kK KK K 4 33 Connector Board ies dela kal deka WA A deke iia Mes haran k n da a
8. Before you begin any Removal and Replacement Procedure 1 Switch OFF the printer power and disconnect the power cord from the wall outlet 2 Remove the Print Cartridge and protect it from exposure to light by covering it with a light proof bag or by placing it in a light tight container 3 Disconnect all computer interface cables from the printer 4 Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards 5 Remove the Fuser Assembly or wait at least 5 minutes after you have switched OFF printer power for the Fuser to cool before you work on or around the Fuser 6 Tray 2 can interfere with the removal of many printer parts Remove Tray 2 before further disassembly Wherever this video icon appears throughout the manual detailed instructions for that procedure are available with videos on the Phaser 3500 Product Training CD ROM Note Part names that appear in the disassembly procedures may not exactly match the names that appear in the Parts List For example a part called the Registration Transport Assembly may appear on the Parts List as Assembly Transport Regi Caution Many parts are secured by plastic tabs DO NOT over flex or force these parts Do not over torque the screws threaded into plastic parts Always use the correct type and size screw Using the wrong screw can damage tapped holes Do not use excessive force to either remove or install either
9. Button Function BACK Returns to the prior higher level menu structure if available Stops the actively running test CANCEL Terminates the current test MENU Cycles through all of the top level menu items UP 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 Sub Menu Description Function Control Panel Display Optins Tray 3 Tests the interface between Tray 3 Interface Interface Interface the main controller and the Pass Fail x x x Tray 3 interface board Duplex Tests the interface between Duplex Interface Interface the main controller and the Pass Fail x x x duplex interface board Test Simplex Prints the test print page in Simplex Print Pattern simplex mode The Control Start gt Feed On gt Exit On Panel will display the papers location during the print process This process will print continuosly until stopped by the user Duplex Prints the test print page in Duplex Print 2 sided or duplex mode Start gt Feed On gt Exit On gt Duplex This process will print On continuosly until stopped by the user Motor Fan Main Motor Main drive motor runs when Main Motor the OK button
10. Phaser 3500 Laser Printer Service Manual 5 7 PL 8 2 Cover Assembly Nin AN PL 8 2 Parts List Table Cover Assembly Parts List Item No Description Qty Part Number 1 1 X AS UNIT COVER TOP 002N02411 1 1 COVER M TOP 1 2 COVER M OPEN XRX 1 3 PMO STACKER RX 002N02418 1 4 LEVER M STACKING 38 036N00030 1 5 STOPPER M HINGE OPEN 1 6 COVER M OP PANEL XRX 1 7 SHEET OVERLAY BUTTON 1 8 MEC BRUSH ANTISTATIC 1 9 PBA SUB PANEL B D 123N00241 1 10 KEY M BUTTON XRX 1 11 KEY M CANCEL 1 12 CAP M LED XRX 1 13 WINDOW M LCD 1 14 GROUND TOP COVER 2 COVER M LEFT 002N02413 3 COVER M RIGHT 002N02414 4 COVER M CONTROL BOX 002N02419 5 COVER M FRONT INNER 002N02415 6 MEA UNIT COVER REAR 002N02416 6 1 COVER M REAR 6 2 PMO STACKER REAR 6 3 ICT BRKT REAR COVER 6 4 GUIDE M EXIT 6 5 PMO STRIPE 001N00462 6 7 PEX ROLLER F UP 2 6 8 SPRING ETC SEPARATION 6 9 LABEL P JAM REMOVAL 7 CO VER M FRAME EXIT 002N02417 8 COVER M DUMMY DUP FILLER PANEL 002N02420 Phaser 3500 Laser Printer Service Manual 5 8 Parts List PL 8 3 Frame Assembly Phaser 3500 Laser Printer Service Manual 5 9 Parts List 498 aS ay Phaser 3500 Laser Printer Service Manual 5 1
11. Printer Controls Image Processor Function The host computer connects to the Main Board using a bi directional parallel Universal Serial Bus USB cable or via an optional Ethernet Network Card The Main Board receives image data from the host computer converts this to a bitmap image and then sends the current image to the Laser Scanner Assembly Print Engine Control The engine control section provides all of the principle operating voltages and control signals for the following printer operations Main Drive Motor Fuser Assembly High Voltage Power Supply HVPS Laser Scanner Unit LSU Sensors Solenoids Thermistor All parts related to the xerographic process Optional Paper Tray 3 and Tray 1 Phaser 3500 Laser Printer Service Manual 8 9 Theory of Operation Main Board The Main Board combines the Image Processor and Engine Control functions It contains a 32 bit RISC processor and comes with a standard memory capacity of 32 Mbytes of RAM and 4 Mbytes of flash memory The board provides one expansion slot that allows available memory to be expanded up to 288 Mbytes by adding an additional RAM DIMM k E 4 Phaser 3500 Laser Printer Service Manual 8 10 Theory of Operation Power Supply The HVPS section generates and supplies the following voltages Transfer Voltage Charge Voltage Bias Voltage Supply Voltage The Bias Supply and Charge voltages are
12. cloth see Unfused Image on page 3 11 HHHH PROCESS 3500 039 Phaser 3500 Laser Printer Service Manual 3 4 image quality Troubleshooting Resolution Observe the three resolution check points on several test prints m 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 m Characters in the text paragraphs should be uniform and equal in density m 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 IZ s4400 293 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 is 1 0 mm If the image does not meet the criteria see Skewed Image on page 3 11 H1 PROCESS I SCAN Fold Line HHTHHH gt PROCESS itt SCAN s4400 295 Fold Line IN s4400 294 Phaser 3500 Laser Printer Service Manual 3 5 Skips or Smears image quality Troubleshooting Check the test print in the indicated areas for loss str
13. m Covers on page 4 4 m Left Cover on page 4 5 m Top Cover on page 4 8 Note When you remove the exit rollers the rollers underneath are spring loaded and can become lost if not careful 2 Remove the locking bearings from both ends of the shaft Exit Roller 3500 101 Phaser 3500 Laser Printer Service Manual 4 39 Repairs and Adjustments Exit Gear 1 Remove the bearing in order to remove the gear Bearing N Exit Gear s3500 102 Tray Full Actuator 1 Remove the actuator from the exit roller Actuator s3500 100 Phaser 3500 Laser Printer Service Manual 4 40 Repairs and Adjustments Duplex Roller 1 Using a small flatblade screwdriver spread apart the bearings on both side of the duplex roller and remove from the printer Duplex Exit Roller 3500 103 Phaser 3500 Laser Printer Service Manual 4 4 Repairs and Adjustments Laser LSU Assembly and Lower Cover 1 Remove m Covers on page 4 4 m Left Cover on page 4 5 m Top Cover on page 4 8 Remove the cover frame exit cover Disconnect the connector from the LSU to the Main Board Remove the 3 screws securing the LSU to the chassis mom Remove the LSU from the printer Note The screws are numbered and need to be replaced and tightened in the correct order 3500 106 Phaser 3500 Laser Printer
14. CLAMP 10 IPR TERMINAL GND DUP 11 LOCKER M DUP 12 SHEET FRAME DUP 13 SPRING TS 14 PMO ACTUATOR FEED DUP 15 PBA SUB MP SEN 16 CBF HARNESS POWER GND 17 MOTOR STEP Phaser 3500 Laser Printer Service Manual 5 26 Duplex Assembly Parts List Item No Description Qty Part Number 18 BRACKET P MOTOR DUP 19 PULLEY M 30 DUP 20 BELT TIMING GEAR 21 PULLEY M 30 DUMMY DUP 22 RING E 23 CBF HARNESS D JOINT Phaser 3500 Laser Printer Service Manual 5 27 General Information and Specifications This section covers the following Printer Configurations on page 6 2 Parts of the Printer on page 6 4 Control Panel on page 6 5 Control Panel on page 6 5 Printer Specifications on page 6 6 Media and Tray Specifications on page 6 9 Phaser 3500 Laser Printer Service Manual 6 1 Printer Configurations General Information and Specifications Printer Configurations Features 3500B 3500N 3500DN Maximum Print Speed Letter A4 35 ppm 35 ppm 35 ppm Memory Standard 32 MB 32 MB 32 MB Up to 288 MB Optional PostScript and PCL Fonts Yes Yes Yes Default Resolution 600 x 600 dpi Maximum Resolution 1200 x 1200 dpi 500 Sheet Feeder Tray 3 Optional Optional Optional Network Interface Optional Standard Standard Automatic 2 Sided Printing Separate Duplex Optional Optional Standard Unit USB Parallel Interface Yes Yes Yes
15. EXIT DUP 12 BUSH M EXIT D7 013N13839 13 GEAR M EXIT DUP Z21 007N01363 14 ELA HOU CST SENSOR 110K14290 14 1 PBA SUB CASSETTE 14 2 IPR PLATE SENSOR 14 3 IPR BRACKET SENSOR 15 CBF HARNESS PSIZE 16 GUIDE P REGI UPPER 17 SPRING ETC LEVER 18 HOLDER M BUSHING TX 19 GUIDE PLATE PAPER 20 IPR P GROUND PLATE PAPER 21 PHOTO INTERRUPTER 110K14300 23 CBF HARNESS THERM 24 PMO HOUSING TERMINAL 25 IPR TERMINAL FU 26 CBF HARNESS FUSER 27 CAP M HOUS TERM 28 SHIELD P CTRL 29 GROUND P MOTOR DEVE 30 GROUND P GUIDE TR 31 GROUND P REGI ROLLER 32 GROUND P PICK UP MP Phaser 3500 Laser Printer Service Manual 5 12 Frame Assembly Continued Parts List Item No Description Qty Part Number 33 GROUND P SCF MAIN 34 GROUND P MOTOR MAIN 35 GROUND P GUIDE DUP 36 CAP M GUIDE HARNESS 37 PMO DUMMY DEVE 38 ELA HOU VARISTOR 39 FOOT ML80 40 PMO REMOVE LOCK CST 41 SHAFT M GEAR RETARD 42 SHAFT M COUPLING RETARD 43 PMO BEARING SHAFT 44 GEAR REGI Z25 45 PMO BEARING SHAFT 47 MEA UNIT FRAME LSU LOW 140N63017 47 1 FRAME M LSU LOWER 47 2 PBA TONER SENSOR 47 3 TERMINAL P DEVE 47 4 CBFHARNESS TONER SENSOR 47 5 CAP M COVER OPEN 48 ELA UNIT FEED 3X5 022N02174 48 1 HOLDER M SAW 48 2 GUIDE P TRANSFER FRONT 48 3 PLATE P SAW 48 4 SHAFT M ROLLER BELT 48 5 ROLLER M IDLE BELT 48 6 IEX SHAFT IDLE F UP 48 7 RU
16. Registration Assembly from the printer 3500 114 REGI Ass y 3500 116 Phaser 3500 Laser Printer Service Manual 4 22 Repairs and Adjustments PTL Board 1 Remove m Covers on page 4 4 m Left Cover on page 4 5 m Top Cover on page 4 8 m Registration Assembly on page 4 21 2 Disconnect the wiring harness 3 Remove 1 screw and take out the PTL board T gh PTL Upper T S terminal E PTL PBA 3500 117 Phaser 3500 Laser Printer Service Manual 4 23 Repairs and Adjustments Main Drive Assembly and Registration Feed Clutch 1 Remove m Covers on page 4 4 Feed Clutch 1 Loosen the grounding bracket screw attached to the plate on the Main Drive Assembly and rotate the grounding bracket to gain access to the e ring 2 Remove the e ring securing the clutch to the feed roller shaft 3 Disconnect the connector to the connector board and remove the clutch from the printer 3500 073 Phaser 3500 Laser Printer Service Manual 4 24 Repairs and Adjustments Main Drive Assembly 1 Disconnect 1 connector from the main motor assembly 2 Remove the 6 screws securing the Main Drive to the printer 3 Remove the Main Drive from the printer Main Drive 3500 074 Replacement Notes Note Ther
17. THSU OT INT TUG n0 18u 8 ax Tanva V 08203 AZZ WSN 203 ADIT Ting NI LN0 ZT TE NO NESDi OL Z ANAL k NI WUSHL 8 L TAZIS d 9 NIV NYA p snrd r odA 8 smuru TOTAL SNIA rOdA 9 snuru Toqa S DST Z GND THZIS d P SdWS NHL CHZS dt AWT TO T AAMOT OTY cuz MOT ATE dXL T3NVd Phaser 3500 Laser Printer Service Manual 7 2 Wiring Data 6p L 00SES lt p up NGLdO AAO NAN VINO ucdo quvo WN peppe dq WH umido quo M NIOd Y OST NddO iH A O0 N I I OS XdTdnd ud co Ud gz NO 9ND S NO ud 8T ILd A0 N AXA Phaser 3500 Laser Printer Service Manual 7 3 Wiring Data 3500 150 110V for USA 240V for EU MAIN B d Phaser 3500 Laser Printer Service Manual 7 4 Theory of Operation This section covers the following Overview of the Phaser 3500 Laser Printer on page 8 2 Printer Paper Path on page 8 4 Major Assemblies and Functions on page 8 6 Sensor Functions on page 8 8 Printer Controls on page 8 9 Power Supply on page 8 11 Phaser 3500 Laser Printer Service Manual 8 1 Theory of Operation Overview of the Phaser 3500 Laser Printer Summary of the Printing Process The Phaser 3500 Laser Printer is a desktop monochrome laser printer applying the principals of an electrophotographic system The printing process is composed of the follo
18. 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 2 3 Turn the printer power OFF Hold down the OK button and turn the printer back ON 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 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
19. is pressed and stops when the Cancel button is pressed Running Test ON OFF Phaser 3500 Laser Printer Service Manual 2 5 Repair Analysis Procedures Main Menu Sub Menu Description Function Control Panel Display DEV Motor Developer motor runs when DEV Motor the OK button is pressed Running Test and stops when the Cancel ON OFF button is pressed Laser Laser motor runs when the Laser Motor Motor OK button is pressed and Running Test stops when the Cancel ON OFF button is pressed Duplex Duplex motor runs when the Duplex Motor Motor OK button is pressed and Running Test stops when the Cancel ON OFF button is pressed Tray 3 Tray 3 motor runs when the Tray 3 Motor Motor OK button is pressed and Running Test If installed Stops when the Cancel ON OFF button is pressed If Tray 3 is not installed test Trays Not Installed does not run Main Fan Main fan runs when the OK Main Fan button is pressed and stops Running Test when the Cancel button is pressed ON OFF SMPS Fan SMPS fan runs when the SMPS Main OK button is pressed and Running Test stops when the Cancel button is pressed ONOFF Duplex Fan Duplex fan runs when the Duplex Fan OK button is pressed and Running Test stops when the Cancel button is pressed ON OFF Solenoid Tray 1 When the OK button is Tray 1 Solenoid Clutch Solenoid pressed the Tray 1 solenoid ON OFF is turned on for 200ms and then it a
20. kk kk kk KK KK KK kK kk eh 2 10 Jam At Tray 1 2 3 Jam 0 SS KK KK KK KK KK KK KK KK KK KK 2 11 Jam At Top Jam 1 xi kya sla da malane n elok EROR s l aran claws dacs 2 11 Jam At Exit Jam 2 sya nn kl aba xuwa Ru a Oe ec euer cdd Pid teca SUR d aA 2 12 Jam At Rear Duplex Jam 1 kk kK KK KK KK KK KK KK KK KK KK KK KK KK KK K 2 12 Jam At Duplex Duplex Jam 2 0 0 kk kk kk kK KK KK KK KK KK KK KK KK KK KK k 2 14 Check Cartridge Invalid Print Cartridge Non Xerox Cartridge Replace Print Cartridge sun x ds da ka w ae gre reg eade ee a 2 14 Close Fuser DOOL eee ake ae wana W y a Sk l halk e RR e kirar a mle e 2 14 Close Top Cover iini AW eee ku a ee RR k qi ene ER Wa See 2 15 Fuser Failure Engine Fuser Low Heat Error or Engine Fuser Over Heat Error 2 15 Laser Failure ese cia sei eee p 0 ke eae Se v RERO Ce 2 15 Output Tray IS Full s 3k esr repu E SACS ono bees 2 16 Phaser 3500 Laser Printer Service Manual viii Contents General Troubleshooting iy i ku ee n eee ee ema Wa a er ee eee 2 17 Control Panel Troubleshooting kK KK KK KK KK KK KK KK KK KK KK KK K 2 17 No Control Panel Display after Power Is Turned ON 2 17 Control Panel LED is On Control Panel Display Is Blank 2 17 Power Supply Troubleshooting seeeeeee eee kK kk kk 2 18 Taking Voltage Measurements l
21. parts showing part numbers are available for support Parts not showing part numbers are available on the parent assembly Legend Identifier Meaning C C ring E E ring KL K clip S Screw Phaser 3500 Laser Printer Service Manual 5 2 Parts List PL 8 1 Main Assembly Network only Phaser 3500 Laser Printer Service Manual 5 3 PL 8 1 Parts List Table Main Assembly Parts List Item No Description Qty Part Number 1 ELA UNIT FRAME BASE 2 ELA HOU BASE HOUSING 3 MEA UNIT KNOCK UP MP 050N00475 3 1 PLATE M KNOCK UP MP 3 2 MPR PAD KNOCK UP MP 3 3 PMO SIDE GUIDE MP R 3 4 PMO SIDE GUIDE MP L 3 5 GEAR PINION 3 6 SHAFT REINFORCEMENT 4 MEA UNIT COVER MP XRX 002N02410 4 1 COVER M MP XRX 4 2 TRAY M EXTND MP 5 TRAY M LINK MP L 012N00521 6 TRAY M LINK MP R 012N00522 7 ROLLER TRANSFER 022E29520 8 ELA UNIT HOLDER TR R 019E63470 8 1 PMO BUSHING TR 8 2 SPRING ETC TR R HAWK 8 3 PMO TRANSFER HOLDER 8 4 IPR PLATE TR 9 ELA UNIT HOLDER TRL 019E63480 9 1 PMO BUSHING TR 9 2 SPRING ETC TR R HAWK 9 3 PMO TRANSFER HOLDER 10 PMO CAP TR 021N02248 11 GEAR TR29 Transfer 007N01013 12 ELA UNIT REGI Registration Assembly 022N02171 13 GEAR REGI Z25 007N01360 14 CAP M GEAR 807E06450 15 UNIT LSU Laser Unit 122N00242 Phaser 3500 Laser Printer Service Man
22. pick selection at power ON is Tray 2 Auto Select ON is also default If the default tray is empty the printer will automatically switch to any other tray that contains paper unless Auto Select is set to OFF Toner Control Print Cartridge installation and Toner Level are detected by the Print Cartridge Interconnect Board and the associated signals are supplied to the Main Board The CRUM not only detects cartridge presence it also determines whether it is a genuine Xerox cartridge When the toner remaining falls to 15 the printer displays a low toner message on the Control Panel display Phaser 3500 Laser Printer Service Manual 8 12 Theory of Operation Laser Light Intensity Control Image data is transmitted to the laser diode in the Laser Unit as digital signals The laser diode converts the image data from digital signals to optical signals data expressed by blinking laser beams The Laser Unit monitors the output to determine if variations in the light intensity from the laser beam variations in the optical system such as mirrors and lenses or variations in drum sensitivity are preventing the system from obtaining a proper electrostatic image and if necessary adjusts the light intensity to attain a stable electrostatic image LSU Error Table Error Description Error Message Polygon Motor The plygon motor speed cannot obtain a steady state Laser Failure Error The polygon motor speed is steady but the Hsync
23. remove it from the printer o 2 g 2 2 Oo lt 3500 128 9 Remove the 4 screws securing the pick assembly and manuever the pick assembly out of the printer Pick Up Unit 3500 129 Phaser 3500 Laser Printer Service Manual 4 31 Repairs and Adjustments Feed 2 Unit 1 Perform all steps for Tray 2 Pick Up Assembly and Rollers on page 4 29 Remove the pick up gear Remove remove the locking bearing pS Pp Remove the 4 screws securing the Feed 2 Unit to the printer and remove the assembly 3500 126 Phaser 3500 Laser Printer Service Manual 4 32 Repairs and Adjustments Developer Drive Assembly 1 Remove m Covers on page 4 4 2 Disconnect the connector from the developer drive assembly 3 Remove 4 screws securing the developer drive to the printer DEVE Drive Ass y 3500 075 Replacement Notes Note There are numbers for replacing each of the 4 screws in the appropriate order when reassembling the Developer Drive Assembly Phaser 3500 Laser Printer Service Manual 4 33 Repairs and Adjustments Connector Board 1 Remove m Covers on page 4 4 2 Disconnect all connectors to the connector board a Remove 1 screw securing the board to the chassis 4 Remove the connector board 3500 076 Phaser 3500 Laser
24. used by the Print Cartridge The power distribution section receives AC voltage and creates the required DC outputs 3 3 VDC 5 VDC and 24 VDC to power the printer components It also supplies AC voltage to the Fuser Assembly 31 Phaser amp 3500 Laser Printer Service Manual 6 11 Theory of Operation Paper Size Control The paper size selection for Tray 2 and Tray 3 is set by moving the paper guide in the tray This in turn sets the plastic fingers on the side of the paper tray to a specific postion The position of the fingers activates the correct combination of the three paper size switches located in each paper tray slot for the selected paper size Additionally the back of the tray must be pulled down in order to select the two largest sizes US Folio and Legal Not all sizes can be used in both trays See Media and Tray Specifications on page 6 9 for a complete listing of the media types for each tray Additional media types can be used in Tray 1 MPT After inserting the media in Tray 1 use the Control Panel controls to select the media type Paper Size Switches are identified as SW1 SW2 and SW3 Paper Size Switch Paper Size SW1 SW2 SW3 LEGAL 14 ON ON OFF US FOLIO LEGAL 13 OFF OFF OFF A4 OFF ON ON LETTER ON OFF OFF EXECUTIVE OFF ON OFF B5 ON OFF OFF B5 JIS B5 OFF OFF ON A5 ON ON ON No Tray OFF OFF OFF Paper Pick Auto Select The default paper
25. zc 2 Sal ane A traced e aee o Re NA Gul aces 8 11 Paper Size Control seien trek RAO EA CREER diane deba ce ig 8 12 Paper Pick AU tO0 S l CL 55 s 2 4 a a0 kk waya porn a 8 12 Toner Control o 3 a ya a wo WA ia aliy la Da Eda wa aoe ea 8 12 Laser Light Intensity Control 8 13 Fuser Temperature Controles erros 4 nalan s xel n at n e 8 13 Phaser 3500 Laser Printer Service Manual xii Service Call Procedures This section includes the following m Servicing Instructions on page 1 2 m 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 m any image quality problems in the test prints m any mechanical or electrical abnormalities present m 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 Cle
26. 0 PL 8 3 Parts List Table Frame Assembly Parts List Item No Description Qty Part Number 1 FRAME M BASE 2 MEA UNIT PICK UP MP 022N02172 2 1 SHAFT M PICK UP MP 2 2 PMO IDLE PICK UP MP 2 4 ELA UNIT ROLLER P UP MP 022N02182 2 4 1 HOLDER M PICKUP MP 2 4 2 HOUSING M PICK UP MP 2 4 3 RUBBER PICK UP MP 2 5 CAM M SHAFT 3 MEA UNIT GEAR IDLE 007N01362 3 1 BRACKET P GEAR IDLE 3 2 GEAR FUSER IDLE 3 3 3 GEAR M FUSER IDLE 2 3 4 GEAR M FUSER DRV IN 3 5 CLUTH M HUB 3 6 GEAR RDCN FUSER OUT 3 7 RING E 4 ELA HOU BASE HOLDER 022N02173 4 1 FRAME M HOLDER PAD 4 2 HOLDER M PAD 4 3 RPR FRICTION PAD MP 4 4 SPRING ETC PAD 4 5 PMO ACTUATOR EMPTY MP 4 6 SPRING ETC EMPTY 4 7 PHOTO INTERRUPTER 4 8 CBF HARNESS MP EMPTY 5 MEA RACK EXIT ROLLER 059K39110 5 1 PMO HOLDER EXIT ROLL 5 2 PMO ROLLER FD F 5 3 PMO ROLLER FD R Phaser 3500 Laser Printer Service Manual 5 11 Frame Assembly Continued Parts List Item No Description Qty Part Number 5 4 SPRING EXIT ROLL FD 6 ROLLER EXIT F DOWN 006N01264 7 HOLDER M BUSHING EXIT 013E25770 8 PMO ACTUATOR OUT FULL 120N00479 9 GEAR M EXIT Z17 007N01364 10 HOLDER BUSHING EXIT F DOWN 013E25770 11 MEA UNIT ROLL EXIT DUPLEX 006N01265 11 1 SHAFT M EXIT DUPLEX 11 2 RMO RUBBER
27. 27 GUIDE M PAPER SIZE Phaser 3500 Laser Printer Service Manual 5 21 Parts List PL 8 10 Tray 3 Cassette Phaser 3500 Laser Printer Service Manual 5 22 Parts List PL 8 10 Parts List Table Tray 3 Cassette Item No Description Qty Part Number 0 ELA UNIT SCF 1 FRAME M SCF 2 COVER M RIGHT SCF 3 COVER M LEFT SCF 4 COVER M DUMMY SCF 5 PBA SCF 140N63018 6 CBF HARNESS OPE 8 BUSH CABLE 9 CBF HARNESS SCF INTERFACE 152N11620 10 SOLENOID MAIN 11 ELA UNIT MOTOR SCF 127N07392 11 1 BRACKET P SCF MOTOR 11 2 MOTOR STEP 7 5 DEG 11 3 GEAR M SCF RDCN RETARD 11 4 GEAR M SCF RDCN FEED 11 5 GEAR M SCF RDCN PICK UP 12 CBF HARNESS OPE 13 IPR GROUND SPRING FEED 14 PMO BEARING SHAFT 15 MEP CLUTCH FEED SCF 121N01104 16 RING E 17 SHAFT M COUPLING RETARD S 18 SHAFT M GEAR RETARD 19 GEAR REGI Z25 20 BAR P CROSS BOTTOM 21 PMO REMOVE LOCK CST 22 ELA UNIT RETARD SCF 022N02179 22 1 RING E 22 2 SPRING TS 22 3 SPRING ETC PAD Phaser 3500 Laser Printer Service Manual 5 23 Tray 3 Cassette Continued Parts List Item No Description Qty Part Number 22 4 HOUSING M RETARD 22 5 HOLDER M RETARD 22 6 BUSH M RETARD 22 7 SHAFT RETARD 22 8 SHAFT HUB IN 22 9 PMO HUB OUT RETARD 22 10 PMO HU
28. 300 dpi m 600 Used for printing with a resolution of 600 x 600 dpi m Enhanced mode Used for printing on plain paper with an addressable resolution of 1200 x 1200 dpi Phaser 3500 Laser Printer Service Manual 8 3 Theory of Operation Printer Paper Path Imaging Drum OPC Exit Roller Registration Sensor Heat Roller V Exit Duplex Roller Tray 1 Pick Roller e n zoe NE Idler Tray 1 LL Fuser Exit Roller No du he M LL Sensor Nee Fuser Exit Sensor Feed 2 Idler i Pressure Roller Feed 2 we je Roller Ss Retard 7 uad Feed 1 e Duplex Tray 2 Rollers Pick okr 7 Duplex Sensor Retard Roller Tray 3 Feed Roller Tray 3 Pick Roller Tray 3 No Paper Sensor Tray 2 No Paper Sensor Media that meets printer specifications can be fed from Trays 1 and 2 or the optional Tray 3 If you use thick paper with a weight of more than 105 gsm 60 lbs you must insert the paper into Tray 1 and select the paper type Paper will exit the printer to the face down top tray A door at the rear of the printer provides access for jam clearance The diagram below shows the paper path and identifies the major components of the printer The simplex paper path is shown in black and the duplex path is shown in gray All major components of the printer are explained in greater detail under Printer Controls on page 8 9 Duplex Paper Path When 2 sided printing is selected side two is printed first the
29. 4 RING E 3 MEA UNIT FUSER LOWER 3 1 ROLLER PRESSURE 3 2 BUSH M PR 3 3 SPRING PR ROLL 3 4 COVER M FUSER LOWER 3 5 LEVER P RELEASE L 3 6 SPRING CS 3 7 CAP M FUSER LOCK 3 8 LEVER P RELEASE R 3 9 HOLDER M PR SHAFT 3 10 GROUND P HR 3 11 SPRING ETC ACTUATOR 3 12 PMO ACTUATOR EXIT 3 13 CAP M ACTUATOR 3 14 SCREW TAPTITE 4 MEA UNIT GUIDE REAR 4 1 GUIDE M REAR 4 2 PMO BUSHING TX 4 3 SHAFT M EXIT F UP 4 4 GEAR M EXIT DUP Z21 4 5 RUBBER EXIT F UP Phaser 3500 Laser Printer Service Manual 5 19 Parts List PL 8 9 Tray 2 Cassette 20 3 20 420 Phaser 3500 Laser Printer Service Manual 5 20 PL 8 9 Parts List Table Parts List Tray 2 Assembly Item No Description Qty Part Number 0 ELA UNIT CASSETTE FRAME M CASSETTE 2 GUIDE M HANDLE 3 INDICATOR EMPTY 4 PLATE P KNOCK UP 5 SPRING PLAT K UP 6 GEAR PINION 7 CAP M GUIDE SIDE L 8 GUIDE P SIDE L 9 GUIDE M SIDE LOCK 10 GUIDE P SIDE R 11 GUIDE M REAR 12 GUIDE P REAR PAPER 13 SPRING ETC GUIDE PAPER 14 GUIDE M LOCK 15 GUIDE M REAR 16 GUIDE M EXTENTION 17 BRACKET P EXTENTION 18 GUIDE M PAPER 19 HOLDER M PAD HOUSING 20 MEA UNIT HOLDER PAD 019N00831 20 1 HOLDER M PAD 20 2 SHEET HOLDER PAD R2 20 3 RPR FRICTION PAD 20 4 IPR PLATE PAD 21 SPRING EXIT ROLL FD 25 PMO LOCKER PLATE 26 SPRING LOCKER PLATE
30. 5 22 PL 8 11 Duplex Assembly on page 5 25 Phaser 3500 Laser Printer Service Manual 5 1 Parts List Using the Parts List 1 No The callout number from the exploded part diagram 2 Part Number The material part number used to order specific parts 3 Qty This number represents the parts per printer not the number of parts supplied in the actual part order 4 Name Description Details the name of the part to be ordered and the number of parts supplied per order 5 Parts identified throughout this manual are referenced PL For example PL 3 1 10 means the part is item 10 of Parts List 3 1 6 A black triangle preceding a number followed by a parenthetical statement in an illustrated parts list means the item is a parent assembly made up of the individual parts called out in parentheses 7 The notation with X Y following a part name indicates an assembly that is made up of components X through Y For example 1 with 2 4 means part 1 consists of part 2 part 3 and part 4 8 An asterisk following a part name indicates the page contains a note about this part 9 The notation NS next to a part indicates that pariticular part is not spared but contained in a kit or major assembly 10 The notation J1 lt gt J2 and P2 is attached to a wire harness It indicates that connector Jack 1 is attached to one end of the wire harness and connector J2 is attached to the other end that is plugged into P2 Only
31. B IN RETARD 22 11 FRAME M RETARD 22 12 RUBBER RETARD 23 PMO M DUMMY SCF LEFT 24 PMO M DUMMY SCF RIGHT 25 SHAFT PICK UP SCF 27 PBA SCF COVER OPEN 28 ELA HOU CST SENSOR 29 PHOTO INTERRUPTER 30 PMO ACTUATOR EMPTY SCF 120E26100 31 GEAR SCF PICK UP CAM 007N01366 32 FOOT ML80 33 IPR GROUND TOP 34 MEA UNIT PICK UP HOU 34 1 PMO M IDLE PICK UP 34 2 RUBBER PICK UP 34 3 HOUSING M PICK UP 35 PMO BUSHING FEED 36 PMO M DUMMY SHAFT 37 SPRING ES 38 HOUSING M FEED1 39 RUBBER FEED1 40 CBF HARNESS MOTOR 41 CBF HARNESS SCF EMPTY 42 CBF HARNESS SCF CASSETTE 43 CBF HARNESS SCF P SIZE Phaser 3500 Laser Printer Service Manual 5 24 Parts List PL 8 11 Duplex Assembly I D D yr Phaser 3500 Laser Printer Service Manual 5 25 PL 8 11 Parts List Table Duplex Assembly Parts List Item No Description Qty Part Number 0 ELA UNIT DUPLEX 1 FRAME M DUPLEX 2 GUIDE M UPPER DUP 3 COVER M REAR DUP 4 MEA ETC ALIGN DUP 4 1 GUIDE M ALIGN DUP 4 2 SHAFT IDLE ROLL DUP 4 3 ROLLER M IDLE DUP 4 4 PCT SLIP WASHER 4 5 SPRING ETC DUP 4 6 PULLEY M 18 DUMMY DUP 4 7 PULLEY 18 DUP 4 8 BUSH M FEED DUP 4 9 BELT TIMMING 4 10 ROLLER FEED DUP 4 11 RING C 4 12 ICT STUD PAPER GUIDE DP 5 CAP M CONNECTOR DUP 6 DUCT M FAN DUP 7 FAN DC HAWK 8 PBA SUB DPX SCF 9 CABLE
32. BBER BELT FEED 48 8 GUIDE M SHAFT BELT 49 ELA UNIT RETARD 022N02175 49 1 FRAME M RETARD 49 2 HOLDER M RETARD 49 3 SPRING ETC PAD Phaser 3500 Laser Printer Service Manual 5 13 Frame Assembly Continued Parts List Item No Description Qty Part Number 49 4 BUSH M RETARD 2 49 5 HOUSING M RETARD 49 6 SHAFT RETARD 49 7 RING E 49 8 PMO HUB OUT RETARD 49 9 SPRING TS 49 10 PMO HUB IN RETARD 49 11 RUBBER RETARD 50 ELA UNIT FEED2 IDLE 022N02176 50 1 HOLDER IDLE FEED2 50 2 CAP M IDLE FEED2 50 3 SPRING ETC PAD 50 4 BUSH M RETARD 50 5 SHAFT IDLE FEED2 50 6 RING E 50 7 ROLLER M IDLE FEED2 50 9 SHAFT HUB IN 51 STOPPER M KNOCK UP MP L 52 STOPPER M KNOCK UP MP R 53 RAIL M LEFT DUPLEX 032N00441 54 RAIL M RIGHT DUPLEX 032N00442 55 PMO BEARING SHAFT 56 GEAR REGI E25 57 BEARING PICK UP 58 PMO ACTUATOR EMPTY 120E26090 59 ELA UNIT PICK UP 022N02183 59 1 SHAFT PICK UP 59 2 MEA UNIT P UP HOUSING PICK ROLLER 022N02177 59 2 1 PMO M IDLE PICK UP 59 2 3 RUBBER PICK UP 59 3 PMO M CAM PICKUP 59 4 SHAFT FEED 1 Phaser 3500 Laser Printer Service Manual 5 14 Frame Assembly Continued Parts List Item No Description Qty Part Number 59 5 AS FEED 1 ROLL ASSY 022N02187 59 5 1 HOUS
33. Charge Roller Voltage Charge Roll Roll 1200V is supplied when ON OFF Voltage OK is pressed and goes off when Cancel is pressed Transfer Positive Transfer Voltage Transfer Roll Roll 1200V is supplied when 95d OK is pressed and goes off when Cancel is pressed ON OFF d is the value of the ADC Transfer Negative Transfer Voltage Transfer Roll Roll 800V is supplied when ON OFF OK is pressed and goes off when Cancel is pressed Measure voltage with a DMM if required Pre PTL turns on when OK is Pre transfer Lamp transfer pressed and goes off when ON OFF Lamp Cancel is pressed Visual PTL confirmation is possible with the cover open and the Print Cartridge removed Laser Scan Laser Laser Diode0 On is Laser DiodeO Unit Diode 0 displayed when the laser ON OFF diode is on In the other case Laser DiodeO Off is displayed Laser Laser Diode1 On is Laser Diode1 Diode 1 displayed when the laser diode is on In the other case Laser DiodeO Off is displayed ON OFF Phaser 3500 Laser Printer Service Manual 2 8 Repair Analysis Procedures Main Menu Sub Menu Description Function Control Panel Display L Motor Ready This tests if the laser unit is ready and capable of printing or at a stable polygon motor speed Laser Ready Test Pass Fail Fuser Fuser Temp When the Target Temp is displayed INput the temperature you would like to set with the arrow bu
34. Duplex Paper Path 34 s sh na meet exem ero RE Rey eye eie wen 8 4 Paper F ed Sequence i oia d ea cetera cox aa dca sana s 8 5 Paper Transport esee err eth VR Oe eye eye e 5 5 8 5 Paper Feed Dive oeiee sa k ka tede ugue Bee ae bale 8 5 Major Assemblies and Functions 0 0 cee KK KK KK ee kK KK KK KK KK KK KK kk 8 6 Tagin oe aioe state dee ml bb 8 6 Print Cartridge yi k n ctr aa xa a eoe 8 6 Laser Scan Unit LSU eissi sk kay k a eem eee o D hera s 8 7 Transfer Roll r gg is s ede eo tee d taeda di d z aaa CR s 8 7 Fuser Assembly eec doe ee ee nes dee E a OE da d i W L 8 7 Sensor Functions ovr y ee bas na alen shee HERRERA UOS VIERTE Re EEUU oe eee 8 8 Paper Empty Sensor 1 0 0 cece KK KK KK KK KK KK KK KK KK KK K 8 8 Tray 1 Paper Empty Sensor 20 kk k kk kk kk kk kk kk kk lk kel 8 8 Registration Sensor kk kK KK KK KK KK KK KK KK KK KK KK KK KK KK KK k 8 8 Fuser Exit SensOE oes eet ete eee ae a n a dl s dal en ep eed 8 8 Cover Open Sest rra x a a ens ch 2una eb a cla i 2 0 2k 8 8 Duplex Unit Sensor e cc twee ew a a Sa pa pedibus 8 8 Printer Controls etie shee epe s bbe eae Q sated ee W Ar 8 9 Image Processor Function 8 9 Print Engine Control usa eu ia REA RA Wo ua e RU E a ed 8 9 Main Bo rd s aceto ced eara ka 2 ee Wed i 029e er reds 8 10 Power Supply
35. ING M FEED1 59 5 2 RUBBER FEED1 59 6 GROUND P PICK UP MAIN 59 7 BEARING PICK UP 59 8 PMO BUSHING FEED 59 9 GUIDE P FRONT DUP PICKUP 59 10 GUIDE M SUPPORT PICKUP 60 ELA UNIT FEED2 022N02178 60 1 FRAME M PICK UP 60 2 PMO BUSHING FEED 60 3 SHAFT M FEED2 60 4 BEARING PICK UP 60 5 RUBBER ROLLER FEED2 61 PBA SUB JOINT 140N63022 62 CBF HARNESS TRAY OUT 63 CAP M POWER 64 CBF HARNESS INLET 152N11619 65 SHAFT M BELT GEAR 66 PMO BEARING SHAFT 67 GEAR M EXIT Z17 68 CAP M DEVE MOTOR 69 CBF HARNESS DUPLEX 71 CAP M WIRE PTL LOWER 021N02249 72 TERMINAL P PTL 116N00243 73 CBF HARNESS PTL 74 PBA SUB COVER OPEN 130N01399 76 PBA SUB EXIT SENSOR 130N01400 77 PBA FUSER SW 130N01401 78 GUIDE M FRONT 79 TERMINAL P GUIDE FRONT Phaser 3500 Laser Printer Service Manual 5 15 Frame Assembly Continued Parts List Item No Description Qty Part Number 80 ELA UNIT FUSER 110V 126N00242 ELA UNIT FUSER 220V 126N00243 81 PMO GUIDE DEVE L 82 PMO GUIDE DEVE R 83 SPRING ETC GUIDE DEVE 84 TERMINAL P TR KESTREL 86 TERMINAL SPRING TR 87 PBA MAIN ZENER 88 CBF HARNESS EARTH 89 GROUND P ZENER 90 GROUND P FUSER 91 TERMINAL P HV CARDINAL 92 MEA UNIT TERMINAL TR 93 CBF HARNESS HVPS 94 IPR P GROUND OPC 95 PBA SUB EMPTY SENSOR 140N63023 96 CBF HARNESS SENSOR 97 PBA SUB FEED SENSOR 140N63024 98 CAP M HV 99 CAP M SENSOR FEED 100 DUCT M FAN
36. Laser Failure signal is not generated Hsync Error Fuser Temperature Control During Fuser temperature control the printer s target temperature is set The heat roller surface temperature is controlled to match the target temperature by turning the heat element ON OFF The heat roller surface temperature is detected by a Thermistor If the Thermistor shows that the temperature is higher than the target the heat element is turned OFF If the detection result is low the heater lamp is turned ON The fuser control circuit keeps the Fuser temperature at 185 C during printing and at 145 C during standby m When the power voltage for the printer is too high or too low the Fuser is stopped to protect the Fuser m When the AC voltage is not applied to the Fuser control circuit the fuser will not work and a Fuser Low Heat Error will occur m When the temperature of the Fuser is too high an Engine Overheat error occurs if the cooling operation is insufficient Fuser Error Table Error Description Error Message Open Heat Error When warming up the Fuser has been lower than 60 degrees C for over 35 seconds Fuser Failure Low Heat Error Stand by m Lower than 130 degrees C for over 10 seconds Printing m Upto 2 consecutive pages Lower than 155 degrees C for over 7 seconds m From 3 consecutive pages Lower than 25 degrees C than the fixed fusing temperature over 7 seconds Engine
37. Low Heat Error Over Heat Error Temperature is higher than 230 degrees C over 10 seconds Engine Over Heat Error Phaser 3500 Laser Printer Service Manual 8 13 071 0877 00
38. Printer Service Manual 4 34 Repairs and Adjustments Tray 1 MPT Solenoid 1 Remove m Covers on page 4 4 2 Disconnect the connector to the Tray 1 Solenoid 3 Remove 1 screw securing the Tray 1 Solenoid 3500 078 Phaser 3500 Laser Printer Service Manual 4 35 Repairs and Adjustments Main Solenoid 1 Remove m Covers on page 4 4 m Feed Clutch on page 4 24 2 Disconnect the connector to the Main Solenoid 3 Remove 1 screw securing the Main Solenoid 3500 079 Phaser 3500 Laser Printer Service Manual 4 36 Repairs and Adjustments Fuser Assembly 1 Remove m Rear Cover on page 4 6 2 Pull the locking lever and take out the Fuser Assembly Thermistor Connector 3500 090 Phaser 3500 Laser Printer Service Manual 4 37 Repairs and Adjustments Exit Solenoid Assembly 1 Remove m Covers on page 4 4 m Left Cover on page 4 5 m Top Cover on page 4 8 2 Disconnect the connector running to the main board 3 Remove 3 screws securing the solenoid to the printer 4 Remove the solenoid assembly Note There is a resistor attached by the upper right hand screw When reassembling the printer ensure the resistor is in place 3500 099 Phaser 3500 Laser Printer Service Manual 4 38 Repairs and Adjustments Exit and Duplex Rollers 1 Remove
39. Running Mode Print engine capable of making prints immediately Ready Mode 20 seconds from completion of a print Sleep Low Power Power Saver Mode Entered after a specified period of Print Engine inactivity since completion of the last print Continuous Operating Printing Speed ppm pages per minute Letter Up to 35 ppm A4 Up to 33 ppm Cleaning Cycle interval for continuous printing First Print Out in seconds 10 seconds or less Warm Up Time Power on Boot 40 seconds or less Phaser 3500 Laser Printer Service Manual 6 7 Electrical Specifications General Information and Specifications Characteristic Specification Primary line voltages 110 127 V Printer 100 135 V 13 amp circuit 220 240 V Printer 180 264 V 7 8 amp circuit Primary line voltage frequency range 100 135 V Printer 50 60 Hz 3 Hz 220 240 V Printer 50 60 Hz 3 Hz Power consumption Printing 550 Watts average Sleep under 10 Watts Environmental Specifications Characteristic Specification Optimal Temperature 10 30 degrees C 50 60 degrees F Optimal Humidity 20 80 Relative Humidity Altitude Operating Low Altitude Setting High Altitude Setting Transportation 0 2 500 meters 8 200 ft 0 2 050 meters 6 726 ft 2 050 2 500 meters 6 726 8 200 ft 0 6 092 meters 20 000 ft Acoustic Noise Idle Printing 35 0
40. S 6 4 Front View sa tte d n eed n na c v da ERE Edd BER ee 6 4 Rear View cois A ke a kalan len a lk dea lal wade lh n ar law p w ea es ul kh 6 4 Control Panel os suk se bee ey etre E egy ee ce See W n EE k LE nr d 6 5 Men Ma sek rmm aw a Seb Qi adit Wate e p qoe eg e ree e dp e pan qi ar vaka 6 5 Error and Warning Messages l l 6 5 Printer Specifications llle m 6 6 Printer Location and Clearance W k kk kK KK KK KK KK KK ee 6 6 Printer Physical Specifications kK kK KK KK KK KK KK KK KK KK KK KK KK KK k 6 7 Functional Specifications 0 0 kK KK KK KK KK KK KK KK KK KK KK KK KK KK kk k 6 7 Electrical Specifications 0 0 ccc cee e 6 8 Environmental Specifications 0 0 kk KK KK KK KK KK KK KK KK KK KK KK KK k 6 8 Media and Tray Specifications kk kk lk kal kalk k l k al l9 a kk anal kl a a arl kl a 6 9 1 Wiring Data Block Diapram eee aw e ae a Ride alae x gue n pe ce RR 7 2 Phaser 3500 Laser Printer Service Manual xi Contents 8 Theory of Operation Overview of the Phaser 3500 Laser Printer 0 0 KK KK KK KK KK KK KK KK KK KK KK 8 2 Summary of the Printing Process 0 0 cece KK KK KK KK KK KK KK kK KK kk k 8 2 Print MOGES copre pesce mee eR mm eee dre 8 3 Printer Paper Path i lt 54 5 431 255 e E Guts d wiha Op ciega he d pe a e doa a RE x 8 4
41. Service Manual 4 42 Repairs and Adjustments LSU Lower Cover 1 Remove 1 screw securing the fan duct Remove the fan and duct to access the screw in the next step Remove 3 screws securing the LSU Cover and remove the cover pm Disconnect all the connectors running to the LSU Cover 3500 113 Phaser 3500 Laser Printer Service Manual 4 43 Repairs and Adjustments Left Side Cooling Supply Fan and Duct 1 Remove m Covers on page 4 4 m Left Cover on page 4 5 m Top Cover on page 4 8 m Laser LSU Assembly and Lower Cover on page 4 42 2 Disconnect the connector to the Toner Sensor Board 3 Remove 1 screw to remove the fan from the printer 3500 108 Phaser 3500 Laser Printer Service Manual 4 44 Repairs and Adjustments Toner Sensor Board and CRUM 1 Remove m Covers on page 4 4 m Left Cover on page 4 5 m Top Cover on page 4 8 m Laser LSU Assembly and Lower Cover on page 4 42 2 Disconnect all connectors running to the toner sensor board o Remove 2 screws securing the toner sensor board to the LSU cover 4 Release the 2 locking tabs to remove the board f Toner Sensor PBA HV Small LAM Spring Ka Ai D 3500 111 Phaser 3500 Laser Printer Service Manual 4 45 Repairs and Adjustments Cover Open Board and Harness Cover 1 mom mM Remove Cove
42. Use diagnostics to check the laser motor function 2 Did the laser motor fail Replace the Laser Unit Replace the Main Board Output Tray Is Full Step Actions and Questions Yes No 1 1 Check the Output Tray sensor and Replace the actuator Go to Step 2 actuator for obvious damage 2 Is the actuator damaged 2 1 Use diagnostics to test the output tray Replace the Main Replace the Output sensor 2 Does the sensor operate correctly Board 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 ae eS ee Verify that power cord is securely plugged into both the printer and the grounded three prong AC outlet with the appropriate power available Ensure that all covers are securely closed Verify the Top Cover Print Cartridge and Fuser interlocks are functional Verify voltages at the Main Board see Power Supply Troubleshooting on page 2 18 Replace the Power Supply Board Replace the Main Board Replace the Control Panel Control Panel LED is On Control Panel Display Is Blank 1 2 3 Remove and reseat the Control Panel wiring to the Main Board Replace
43. XEROX 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 Up 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 J enson 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 Sta
44. a screw or a printer part A spring hook is required for removal and replacement of the various springs in the printer Springs can be damaged using pliers or other tools for this task Warning Unplug the AC power cord from the wall outlet before removing any printer part Notations in the Disassembly Text W The notation item X points to a numbered callout in the illustration corresponding to the disassembly procedure being performed m The notation PLX X X indicates that this component is listed in the Parts List m Bold arrows in an illustration show direction of movement when removing or replacing a component Phaser 3500 Laser Printer Service Manual 4 3 Repairs and Adjustments Covers Right Cover 1 Disconnect the power cord 2 Remove the Duplex Unit 3 Remove the 2 rear screws securing the Right Cover to the rear of the printer Note In the next step ensure the power switch is in the OFF position in order to free the Right Cover 4 Slide the Right Cover towards the rear of the printer to release the 3 tabs and remove it from the printer 3500 068 Phaser 3500 Laser Printer Service Manual 4 4 Repairs and Adjustments Left Cover Disconnect the power cord Remove the Duplex Unit Open the Rear Cover for access to the rear top screw Remove 2 screws from the rear of the printer securing the Left Cover Close the Rear Cover W W SS PS Slide
45. ale ER o ee he k0 l 5 2 PL 8 1 Main Assembly ccce cereti eee ec eee ee eee a Ei 5 3 PL 8 1 Parts Last Table es beoe Ve karek Penh Ree das 5 4 PL 2 Cover Assembly iu data b ol e kn erar alea als bea dhe x 5 7 PL 8 2 Parts List Table iecur lk ad a Wak ERR E REESE 5 8 PL 8 3 Frame Assembly 2 aatia w eee pa kr el l le ul IR dp E EORR ADR a l 5 9 PL 8 5 Pafts List Table sea ea ee d ecd eee eds 5 11 PI 8 4 Euser Assembly i s ka ae al a e ex UR al a ne esed oh ees ee TR ecc RR 5 17 PL 8 4 Parts List Tables A ss n Sa Ayl Nun a l err WWW eR eR 5 18 PL 8 9 Tray 2 Cassette Zi heehee besa eR nde dee RE ERU hee ea GR Y coe cues 5 20 PL8 9 Parts List Table ues eee re Mpa bee ad daka e ace gis 5 21 PI 8 10 Tray 5 Cassettes s est cia eR Uere Ra E OA S EROR elas 5 22 PL 8 10 Parts List Table ci cee eee eee be Re E rn 5 23 PL 8 11 Duplex Assembly onci 4 525 4 23 2L2 2 l 2 RR US U An Wa 4 A r W u ves 5 25 PL 8 11 Parts Last Table cco cina its esee h al Hatta a e arika al 4 hed 5 26 6 General Information and Specifications Printer Configurations ss rre e Va ee e k 8ye 4 lk og leva e nta 6 2 Printer Options and Supplies kk kK kk kk kk KK KK KK KK KK KK re 6 2 Consumable and Service Part Life Expectancy 0 0 cece KK KK KK KK KK KK K KK KK 6 3 Parts of the Print E ue Ak bal n dla al l ki CE RERO ha 4 dd o j heb lk she pud
46. an 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 m Do not use solvents or chemical cleaners to clean the printer interior m Do not use any type of oil or lubricant on printer parts m 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
47. and are easy to lose 3500 059 4 Slide Tray 1 to the right side of the printer to release the 4 pivot points securing the Tray then remove the Tray 1 Assembly from the printer Phaser 3500 Laser Printer Service Manual 4 13 Repairs and Adjustments Tray 1 Knock Up Plate 1 Follow all the steps for removing the Tray 1 MPT Assembly on page 4 12 2 Rotate the tray links down slightly until they come free from the printer Note The tray links are marked L for the left and R for the right 3 To free the Knock Up Plate carefully spread the slotted hinge piece to release the post then remove the Knock Up Plate Note Tray 1 and the Knock up Plate contain unsecured plastic parts that fall off and are easy to lose Tray Link 3500 060 Phaser 3500 Laser Printer Service Manual 4 14 Repairs and Adjustments Tray 1 Pick Up Rack 1 Remove 2 screws securing the Pick Up Rack and remove the rack 2 Separate the clips from the Pick Roller shaft and remove the Pick Up Rack Caution Do not remove or loose the springs MP Pick Up Rack v Sud 3500 118 Phaser 3500 Laser Printer Service Manual 4 15 Repairs and Adjustments Inner Cover 1 Remove m Tray 1 MPT Assembly on page 4 12 m Top Cover on page 4 8 2 Open or remove Tray 2 for better access Remove 2 screws securing the Inner Cover to th
48. b diw Banded doe 4 34 Tray MPT Solenoid iive bete Fed RE do wees seed 4 35 Main Solenoid gt 24 552k sn H ka w P ken P k G N V din E pEEIaWHEpLUPIA ie 4 36 Fuser Assembly siz Kl k l n Wi b l n Kil Wa li PE WE ee E l WE A S LEBER 4 37 Exit Solenoid Assembly 0 00 2 cece KK HRW WR n k Ke 2 WEN 6 4 38 Exit and Duplex Rollers x k s k eee Ewdi a kula a e Kala ran 4 39 Exit GER gt 42 35554508 5 32 key k Sites Shee Wi e n ELE REESE 4 40 Tray Pull Actuator aons 23 0 nn lana Wa al n E ete held dle Q R a ene le Kn ekani 4 40 Duplex Roller epee prerade LEA ea K la i ko Wek E QE ee 4 41 Laser LSU Assembly and Lower Cover 0 0 0 cece cece cece eee 4 42 LSU EoWetCOVer a p bata dee Maa aa AS Ra n bee ER E E 4 43 Left Side Cooling Supply Fan and Duct 0 0 0 eee eese 4 44 Toner Sensor Board and CRUM kk kk kk kk kk kK kk KK KK KK kk kk teenies 4 45 Cover Open Board and Harness Cover 0 0 00 KK eese 4 46 Main Board and Shield gt As xu Sean belek Waly AN k W y e eh 4 47 Power Supply and Shield 2 0 1 ne a E cece k l n teens 4 48 Fuser Gear Assembly gt 2a 22e ll k oe bas doen he klr ERE HU bee edie ban 4 50 Paper Size Sensor posene bd eee hae S A eer dds dad eee honed on 4 51 Phaser 3500 Laser Printer Service Manual x Contents 5 Parts List Using the Parts List eer aoo le eek veda e e
49. cal Defect Print Cartridge Developer Roller 50 mm 1 97 in Horizontal image band Drum 94 mm 3 70 in White spots on black image or black spots on white Drum Charge Rollers 38 mm 1 50 in Black spots Supply Roller 42 mm 1 65 in Light or dark horizontal image bands Transfer Roller Transfer Roller 56 mm 2 20 in Image ghost Fuser Assembly Heat Roller 126 mm 4 96 in Black spots and image ghost Pressure Roller 126 mm 4 96 in 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 image quality parameter The following pages explain each of the areas and the image quality parameters Follow these guidelines when generating the test print m Use supported paper from a fresh unopened ream m Print five copies of the test print m 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
50. ctors clear the bracket and remove the Main Board to the right Remove 1 screw in the center of the shield Turn the printer onto its left side and remove the rear crossbar and the right duplex guide Remove the right rear corner screw from the power supply shield to remove 3500 071 Phaser 3500 Laser Printer Service Manual 4 47 Repairs and Adjustments Power Supply and Shield 1 Remove Print Cartridge Tray 2 and Tray 3 if installed Covers on page 4 4 Rear Cover on page 4 6 Fuser Assembly on page 4 37 Turn the printer onto it s left side Remove the rear crossbar secured by 2 screws Remove the Tray 2 no paper actuator for better access PS Remove the left and right duplex unit guides Y Zu SEN HEK 23 7 Guide Duplex R 53500 136 Phaser 3500 Laser Printer Service Manual 4 48 Repairs and Adjustments 6 Remove 5 screws from the power supply shield 7 Remove 1 grounding screw from the rear of the power supply shield Engine Shield im SSy ES 3500 135 8 Pull out the shield slightly and disconnect all connectors to the power supply board 9 Remove the power supply from the printer 3500 137 Phaser 3500 Laser Printer Service Manual 4 49 Repairs and Adjustments Fuser Gear Assembly 1 Remove Print Cartridge Tray 2 and Tray 3 if installed Covers on page 4 4 Rear Cov
51. db or less 49 0db or less Phaser 3500 Laser Printer Service Manual 6 8 General Information and Specifications Media and Tray Specifications Media Input Size Weight Source Media Types Media Sizes Media Weights Tray 1 Paper Envelope Paper A4 Letter Legal Folio 16 Ib 28 Ib Labels Transparency ISO and JISBS 60 176 gsm Tray 2 Paper Cardstock A4 Letter Legal Folio 16 Ib 43 Ib Min 76 mm x 127 mm apes ra m nn 60 105 gsm 3 in x 5 in A6 Statement Monarch COM 10 C5 DL 8 x5 99 Cover Max Legal Tray 3 Paper A4 Letter Legal Folio 16 Ib 28 Ib Executive ISO and JISB5 60 105 gsm A5 Duplex Paper A4 Letter Legal Folio 20 Ib 24 Ib 75 90 gsm Phaser 3500 Laser Printer Service Manual 6 9 Wiring Data Phaser 3500 Laser Printer Service Manual 7 1 iring Data Wi Block Diagram 81 0068 GND SZ LZ 9Z NO WiSni St aweze ama oasa Te qwooz Ni AlLU 6T 22A 8T GWEN AHL LI Dv 9T WMT ABL SI ACER VE QVE ABW ET SERRE meen es AGTEH TT Wa AH TE AE E OT N MI SIG ESSDi 6 SAPE 9 W Hd OON ARC L Ave C9 NOD OW AND S Ave dd ov nga ave Z wud OW MATO NO LOW AgaU X1 LOW Aud E ogu Epi tj Xl1dd0S S AH V move ED E nar ALAWI d 9T NIG IndG INVO ST I XH d WI XI RIVO ET SA Stuy ON ASHU ET ZHSU ZIZHSU IT
52. 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 iil ue XV ERERUEN T bead EE E E deal coda bee se eater aes ii Cautions Notes and Warnings kk kk kk kK KK KK KK KK KK KK KK KK KK kK kK kK kk ii Product Terms os ele sla 252 53 Mae ba es Shae AN ad ee A abe ii Symbols Marked on the Product ii Power Safety Precautions 2 senses end vende ma ak e rr RR ede ig iv PowerSource u s kl a cba e nth w Gi EA ed how pd er eden iv Disconnecting POWEL s 4 33 548 2331500 21 ex
53. ductors 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 In
54. e U Cartridge print cartridge Main board 2 Replace in the following m Laser is always ON order m Print Cartridge m Power Supply Board m Main Board m Laser Assembly s3500 045 Dark Image m Incorrect Control Panel 1 Verify Remote Control Panel settings setting for the Print Density fs rk of the print are too a Print Cartridge menu is not set to dark m Incorrect high voltage 2 Verify that the high voltage outputs Developer Bias contacts are operational and voltage make good contact with the print cartridge m Laser assembly 3 Replace the following in order m Print Cartridge m Power Supply Board m Laser assembly Background Contamination Media paper 1 Verify that paper meets i i printer specifications Print 20 Uniform toner contamination in Bi kulmek o E to 30 pages using non image area QW MIDI recommended paper If using m Transfer Roller recycled paper try non m Incorrect High Voltage recycled paper 3500 046 outputs Printer is installed in specified environment Replace Print Cartridge Inspect Transfer Roller for contamination and good electrical contact replace if required Clean the Pre transfer Lamp Replace Power Supply Board Phaser 3500 Laser Printer Service Manual 3 8 image quality Troubleshooting Image Defect Possible Causes Solutions Ghosting Image from the previous page prints on consecutive pages 3500 047 Operating en
55. e are numbers for replacing each of the 6 screws in the appropriate order when reassembling the Main Drive Assembly There is a veristor that is secured underneath the number 3 screw Phaser 3500 Laser Printer Service Manual 4 25 Repairs and Adjustments Tray 1 Pick Up Assembly and Pick Rollers Tray 1 Pick Roller Only Note If you are only removing the Pick Roller and not the shaft it may be necessary to rotate the shaft release the solenoid and then rotate the shaft gear clockwise to position the roller properly Caution Do not break the pick shaft by trying to force the pick roller off 1 Slide the idle gears outward Release the locking tab on the pick roll assembly and slide the roller to the right Pick Roller 3500 123 Phaser 3500 Laser Printer Service Manual 4 26 Repairs and Adjustments Pick Roller and Shaft Removal 1 Remove Covers on page 4 4 Left Cover on page 4 5 Top Cover on page 4 8 Tray 1 MPT Assembly on page 4 12 Inner Cover on page 4 16 Main Drive Assembly and Registration Feed Clutch on page 4 24 On the left side of the printer remove the locking bearing on the front of the shaft by rotating it in the direction of the arrows shown below RE a M AR s SS A j Bearing s3500 119 Phaser 3500 Laser Printer Service Manual 4 27 Repairs and Adjustments 3 Remove screw on the right end of the shaft securing th
56. e bracket remove the bracket with the bearing 3500 120 4 Remove the right side gear from the shaft 5 Lift the latch on the idle cam and slide the shaft to the right throught the cam to free it from the printer Idle Cam 3500 121 Phaser 3500 Laser Printer Service Manual 4 28 Repairs and Adjustments Tray 2 Pick Up Assembly and Rollers Note It is not necessary to remove the entire assembly in order to remove the Pick Rollers 1 Remove Covers on page 4 4 Left Cover on page 4 5 Top Cover on page 4 8 Tray 1 MPT Assembly on page 4 12 Inner Cover on page 4 16 Main Drive Assembly and Registration Feed Clutch on page 4 24 Tray 2 and Tray 3 if installed 2 Release the latch on the pick up cam and slide off the right side of the shaft Gear Pick Up Cam 53500 124 Phaser 3500 Laser Printer Service Manual 4 29 Repairs and Adjustments 3 Remove the e clip from the feed shaft 4 Remove the locking bearing rotating in the direction of the arrow as shown below Bearing Feed2 p Gear Z 7 3500 125 5 Remove the gear by sliding off the shaft 6 Turn the printer onto its left side 7 Remove the front crossbar secured by 2 screws _ lt Pa ji Bottom Cross Bar 3500 127 Phaser 3500 Laser Printer Service Manual 4 30 Repairs and Adjustments 8 Slide the actuator down and
57. e must be eliminated The following guidelines should be used before troubleshooting an image quality problem m 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 m Generate the Control Panel Internal Test Print on page 3 4 and see if the image quality problem still exists m 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 m 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 Fuser Toner on the back side of the printed page simplex mode Light Prints Repeating Defects Spots on Image Hot or Cold Offsetting Repeating Defects Voids Repeating Defects Measurement Table Distance between Assembly Component Defects Typi
58. e printer frame C 4 Remove the Inner Cover D Gy s3500 089 Phaser 3500 Laser Printer Service Manual 4 16 Repairs and Adjustments Transfer Roller POM Caution Do not touch the surface of the Transfer Roller Open the Top Cover Remove the Print Cartridge and protect it from exposure to light Remove the cap from the left side of the Transfer Roller Pinch the bearing clips on both ends of the Transfer Roller Note The gear on the left end of the Transfer Roller shaft is not secured in place Hold the gear when removing the roller to prevent it from falling into the printer Note The 2 bearing clips are not interchangeable and the levers face the rear of the printer The clip with the ground contact goes on the gear side of the Transfer Roller Slide the roller slightly to the right so the end of the shaft clears the lip on the printer case and lift the Transfer Roller together with the Bearing Clips and the Transfer Roller Gear out of the printer Transfer Roller 3500 057 Phaser 3500 Laser Printer Service Manual 4 17 Repairs and Adjustments Retard Assembly 1 Remove m Tray 1 MPT Assembly on page 4 12 2 Squeeze the lock as shown below and take out the retard assembly 3500 065 Reassembly Notes Note When reassembling the retard roller insert the left end of the retard shaft through th
59. e retard roller first s3500 066 Phaser 3500 Laser Printer Service Manual 4 18 Repairs and Adjustments Tray 1 Separator Holder Pad Assembly 1 Remove m Tray 1 MPT Assembly on page 4 12 m Tray 1 Knock Up Plate on page 4 14 m Retard Assembly on page 4 18 2 Disconnect the connector from the Separator Pad Assembly Caution Be careful not to break the actuator flag There is a spring located behind the separator pad do not loose the spring 3 Remove the 3 screws shown below and then remove the Separator Pad Assembly from the printer 3500 063 Phaser 3500 Laser Printer Service Manual 4 19 Repairs and Adjustments Feed2 Idle Unit 1 Remove m Tray 1 MPT Assembly on page 4 12 m Retard Assembly on page 4 18 m Tray 1 Separator Holder Pad Assembly on page 4 19 2 Remove 4 screws 2 for each of the feed idle units 3 Remove each idle unit ef 3500 067 Phaser 3500 Laser Printer Service Manual 4 20 Repairs and Adjustments Registration Assembly 1 Remove m Covers on page 4 4 m Left Cover on page 4 5 m Top Cover on page 4 8 2 Remove the Gear Cap located on the right side of the Registration Assembly the release is on the front of the cap A uu 3500 115 Phaser 3500 Laser Printer Service Manual 4 2 Repairs and Adjustments 3 Remove the 4 screws securing the Registration Assembly to the printer 4 Remove the
60. emperature range is 50 degrees F to 89 degrees F 10 degrees C to 32 degrees C and the relative humidity range is between 20 to 80 m Place the printer in an area where there is adequate space for ventilation operation and servicing See the clearance graphic below m Do not block or cover the slots and openings on the printer The printer can overheat without adequate ventilation m For altitudes under 2 050 meters 6 726 feet use the Low Altitude setting For altitudes over 2 050 meters 6 726 feet use the High Altitude setting Do not place the printer near a heat source Do not place the printer in direct sunlight Do not place the printer in line with the cold air flow from an air conditioning system Place the printer on a level solid surface with adequate strength for the weight of the printer 1211 6mm 482 6mm 3500 018 Phaser 3500 Laser Printer Service Manual 6 6 General Information and Specifications Printer Physical Specifications Print Engine Dimensions Value Height 348 mm 13 7 inches without optional cassette Width 396 mm 15 6 inches Depth 453 mm 17 8 inches Weight 17 Kg 38 Ibs Functional Specifications Characteristic Specification Printing process Non Impact Electrophotography Color medium Monochrome Resolution Addressability True 600 x 600 dpi Addressable 1200 x 1200 dpi Operating Modes
61. er on page 4 6 Fuser Assembly on page 4 37 Exit Solenoid Assembly on page 4 38 Main Board and Shield on page 4 47 2 Remove the 3 screws securing the fuser gear train and remove it from the printer Phaser 3500 Laser Printer Service Manual 4 50 Repairs and Adjustments Paper Size Sensor Note If the optional Tray 3 Feeder is installed it must be removed before perfoming this procedure 1 Remove m Print Cartridge m Tray 2 and Tray 3 if installed m Left Cover on page 4 5 2 Disconnect CN 1 from the Paper Size Sensor 3 Gently turn the printer upside down Note The Paper Size Sensor can be removed and replaced without removing the rear crossbar However to provide improved access remove the crossbar screw above the Paper Size Sensor and loosen the screw on the other side so you can swing the crossbar out of the way 4 On the left side of the printer remove 2 screws one on either side of the rear crossbar that secure the Paper Size Sensor to the printer chassis 5 Pull up on the sensor assembly until it is clear of the mounting pins and then remove it from the printer Phaser 3500 Laser Printer Service Manual 4 5 Parts List This section covers the following Using the Parts List on page 5 2 PL 8 1 Main Assembly on page 5 3 PL 8 2 Cover Assembly on page 5 7 PL 8 3 Frame Assembly on page 5 9 PL 8 4 Fuser Assembly on page 5 17 PL 8 9 Tray 2 Cassette on page 5 20 PL 8 10 Tray 3 Cassette on page
62. er or With Paper T3 NP Pull out Tray 3 and manually Tray 3 Sensor toggle the actuator W Out Paper or With Paper When Tray 3 is not installed Tray 3 Not Installed this function does not work Duplex With the rear cover open Duplex Sensor Sensor push a piece of paper into W Out Paper or With Paper the duplex path and watch the control panel display Cover Open the top cover and Cover Open toggle the actuator Open Closed Sensor Feed Open the top cover remove Feed Sensor Sensor the print cartridge and then w Out Paper or With Paper actuate the sensor Exit Sensor Open the rear cover and Exit Sensor insert paper into the exit W Out Paper or With Paper path Out Bin Actuate the output sensor Out Bin Sensor Sensor Not Full Full Phaser 3500 Laser Printer Service Manual 2 7 Repair Analysis Procedures Main Menu Sub Menu Description Function Conirol Panel Display Tray 2 Out Remove Tray 2 from the Tray 2 Sensor printer IN OUT Tray 3 Out Remove Tray 3 from the Tray 3 Sensor printer IN OUT Fuser Door Open the rear cover and Fuser Door Sensor Sensor actuate the fuser door Closed Opened sensor HVPS Dev Bias Developer Bias DC is Dev Bias DC DC applied when the OK button ON OFF is pressed and then goes off when the Cancel button is pressed Dev Bias Developer Bias AC is Dev Bias AC AC applied when OK is pressed ON OFF and goes off when Cancel is pressed Charge
63. ervice diagnostics to test the Go to Step 3 Replace the operation of the Registration roller and Registration clutch Assembly 2 Does the registration roller and clutch Phaser 3500 Laser Printer Service Manual 2 11 Repair Analysis Procedures Step Actions and Questions Yes No 3 1 Use service diagnostics to test the exit Go to Step 4 Replace the exit sensor sensor 2 Does the sensor operate correctly 4 1 Replace the Fuser Assembly and Complete Replace the SMPS retest 2 Did this correct the problem Jam At Exit Jam 2 Step Action and Questions Yes No 1 1 Is the Exit Sensor Actuator damaged or Repair or replace the Go to Step 2 binding actuator and or sensor 2 1 Inspect the Exit Roller Assembly Replace the Exit Go to Step 3 2 Use service diagnostics to test the main Roller Assembly drive to exit 3 Is the exit roller damaged or binding 3 1 Visually inspect the Fuser Remove obstruction Go to Step 4 2 Is there paper wrapped around the and clean Fuser Fuser rollers rollers 4 1 Is the Fuser Assembly operational Go to Step 5 Replace the Fuser 2 Dothe Fuser gears rotates when the Assembly Main motor is on 5 1 Use the embedded diagnostics to check Replace Main Board Replace SMPS the Exit Sensor 2 Is the sensor operational Jam At Rear Duplex Jam 1 operation of the Duplex Sensor 2 Does the
64. etching or distortion of the image in bands across the process direction that make the image seem distorted blurred or compressed If these faults are observed see Skips Smears on page 3 11 We conduct many of ever these mail s coverage Would yo your time to read survey has been de time and effort T test pattern a qu envelope are enclo Test Print Phaser4400 011028 2 S 8 5x11 SEF HHH PROCESS HHH SCAN We conduct many of ever these mail s coverage Would yo your time to read survey has been de time and effort T test a qu s4400 217 Phaser 3500 Laser Printer Service Manual 3 6 image quality Troubleshooting Image Quality Troubleshooting The following table provides examples and descriptions possible causes and the solutions for troubleshooting various image or printing defects that may be observed in the Phaser 3500 Laser Printer Image Defect Possible Causes Solutions No Image Blank Prints m Sealing tape or shipping 1 Ensure that sealing tape and restraint was not removed shipping restraint have been Prints have no visible image from the cartridge removed m Loworno toner 2 Verify Print Cartridge ground m Defective ground to the 3 Verify continuity between the Print Cartridge or OPC cartridge ground and frame Drum 4 Ensure the feed solenoid is m Malfunctioning solenoid or functioning properly drive 5 Rep
65. exe doya 00 z 021 Qi Sadiy P G 1 Q iv Electrostatic Discharge ESD Precautions W KK KK KK KK KK KK KK KK KK KK KK KK KK K V Service Safety Summary kk kk kk kk KK KK KK KK KK KK KK KK KK kk kk kk kK kk KK kk k vi General Guidelines ssas urere 4h A A an WAL RA UR ROT ee ig vi CLASS 1 LASER PRODUCT seseeeeee eens vi Servicing Electrical Components 0 0 KK KK KK KK KK KK KK kK KK kK KK kk kk kk kk k vii Regulatory Specifications vii 1 Service Call Procedures Servicing Instructions cso lt 4 ee x ee eed la ems a e ekad erac a e RR 1 2 Service Preventive Maintenance Procedure 0c 1 3 Recommended Tools sal ccc E E E 1 3 Cleaning 12s ec pete hee dae oo m i Fab pre EE wos ele da 1 3 2 Repair Analysis Procedures Introduction s dei e om RR Un ae Pas wee e a RU Bal ag eee e ERR CR s 2 2 Accessing Fault History kk kk kk kk KK KK KK KK KK KK KK KK KK KK KK kK kK kK kk 2 2 Using the Troubleshooting Procedures KK KK KK KK KK KK KK KK 2 3 Service DIagnOStCs cde Hwa Wana kalara re a Wara y kele eee Pee a aa a lk 2 4 Entering Service Diagnostics 00 ccc KK KK kK kk kk kk kk kk K k k 2 4 Service Diagnostics Menu Map x kk kk kk kk kk kK KK KK KK KK KK kk kk kk kk kk kK kk k 2 5 Service Diagnostic Control Panel Button Descriptions 2 5 Troubleshooting Error Messages kk kk
66. g 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 gt Service Tools gt 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 Printer Error Message 41 Insufficient Memory 44 Output Tray Is Full 5A Laser Failure 53 Replace Print Cartridge 55 Invalid Print Cartridge 56 Fu
67. g the duplex sensor roller shaft 2 1 Use service diagnostics to test the Go to Step 3 Replace the duplex duplex sensor sensor 2 Does the sensor operate correctly 3 1 Inspect the exit and duplex rollers for Replace the problem Go to Step 4 any signs of damage or binding roller 4 1 Replace the Duplex Assembly Replace the Main Replace the Power 2 Does the problem still occur Board Supply Board Check Cartridge Invalid Print Cartridge Non Xerox Cartridge Replace Print Cartridge Step Action and Questions Yes No 1 1 Open the top cover and ensure that the Complete Go to Step 2 Print Cartridge is properly seated 2 Does the error clear after reseating the cartridge 2 1 Check the Print Cartridge for damage Go to Step 3 Replace Print 2 Does the cartridge contain toner and Cartridge appear to be operating properly 3 1 Reseat all harness connections to the Complete Go to Step 4 Toner Sensor CRUM Board 2 Does the error clear 4 1 Check continuity between the Toner Replace the Toner Replace Harness Sensor CRUM Board and CN6 on the Sensor Board Main Board 2 Does the harness show continuity Close Fuser Door Step Action and Questions Yes No 1 2 Visually inspect the fuser door close tab for damage Is the tab broken Replace the Fuser Go to Step 2 Phaser 3500 Laser Printer Service Manual 2 14 Repa
68. ge 4 29 Developer Drive Assembly on page 4 33 Connector Board on page 4 34 Tray 1 MPT Solenoid on page 4 35 Main Solenoid on page 4 36 Fuser Assembly on page 4 37 Exit Solenoid Assembly on page 4 38 Exit and Duplex Rollers on page 4 39 Laser LSU Assembly and Lower Cover on page 4 42 Left Side Cooling Supply Fan and Duct on page 4 44 Toner Sensor Board and CRUM on page 4 45 Main Board and Shield on page 4 47 Power Supply and Shield on page 4 48 Fuser Gear Assembly on page 4 50 Paper Size Sensor on page 4 51 Phaser 3500 Laser Printer Service Manual 4 Repairs and Adjustments Overview This section contains the removal and replacement procedures for selected parts of the printer according to the Service Parts List Not all Replacement Procedures are included in this Service Manual In most cases to reinstall a part simply reverse the Removal Procedure shown In some instances the Replacement Procedure is included because it may contain special steps For specific assemblies and parts see Parts List on page 5 1 Standard Orientation of the Printer When needed the orientation of the printer is called out in the procedure for locating printer parts Refer to the printer orientation graphic for locating the right left front and back sides of the printer FRONT RIGHT 3500 056 Phaser 3500 Laser Printer Service Manual 4 2 Repairs and Adjustments General Notes on Disassembly Preparation
69. generation m Loose defective interface cables cable not within specification Optional DIMM memory Main Board 1 Inspect cable connections verify that cables meet specified requirements 2 Replace optional DIMM memory 3 Replace Main Board Phaser 3500 Laser Printer Service Manual 3 10 image quality Troubleshooting Image Defect Possible Causes Solutions Unfused Image Part or all of the image is unfused Paper quality damp paper Operating environment Remote Control Panel settings m Fuser Assembly m Main Board 1 Paper is too thick damp or contains a high percentage of cotton Printer is not installed in specified environment Verify Remote Control Panel settings such as envelope Inspect clean replace Fuser assembly as necessary Replace Main Board Skewed Image The printed image is not parallel with the sides of the page m Paper Paper tray Pick up roller assembly Paper transportation m Fuser Assembly Inspect paper for damage Replace as necessary Check paper tray for damage Properly install fresh paper in the paper tray Inspect Pick up roller assembly Replace as necessary Inspect paper transportation areas for proper operation Inspect clean replace Fuser assembly as necessary Skips Smears Skips loss or stretching of the image in bands across the process direction Smears the distortion of the image in ba
70. ille 2 18 3 Image Quality Troubleshooting Image Quality Problems Overview 2 0 0 0 cece n 3 2 Repeating Defects ela sha wan plaut e cb io ie aa aaa eta 3 3 Print Cartridge ci ete yed sce 9r dy Wi ne ki eR ee eee 3 3 Transfer Roller xal u e kaya memet eerte Vagos abate arie 3 3 lur TET 3 3 Repeating Defects Measurement Table 0 0 00 KK KK KK KK KK KK 3 3 Control Panel Internal Test Print 2 2 kk kK KK KK KK KK KK KK KK KK KK KK KK KK KK KK 3 4 Del tioBs 5x9 K ala ye ea y beer sce Cae aie a aD es ats 3 4 FUSIN S use epe tre rope nte art pp ert pb pe qna 3 4 Resolution 4 6 i kk he ta be Heke hed eee hea ER RD Euer cbe 3 5 Registration and Skew 0 cece KK KK KK KK KK eens 3 5 Skipsor Smears xak k sa kak eee ee k ER REDE Ern 3 6 Image Quality Troubleshooting W k kk kK kK KK KK KK KK KK KK KK KK KK KK KK KK KK kk 3 7 No Image Blank Prints KK kk KK KK KK KK KK KK KK KK KK KK KK KK kk 3 7 Light Prints 54 a sa ke sao ma n an n a dok 00a ok e WEE Pad dud 3 7 Black Pants aoc san ea order Gi hn DR OE e Bhawan ands 3 8 Dark mage seo s la u w k ee RR al k al ot LR Pa EE be k 3 8 Background Contamination 0 0 KK KK KK KK KK KK KK KK KK KK KK 3 8 Ghosting ooeec be edhe nde eke Do EA bd EAR E det deb e 3 9 Non Uniform mafea e naka en Kilawlal ane k Wla e 3 9 Black Spots Marks kk kk kk kk
71. image being printed is the first image After the first image is being printed the paper is reversed and is fed through the duplexer and back up to the feed roller with side one positioned for printing with the second image Phaser 3500 Laser Printer Service Manual 8 4 Theory of Operation Paper Feed Sequence When the Main Board is ready to feed paper it energizes the paper feed solenoid The solenoid armature releases the clutch and the pick up roller makes one revolution This drives the paper to the feed and retard rollers The feed roller and retard roller drive the paper to the registration transport assembly which in turn drives the paper towards the transfer area Before arriving at the transfer area the paper actuates the Registration Sensor Paper Transport The registration assembly continues to drive the paper into the transfer area where the image is transferred from the drum to the paper After the image is transfered the paper continues to the Fuser Assembly for fusing the image In the Fuser Assembly the heat roller is heated by a heat element and the paper passes in between the heat roller and the pressure roller where toner is melted onto the paper forming a permanent image The temperature of the heat roller is monitored by a thermistor that sends signals to the Main Board The Fuser drives the paper into the exit rollers and the exit rollers drive the paper into the output tray When printing the first side of a d
72. ing 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 y 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 groundi
73. ir Analysis Procedures Step Action and Questions Yes No 2 1 Verify the sensor and actuator on the Replace the Main Replace the Fuser Fuser is operating correctly Board Replace the SMPS Close Top Cover Step Action and Questions Yes No 1 1 Visually inspec the top cover and the Replace the Top Go to Step 2 top cover actuator Cover 2 Is the top cover or actuator damaged 2 1 Use diagnostics to test the cover open Replace the Main Replace the Sensor sensor Board 2 Does the sensor function properly Fuser Failure Engine Fuser Low Heat Error or Engine Fuser Over Heat Error Step Action and Questions Yes No 1 1 Does the error report Fuser Failure Go to Step 2 Go to Step 3 2 1 Check the thermistor Replace the Fuser Replace the Main 2 Is the circuit open Board 3 1 Check the line voltages across the Replace the Fuser Go to Step 4 thermostats 2 Are they open 4 1 Is the Fuser getting power Replace the Fuser Replace the SMPS Replace the Main Board Laser Failure Step Actions and Questions Yes No 1 1 Reseat the connections to the laser Complete Go to Step 2 and visually inspect the laser unit for damage 2 Did this correct the problem Phaser 3500 Laser Printer Service Manual 2 15 Repair Analysis Procedures Step Actions and Questions Yes No 1
74. kk kK kk kK KK KK KK kk kk kk kk kk kk kk k 3 10 Spot or Vertical Deletions 00 0 Kan ARA e Wk ee 3 10 Horizontal Bands ei eca hes siyana da a eg dete todd de ade dea aes 3 10 Character D f ClSs saye xn b 204 84 5 aeeti Rr oet EP bans 3 10 Untused Images 2er e ERE Daka EURO Re k k A aceto 3 11 Skewed mage ci cce ee thee awa Ee ER Hera edd 3 11 Skips SImeatS ix in cool aided dead dene RE ERROR Up Rd XR andis 3 11 OHP Print Distortion se sy ss xe pe neq he ed eed 3 11 4 Repairs and Adjustments OVERVIEW cnt gts ice a dete eather dan tha carn aad anata Gatien eda eas ada ma 4 2 Standard Orientation of the Printer 0 0 KK KK KK KK KK KK KK KK KK KK KK KK 4 2 General Notes on Disassembly 0 0 KK KK KK KK KK KK KK KK KK KK KK KK KK 4 3 Prep aration esate a k ERR eee d Sh adi bea eae ee dae 4 3 Notations in the Disassembly Text W K ak kk KK KK KK KK KK KK KK KK KK KK KK KK e 4 3 Phaser 3500 Laser Printer Service Manual ix Contents Go MEM mm 4 4 Right Cover es o nos eR ta Gace Qi nan avaa Gen ERU Pw Se Mua a d Rd d 4 4 Lett COVES ao sies dp 4eba siet eb boue etu Pa onam ed erbe b dus 4 5 Rear Cover lt Hac al 0k QESE Se ie Ae VS ERN Ee 4 6 TOP COVER dnos vette botes ee tee epe Ee e sra 4 8 Control Panel and LCD Display 0 0 kK KK KK KK A 4 10 Open COVER s53 ioni E S bd Pe NS i aere RE GENE EA A 4 11 Tray 1 MPT
75. lace in the following Main Board order Incorrect high voltage m Print Cartridge an ee e Power m Main Board ava xa ti di m Power Supply Board Sms ulupiesneet teeding m Laser Assembly Light Prints m Unsupported Media paper 1 Verify paper meets printer Seal tape or shipping specifications Print 20 to e eee w da n restraint was not removed 30 pages using the g 9 from the cartridge recommended paper m Incorrect Control Panel 2 Verify image quality menu is settings not set to draft Low toner 3 Ensure that the sealing tape and the shipping restraint Transfer Roller ansie have been removed Laser contamination or 4 Verify low toner warning is not obstruction y g displayed on control panel m Incorrect high voltage Remove the Print Cartridge output and shake reinstall or m Low ambient temperature replace lt 10 C 5 Inspect the Transfer Roller for contamination and verify high voltage contacts Replace as required 6 Inspect the Laser assembly for any obstructions clean the laser exit window 7 Replace the Power Supply Board Phaser 3500 Laser Printer Service Manual 3 7 image quality Troubleshooting Image Defect Possible Causes Solutions Black Prints Nocharge voltage 1 Verify the high voltage Power Supplv Board contacts are operational and The prints are completely black make good contact with the has no visible imag
76. nds across the process direction Causes image Paper transportation Main drive motor assembly Fuser Assembly Print Cartridge Inspect paper transportation areas for proper operation Inspect main drive motor assembly for damage or worn gears Replace as necessary Inspect clean replace Fuser assembly as necessary to appear blurred or 4 Replace Print Cartridge compressed OHP Print Distortion Remote Control Panel 1 Verify Remote Control Panel Trembling appearance when printing on transparencies settings m Recommended Media m Transfer roller voltage is configured to Transparency mode Verify transparency meets printer specifications Inspect the Transfer Roller spring tension and bearing contacts Replace Power Supply Board Phaser 3500 Laser Printer Service Manual 3 11 Repairs and Adjustments This section covers the following Overview on page 4 2 General Notes on Disassembly on page 4 3 Covers on page 4 4 Control Panel and LCD Display on page 4 10 Open Cover on page 4 11 Tray 1 MPT Assembly on page 4 12 Inner Cover on page 4 16 Transfer Roller on page 4 17 Retard Assembly on page 4 18 Tray 1 Separator Holder Pad Assembly on page 4 19 Feed2 Idle Unit on page 4 20 Registration Assembly on page 4 21 Main Drive Assembly and Registration Feed Clutch on page 4 24 Tray 1 Pick Up Assembly and Pick Rollers on page 4 26 Tray 2 Pick Up Assembly and Rollers on pa
77. ng 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
78. not reach the exit sensor in the specified time The exit sensor cannot be ON page 2 11 Jam At Exit JAM 2 m 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 m Thetrailing edge of the paper passes the exit sensor but does not reach the duplex sensor in the specified amount of time page 2 12 Jam at Duplex Duplex JAM 2 m Theleading 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 m A print cartridge is not detected m Anon Xerox print cartridge is installed m Thetoner sensor board is malfunctioning page 2 14 Close Fuser Door m The fuser door sensor or actuator is malfunctioning or damaged page 2 14 Close Top Cover m Top cover is damaged m Sensor or actuator is damaged page 2 15 Fuser Failure Engine Fuser Low Heat Error Engine Overheat Error m Fuseris damaged or malfunctioning page 2 15 Laser Failure m Thelaser unit is malfunctioning or damaged page 2 15 Output Tray is Full m The outbin full sensor or actuator is malfunctioning or damaged page 2 16 Phaser 3500 Laser Printer Service Manual 2 10 Jam At Tray 1 2 3 Jam 0 Repair Analysis Procedures
79. nto the print media using the voltage supplied by the transfer roller The conductive transfer roller receives a high positive voltage approximately 1000 VDC from the HVPS that puts it at a higher potential than the drum Since the transfer roller is located behind the print media the toner image is attracted to the high potential and deposits on the surface of the print media Fixing The finished toner image is impermanent and easily smeared To fix the image the print media goes through the Fuser where it passes between a pressure roller and the heat roller The toner is fused onto the print media by the combination of heat and pressure The heat roller is heated by a heat element The roller surface temperature is detected by a Thermistor The information is fed back to the heater control to maintain a surface temperature of 185 C during printing and 145 C during standby If the thermostats detect a Fuser overheat condition it disconnects AC power to the Fuser Cleaning After the image is transferred to the print media a cleaning blade inside the cartridge removes any remaining toner particles from the drum Phaser 3500 Laser Printer Service Manual 8 2 Theory of Operation Print Modes The Phaser 3500 Laser Printer provides four print modes m Draft mode Uses a combination of reduced toner output and the lowest resolution 300 x 300 dpi to extend print cartridge life m 300 Used for printing with a resolution of 300 x
80. oller The heat roller melts the toner so it adheres to the paper m Pressure Roller Provides pressure on the opposite side of the print media so the heat roller can embed the melted toner in the media m Thermistor Monitors the surface temperature of the Heat Roller This information is used to control the heat lamp and thus keep the heat roller at the correct temperature m Thermostat Prevents overheat damage when unexpected system faults occur Phaser 3500 Laser Printer Service Manual 8 7 Theory of Operation Sensor Functions Paper Empty Sensor Media supply is monitored by the Paper Empty Sensor When a tray runs out of paper the sensor will send a signal to the Main Board the control panel LED will blink orange and the No Paper in Tray 2 3 message will display on the control panel Tray 1 Paper Empty Sensor The Tray 1 paper empty sensors monitors paper from Tray 1 If Tray 1 is selected and there is not paper a message appears on the control panel If there is no paper in Tray 2 or Tray 3 and the printer is in auto select mode the printer will look for paper in all the trays and report No Paper in Tray 1 Registration Sensor The Registration Sensor has two purposes First it is used to monitor paper movement If the paper takes too long getting to the sensor or it stays at the sensor location too long the Main Board will shut down the machine the control panel LED will blink orange and a Jam er
81. r Service Manual 8 6 Theory of Operation Laser Scan Unit LSU The Laser Scan Unit receives the bit mapped image data from the Main Board and uses that information to turn the laser beam on and off as required to correctly expose the drum Image data transfer from the Main Board is controlled by a synchronization signal from the LSU so the vertical scanning line is synchronized with the printed page The LSU contains the following components Laser Diodes Generates the laser beams Rotating Polygon Mirror Scans the laser beam across the drum axially Beam Detector Synchronizes the left margin Optical Lens System Focuses the laser beam onto the surface of the drum Mirrors Reflect the laser beam onto the surface of the drum Transfer Roller The transfer subsystem consists of the Pre Transfer Lamp PTL and the Transfer Roller The PTL exposes the drum surface after the latent image has been developed to lower surface potential of the drum This provides enhanced transfer efficiency The transfer roller provides a high positive potential on the back of the print media This potential attracts the negatively charged toner image from the drum and deposits it on the surface of the print media Fuser Assembly The Fuser Assembly contains the entire Fuser Subsystem and is a field replaceable unit The Fuser Assembly contains the following components m Heat Element and Heat Roller A heat element generates the heat for the heat r
82. ror message will display on the control panel Second the signal generated by the sensor tells the Main Board that the paper is almost at the transfer area and it is time to start the xerographic process It is important that the leading edge of the paper enters the transfer area at the same time as the leading edge of the developed image on the drum Fuser Exit Sensor The Exit Sensor monitors paper exit and detects the Jam at Exit error if the paper takes too long getting to the sensor or it stays at the sensor too long At this point the Main Board will shut down the printer the Control Panel LED will blink red and a Jam at Exit error message will display on the Control Panel The signal from the Exit Sensor is also used to control paper feed to the Duplex Unit for duplex print jobs Cover Open Sensor The cover open sensor detects whether the top cover is open or closed When the top cover is open the Close Top Cover message is displayed on the Control Panel Duplex Unit Sensor The Duplex Unit slides into the rear of the printer above Tray 2 As paper leaves the Fuser Assembly and is picked up by the Exit Rollers the drive direction is reversed to send the paper down to the Duplex Unit As the paper leaves the Duplex Unit it activates the Duplex Sensor This activates the feed roller to position the paper for printing on the front side of the paper Phaser 3500 Laser Printer Service Manual 8 8 Theory of Operation
83. rs on page 4 4 Left Cover on page 4 5 Top Cover on page 4 8 Laser LSU Assembly and Lower Cover on page 4 42 Remove 1 screw securing the cover open housing harness cover Release the latching tab and remove the cover open housing harness cover Disconnect the connector from the main board Using a small flatbladed screwdriver release the 4 tabs to remove the cover open board Cover Open PBA oU Harness Cover s3500 112 Phaser 3500 Laser Printer Service Manual 4 46 Repairs and Adjustments Main Board and Shield e Note If the NIC Board is installed it must be removed to access screws to the main board NVRAM parameters are not transferable to the replacement board These parameters include serial number and copy count Serial Number can be reinstalled via CentreWare IS if the NIC Board is installed or via a downloadable PJL command Observe proper ESD procedures when removing or replacing any circuit boards in the printer Remove m Covers on page 4 4 Disconnect all connectors from the Main Board Remove the NIC card or the dummy bracket from the main board Remove the 6 screws 4 on the Main Board and 2 to the parallel connector securing the Main Board to the printer and then remove the Main Board Position the retainers on the parallel port connector straight out from the connector for removal Move the board toward the front of the printer so the conne
84. sensor operate correctly Step Actions and Questions Yes No 1 1 Does paper jam after reversal but Go to Step 2 Go to Step 3 before reaching duplex sensor 2 1 Replace Transport Roller Shaft Replace Duplex Complete Assembly Assembly 2 Does problem recur 3 1 Use service diagnostics to check the 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 Yes No 4 1 Inspect the Duplex Assembly Is any Remove obstruction Go to Step 5 paper wrapped around the Duplex and clean rollers rollers 5 1 Use service diagnostics to check the Go to Step 6 Replace the exit exit sensor sensor and or 2 Does the sensor operate correctly actuator 6 1 Inspect the exit and duplex roller Replace the exit or Go to Step 7 assemblies duplex roller as 2 Are the rollers damaged or binding necessary 7 1 Inspect the duplex assembly for Replace the duplex Go to Step 8 damage assembly 8 1 Does the Feed Roller Assembly Replace Main Board Replace the Feed operate properly without binding Roller Assembly Phaser 3500 Laser Printer Service Manual 2 13 Jam At Duplex Duplex Jam 2 Repair Analysis Procedures Step Actions and Questions Yes No 1 1 Does the paper jam after reversal but Replace the transport Go to Step 2 before reachin
85. ser Failure Open Fuser Error 57 Fuser Failure Low Heat Error 58 Fuser Failure Over Heat Error Jam History Code Jam Error Message 01 Jam At Tray 1 2 or 3 Jam 0 02 Jam At Top Jam 1 03 Jam At Exit Jam 2 04 Jam At Rear Duplex Jam 1 05 Jam At Duplex Duplex Jam 2 Phaser 3500 Laser Printer Service Manual 2 2 Repair Analysis Procedures Using the Troubleshooting Procedures 1 2 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 The Actions and Questions box contains additional information and or additional procedures you must follow to isolate the problem 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 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 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 Troubleshooting Procedures often ask you to replace
86. t Support Tray 1 MPT Tray 1 MPT Release SN Z Tray 2 WT E gt on off Switch Paper Gauge 3500 013 Rear View Z row Door Network Port 2AN optional for 3500B N xa i USB Port zzz IEEE 1284 Parallel Port Tray 3 Optional Cable Connector Power Cord Receptacle 3500 014 Phaser 3500 Laser Printer Service Manual 6 4 General Information and Specifications Control Panel The Control Panel has three components m Multi colored Light Emitting Diode LED light m Alphanumeric display m Six button cluster Phaser35 00 i Cancel Button Return Button On line Data Error LED Menu Button Status Error Messages and Menus Up Arrow Button OK Button Down Arrow Button N 9 QI B3 N 3500 012 The alphanumeric display provides status messages and control panel menus Menu Map The Menu Map is a visual representation of the Control Panel settings and information pages All Menu Map settings are documented in the User Guide Error and Warning Messages When there is a problem with the printer the Control Panel LED 3 blinks orange for an error and a warning An error or warning message is displayed in the Alphanumeric Display 5 Phaser 3500 Laser Printer Service Manual 6 5 General Information and Specifications Printer Specifications Printer Location and Clearance m Place the printer in a dust free area where the t
87. tegrated 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 brush
88. tes 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 IPX and Novell Distributed Print Services are 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 ZA 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 achie
89. the Control Panel 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 e 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 Measured 3 3 VDC 3 135 to 3 465 VDC 5 0 VDC 4 75 to 5 25 VDC 24 0 VDC 21 6 to 26 4 VDC 0 0 VDC Less than 0 5 VDC Phaser 3500 Laser Printer Service Manual 2 18 Image Quality Troubleshooting This section covers the following m Image Quality Problems Overview on page 3 2 m Control Panel Internal Test Print on page 3 4 m 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 possibl
90. the left cover towards the rear of the printer to release the 3 tabs securing it to the printer 3500 080 Phaser 3500 Laser Printer Service Manual 4 5 Repairs and Adjustments Rear Cover 1 Open the Rear Cover 2 Release the Restraining Strap tie stopper 3500 081 Phaser 3500 Laser Printer Service Manual 4 6 Repairs and Adjustments 3 To release the 2 posts securing the Rear Cover Lift up on the left printer left hinge pin then slide the Rear Cover to the left to free the right hinge pin and remove the Rear Cover from the printer 3500 082 Phaser 3500 Laser Printer Service Manual 4 7 Repairs and Adjustments Top Cover 1 Remove the Print Cartridge and protect it from light exposure 2 Remove m Covers on page 4 4 m Left Cover on page 4 5 Note Open the Rear and Top Covers for access 3 Remove the 2 screws located on the front of the Top Cover 4 On the rear left side of the printer remove 1 screw securing the Top Cover 3500 083 Phaser 3500 Laser Printer Service Manual 4 8 Repairs and Adjustments 5 Release 3 tabs one on the left one on the right and one on the rear of the Top Cover Pise 53500 085 6 Disconnect the Control Panel wiring harnesses from the Main Board note the connector location and routing for reassembly Phaser
91. ttons 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 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 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 m After paper pick paper is not fed m After paper pick paper enters the printer but does not reach the registration sensor in the specified time m 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 m Theleading 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 m Theleading edge of the paper passes the registration sensor but the paper can
92. ual 5 4 Main Assembly Continued Parts List Item No Description Qty Part Number 16 ELA UNIT EXIT SOLENOID 121N01100 17 ELA UNIT DEVE MOTOR 127N07389 18 ELA UNIT MAIN MOTOR 127N07390 19 PBA MAIN Main Board 140N63016 20 MEA UNIT GEAR PICK UP 007N01361 20 1 GEAR M PICK UP CAM 20 2 GEAR M PICK UP 20 3 SPRINT ETC CAM MP 21 MEA UNIT GEAR P UP MP CARDINAL 007K13470 21 1 GEAR MP HOLDER CAM 21 2 GEAR MP PICK UP 21 3 SPRING ETC CAM MP 22 BEARING PICK UP 23 BRACKET P SHAFT MP 24 MEP CLUTCH FEED 121N01101 25 SOLENOID MAIN 121E19250 26 SOLENOID MP 121N01102 27 RING E 28 SHIELD P SMPS 29 SMPS V1 HVPS 110V 105N02059 SMPS V2 HVPS 220V 105N02060 30 BAR P CROSS BOTTOM 31 FAN DC 127E14630 32 STOPPER M FAN80 34 ELA UNIT DEVE Print Cartridge 6K Toner Cartridge 106R01148 12K Toner Cartridge 106R01149 35 ELA UNIT CASSETTE Tray 2 109R00756 36 ELA UNIT SCF Optional Tray 3 050N00476 37 ELA UNIT DUPLEX 084N00718 38 BRACKET P DUMMY CTRL 015N00555 39 ELA HOU NPCE High Network Interface Card 140N63021 Phaser 3500 Laser Printer Service Manual 5 5 Main Assembly Continued Parts List Item No Description Qty Part Number 39 1 BRACKET NIC 39 2 PBA SUB NIC BOARD 40 STOPPER M NETWORK Phaser 3500 Laser Printer Service Manual 5 6 Parts List
93. uplex print job the drive direction is reversed when the exit sensor is actuated Paper is then directed into the Duplex Unit for printing on the second side Paper Feed Drive The drive for all rollers is provided by the Main Drive Motor and a series of drive gears The Main Motor is used for paper feed fusing and the duplex exit roller reversal for 2 sided printing When the main motor turns all the paper path components also turn except the Pick Up Roller The Pick Up Roller assembly includes a mechanical clutch released by the feed solenoid There is a separate Developer Motor for the Print Cartridge Phaser 3500 Laser Printer Service Manual 8 5 Theory of Operation Major Assemblies and Functions Imaging After paper feed the imaging process consists of the Laser Unit Print Cartridge Transfer Assembly Fuser Assembly and Paper Exit Print Cartridge The Print Cartridge receives image data in the form of pulsed laser light from the Laser Scan Unit and creates the image via the xerographic process The Print Cartridge contains the following components m Charge Roller m Drum m Developer Roller D R m Supply Roller S R m Metering Blade m Cleaning Blade Cleaning Roller Cleaning Roller LSU 0 20mW 400 500220V 1 5 i Vo 680V VL 620V l l Charging Roller j 500 600 20V TER j i OPC Drum i l I l l I PIL I Zener Diode b rpi Max 4 2kV Phaser 3500 Laser Printe
94. utomatically stops Tray 2 When the OK button is Tray 2 Solenoid Solenoid pressed the Tray 2 solenoid ON OFF is turned on for 200ms and then it automatically stops Tray 3 When the OK button is Tray 3 Solenoid Solenoid 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 ON OFF Tray 3 Not Installed Phaser 3500 Laser Printer Service Manual 2 6 Repair Analysis Procedures Main Menu Sub Menu Description Function Control Panel Display Reg Clutch When the OK button is Reg Clutch pressed the registration ON OFF 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 Duplex When the OK button is Duplex Solenoid Solenoid pressed the duplex ON OFF solenoid is turned on for 200ms and then it automatically stops Tray 3 When the OK button is Tray 3 Clutch Clutch pressed the Tray 3 clutch ON OFF and motor turn on for 200ms and then they automatically stop Sensors Paper Size Place paper in the tray and Example Sensor compare the size with the Tray2 Legal control panel display Tray3 Letter T1 NP Pull out Tray 1 and manually Tray 1 Sensor toggle the actuator W Out Paper or With Paper T2 NP Pull out Tray 2 and manually Tray 2 Sensor toggle the actuator W Out Pap
95. ved 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 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 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 con
96. vironment Media paper Print Cartridge Transfer Roller Fuser assembly Incorrect high voltage outputs 1 Printer is installed in specified environment 2 Verify that paper meets printer specifications Print 20 to 30 pages using recommended paper 3 Determine ghosting pitch and replace the corresponding assembly NOTE See Repeating Defects on page 3 3 for defect pitch 4 Replace Power Supply Board Non Uniform Image The Line darkness and solid area density image vary across the print 3500 048 m Print Cartridge Print Cartridge grounding Unstable high voltage output m Transfer Roller contamination m Laser Window or optic contamination 1 Ensure that Cartridge is not out of toner Inspect Drum for deterioration or contamination 2 If defective replace the Print Cartridge 3 Verify Print Cartridge ground Check continuity between cartridge ground contact and frame ground Ensure that drum contact is clean and undamaged 4 Inspect the Transfer Roller spring tension and bearing contacts 5 Remove Laser assembly clean window or replace assembly as necessary 6 Replace Power Supply Board Phaser 3500 Laser Printer Service Manual 3 9 image quality Troubleshooting Image Defect Possible Causes Solutions Black Spots Marks There are spots and or marks of toner on the printed side of the page PRINTED IMAGE
97. wing Charging The charge roller is negatively charged at approximately 1400 VDC by the high voltage power supply HVPS The charge roller is kept in contact with the drum surface to provide a uniform negative charge of approximately 800 VDC on the drum surface as it rotates at a constant speed Exposure The laser unit emits laser beams in response to image data from the Main board The laser beams are directed onto the drum surface through a system of mirrors and lenses A rotating polygonal mirror causes the laser beams to scan the drum surface from end to end axially as it rotates The beams are turned on to print a pixel and off when no printing is required The negative charge on the drum surface is reduced to approximately 250 VDC at each point where the energized laser beam strikes to form an invisible electrostatic latent image on the drum surface Development Negatively charged toner particles from the toner hopper are applied to the supply roller and are then applied to the developer roller in a even layer controlled by the metering blade The developer roller turns against the drum and the toner particles are attracted to the relatively positive latent image The toner forms a visible image on the drum surface Pre Clean The pre transfer lamp exposes the developed suface of the drum lowering the surface potential and thereby providing enhanced transfer efficiency Transfer The finished toner image on the drum is transferred o

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