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Phaser
3150
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laser printer
Service
Manual

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Summary of Contents for Xerox Phaser 3150

  • Page 1 Phaser 3150 ® laser printer Service Manual...
  • Page 3: Service Manual

    Phaser 3150 Laser Printer Service Manual 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...
  • Page 4 Copyright © 2004 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 Unpublished rights reserved under the copyright laws of the United States.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.
  • Page 5: Table Of Contents

    Precautions 1.1 Safety Warnings ........... . 1-1 1.2 Safety Cautions.
  • Page 6 4.5 Engine F/W............4-15 4.5.1 Feeding .
  • Page 7 Troubleshooting 7.1 Print Quality Problems ..........7-1 7.1.1 Vertical Black Line and Band .
  • Page 8 Xerox Options and Accessories ........
  • Page 9: Precautions

    High voltages and lasers inside this product are dangerous. This printer should only be serviced by a suitably trained and qualified service engineer. Use only Xerox replacement parts. There are no user serviceable parts inside the printer. Do not make any unauthorized changes or additions to the printer, these could cause the printer to malfunction and create electric shock or fire hazards.
  • Page 10: Safety Cautions

    Take care not to cut or damage the power cable or plugs when moving the printer. Use caution during thunder or lightening storms. Xerox recommends that this printer be disconnected from the power source when such weather conditions are present. Do not touch the printer or the power cord if it is still connected to the wall socket in these weather conditions.
  • Page 11: Handling Precautions

    Do not place candles or burning cigarettes on the printer.These can cause a fire. 1.2.4 Assembly and Disassembly Precautions Always use Xerox parts. Take care to note the exact location of parts and cable routing before disassembling any part of the printer. Ensure all parts and cables are replaced correctly.
  • Page 12: Bodily Injury Warnings

    Precautions 1.2.5 Bodily Injury Warnings Use caution around high temperature parts. The fuser unit works at a high temperature. Use caution when working on the printer. Wait for the fuser to cool down before disassembly. Use caution when around rotating parts. When operating the printer, do not put your hands into the rotating parts (Paper feeding entrance, motor, fan, etc.).
  • Page 13: Esd Precautions

    Precautions 1.3 ESD Precautions Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electro-Static DISCHARGE (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors, and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.
  • Page 14 Precautions...
  • Page 15: Reference Information

    Reference Information This section contains a tools list, list of abbreviations used in this manual, and a clearance required specification when installing the Phaser 3150 printer. 2.1 Tools for Troubleshooting the Printer The following tools are recommended for safe and easy troubleshooting as described in this service manual.
  • Page 16: Acronyms And Abbreviations

    Reference Information 2.2 Acronyms and Abbreviations Definition Definition Analog-to-Digital Conversion Firmware Access Point FCF/FCT Tray 1 or First Cassette Feeder Alternating Current FISO Front In, Side Out ASIC Application Specific Integrated Circuit FPOT First Print Out Time Ass’y Assembly Windows Graphic Device Interface BIOS Basic Input Output Sytem Graphic Interchange Format...
  • Page 17 Reference Information Definition Definition LVPS Low Voltage Power Supply Or SMPS Megabyte Q’ty Quantity Megahertz Random Access Memory MPBF Mean Prints Between Failure Read Only Memory MPF/MPT Multi-Purpose Tray SCF/SCT Tray 2 Or Second Cassette Feeder Network Interface Card SMPS Switching Mode Power Supply or LVPS Network Printer Card SPGPm...
  • Page 18: Selecting A Location For The Printer

    Reference Information 2.3 Selecting a Location for the Printer Leave enough room to open the printer trays, covers, and allow for proper ventilation. Provide the proper environment: A sturdy, level surface. Away from the direct airflow of air conditioners, heaters, or ventilators. Free from extreme fluctuations in temperature, sunlight, or humidity.
  • Page 19: Specifications

    Specifications Specifications The specifiations in this manual are correct at the time of printing. Product specifications are subject to change without notice. 3.1 General Specifications Item Description Print Method Laser diode unit and electrophotography Developing system Non-magnetic, contacting development system Exposure System Semiconductor laser diode beam scanning Fuser (toner fixing)
  • Page 20: Controller/Software Specifications

    Specifications 3.2 Controller/Software Specifications Item Description Processor SPGPM (Samsung Printer Graphic Processor) 166 MHz Memory 32 MB, expandable to 144 MB, SDRAM Emulation SPL, PCL6 (Firmware), Epson, IBM Proprinter, Optional PostScript 3 SPL, PCL6 (Firmware), KS5843, KSSM, KSC5895 Interface Standard: IEEE1284, USB 2.0 Auto Interface sensing Font Flash memory, 45 scalable, 1 bitmap...
  • Page 21: Environmental Range

    Specifications 3.4 Environmental Range Items Operating Storage Optimum Temperature 10 ~ 32 C (50 ~ 90 0 ~ 40 C (32 ~ 104 20 - 25 Humidity 10 - 80% RH 20 - 95% RH 30 - 70% RH Altitude 2,500 meters (8,200 feet) 3.6 Media Specifications 3.6.1 Approved Paper Size and Weights...
  • Page 22 Specifications...
  • Page 23: Product Summary

    Summary of Product Product Summary This section describes the functions and operating principals of the printers main components. 4.1 Printer Components 4.1.1 Front View Top output tray (Face down) Control Panel Output Support Front Cover Power switch Multi Purpose Feeder Paper level indicator Tray Service Manual 4-1...
  • Page 24: Rear View

    Summary of Product 4.1.2 Rear View Top Output Tray Rear Output Tray (Face down) (Face up) Power Receptacle USB Port Parallel Port 4.1.3 Control Panel...
  • Page 25 Tray1/MPT. If the On Line/Error LED is blinking red and orange alternately the printer has detected a non-Xerox toner cartridge. If the installed toner cartridge is empty the On Line/Error LED blinks orange and the toner cartridge needs to be replaced.
  • Page 26: Printer Theory Of Operation

    Summary of Product 4.2 Printer Theory of Operation 4.2.1 System Summary The printer consists of the following main functional components: 1) The Firmware Engine firmware controls the whole printing process. 2) The Print Engine Engine Frame Paper Feed The paper feed system consists of a 250-sheet main paper tray (Tray 2), a multi-purpose paper tray (Tray 1), pickup rollers, friction pads, and feed rollers.
  • Page 27: System Layout

    Summary of Product 4.2.2 System Layout L S U Fuser Toner Cartridge EXIT Sensor MP Sensor MP Sensor Cassette Fuser Manual Feeder LSU(Laser Scan Unit) Transfer Roller Toner Cartridge 4.2.3 Paper Feed The paper feed system consists of a 250- sheet main paper tray (Tray 2), a multi-purpose paper tray (Tray 1), pickup rollers, friction pads and feed rollers.
  • Page 28: Transfer Assembly

    Summary of Product 4.2.4 Transfer Assembly The transfer roller transfers toner from the OPC drum to the paper. Toner is transferred from the OPC drum onto the paper using a PTL (Pre-Transfer Lamp) and a transfer roller. The PTL shines light onto the OPC, reducing the electrical charge on the OPC surface improving the efficiency of the transfer.
  • Page 29: Laser Scanner Unit (Lsu)

    Collected using an electro-static process and retained within the toner cartridge. No waste toner to dispose of. OPC Drum protecting Shutter Toner CRUM Reader Identifies whether toner is Xerox branded toner or whether a Non-Xerox toner cartridge is installed in the printer Service Manual 4-7...
  • Page 30: Main Controller Board (Pba)

    Summary of Product 4.3 Main Controller Board (PBA) The engine board and controller board have been integrated into a single board consisting of the CPU and printer control functions. The CPU functions as the bus controller, I/O handler, motor driver and PC interface. The main board sends the current image video data to the laser unit and manages the electrophotographic printing process.
  • Page 31: Asic (Spgpm)

    Summary of Product 4.3.1 ASIC (SPGPm) ARM946ES 32-bit RISC embedded processor core 16 KB instruction cache and 16 KB data cache No tightly coupled memory Memory protection unit and CP15 control program Dual bus architecture for bus traffic distribution AMBA high performance bus (AHB) System bus with SDRAM IEEE1284 compliant parallel port interface Printer Video Controller for LBP engines...
  • Page 32: Sdram

    Summary of Product 4.3.4 SDRAM Used as a swath buffer, systems working memory area, etc. when printing. Capacity: 32 MB, expandable up to 144 MB Optional Additional DIMM : 16 MB / 32 MB / 64 MB /128 MB Type : SDRAM 100 MHz/133 MHz, 16bit 4.3.5 Sensor Input Circuit 4.3.5.1.
  • Page 33 Summary of Product 4.3.5.9 Transfer The charging voltage, developing voltage, and the transfer voltage are controlled by pulse width modulation (PWM). Each output voltage is changeable according to the PWM duty cycle. The transfer voltage used when the paper passes the transfer roller is decided by environment recognition.
  • Page 34: Switching Mode Power Supply (Smps) And High Voltage Power Supply (Hvps)4-12

    Summary of Product 4.4 Switching Mode Power Supply (SMPS) and High Voltage Power Supply (HVPS) The SMPS and HVPS are on one integrated board. The SMPS supplies the DC power to the printer. It takes either 110 V or 220 V and outputs the +5 V and +24 V supplies to the main board.
  • Page 35: High Voltage Power Supply

    Summary of Product 4.4.1 High Voltage Power Supply 1) Transfer High Voltage (THV+) Input Voltage: 24 VDC ± 15% Output Voltage: MAX +5.0K V ± 5%, (duty variable, no loading 1.2 KV ±15% (when cleaning, 200 M Output Voltage Trigger: 6.5 uA Input contrast of the Voltage stability degree :under ±...
  • Page 36: Switching Mode Power Supply

    Summary of Product 5) Supply Output Voltage: -400 V ~ -800 VDC ±50 V (ZENER using, DEV) Input contrast of the output stability degree: under ±5% Loading contrast: ±5% or less Output Voltage Rise Time: 50 ms maximum Output Voltage Fall Time: 50 ms maximum Output Loading range: 10 Mž...
  • Page 37: Engine F/W

    Summary of Product 4.5 Engine F/W 4.5.1 Feeding While feeding from the universal trays, the drive for the pickup roller is controlled by the pick-up solenoid. The printer feeds the paper from the Tray1/MPT according to the information provided by the MP sensor, and by driving the main motor, insert the paper in front of the feed sensor.
  • Page 38 Summary of Product 4-16...
  • Page 39: Disassembly

    5.1 Precautions for Disassembly/Reassembly Use only approved Xerox spare parts. Ensure that the part number, product name, any voltage, current or temperature ratings are correct. Failure to do so could result in damage to the printer, circuit overload, fire or electric shock.
  • Page 40 Disassembly Do not touch the board with your bare hands or metal objects, this can create a short circuit or cause an electrical shock. Take extra care when handling boards containing sensors, motors or lamps as they may get hot. Take care when fitting, or removing, screws.
  • Page 41: Front Cover

    Disassembly 5.2 Front Cover Remove the paper tray. Open the front door and remove the toner cartridge. Front Cover Cassette With the front cover fully open, carefully release the plastic hinge supports from the guide hooks by pulling inward. Pull the front cover away from the printer to remove. Latch Front Cover Latch Holder...
  • Page 42: Tray 1/Mpt Assembly

    Disassembly 5.3 Tray 1/MPT Assembly Open the Tray1/MPT assembly. With the tray at a 45 angle, carefully release the plastic hinge supports from the guide hooks. Lift the Tray1/MPT assembly off the hinge pins on the front cover. 45°...
  • Page 43: Rear Cover

    Disassembly 5.4 Rear Cover Note When disassembling the rear cover, move the power switch to the OFF position. When reassembling the rear cover, move the power switch to the ON position. Remove 2 screws securing the rear open cover and remove. Rear Open Open the face up cover.
  • Page 44: Top Cover

    Disassembly 5.5 Top Cover Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove 4 screws securing the top cover as shown below. Caution When removing the top cover, lift the front of the top cover slowly to avoid damaging the exit rollers. Use caution to avoid damaging the exit rollers when reassembling the top cover.
  • Page 45: Middle Cover

    Disassembly 5.6 Middle Cover Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the top cover, see "5.5 Top Cover" on page 5-6. Open the front cover. Remove 4 screws securing the middle cover. Disconnect and free the wiring harness from the middle cover. Lift up on the left side of the middle cover to release it from the retaining pin.
  • Page 46: Side Cover (Left And Right)

    Disassembly 5.7 Side Cover (Left and Right) Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the top cover, see "5.5 Top Cover" on page 5-6. Remove the 2 screws securing the right or left cover.
  • Page 47: Exit Roller

    Disassembly 5.8 Exit Roller Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the top cover, see "5.5 Top Cover" on page 5-6. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8. Remove the exit gear, bearing and exit roller as shown below Note It is not necessary to remove the laser unit or middle cover, although the image below shows them...
  • Page 48: Engine Shield Assembly And Exit Board

    Disassembly 5.9 Engine Shield Assembly and Exit Board Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the top cover, see "5.5 Top Cover" on page 5-6. Remove the right cover, see "5.7 Side Cover (Left and Right)" on page 5-8. Remove the paper tray.
  • Page 49 Disassembly Turn the printer onto its top to access and remove the 12 screws on the bottom of the printer securing the engine shield assembly. Exit Board Engine Shield Ass'y Remove 2 screws securing the Exit Board to the print frame. Caution When reassembling the engine shield assembly, be sure the paper out sensor flag is up and out of the way to avoid damaging the flag.
  • Page 50: Smps

    Disassembly 5.10.1 SMPS Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the top cover, see "5.5 Top Cover" on page 5-6. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8. Remove the engine shield assembly, see "5.9 Engine Shield Assembly and Exit Board"...
  • Page 51: Main Board

    Disassembly 5.10.2 Main Board Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the SMPS shield, see step 5 in "5.9 Engine Shield Assembly and Exit Board" on page 5-10. Disconnect all harnesses from the main board. Remove the 8 screws securing the main board to the printer and remove the main board Note 2 screws are securing the network card or plate.
  • Page 52: Removing The Network Card Or Optional Memory Modules

    Disassembly 5.10.3 Removing the Network Card or Optional Memory Modules You only need to open the rear open cover to access the memory modules and network card. Memory Board Thumb Screws 5-14...
  • Page 53: Fuser Assembly

    Disassembly 5.11 Fuser Assembly Warning The fuser assembly is HOT. Let the fuser cool before removing. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Unplug 2 connectors, one from the main board and one from the SMPS. Remove 4 screws securing the fuser assembly.
  • Page 54 Disassembly Caution There are 2 securing nuts the screws go through that are not captured. These can fall out and get lost when tipping the fuser assembly. Caution Hold the Halogen lamp by the end terminals. DO NOT TOUCH the lamp itself, this will damage it and cause the fuser to malfunction.
  • Page 55 Disassembly Free the thermister harness as shown below. Thermistor Harness Remove 1 screw securing the thermister and remove from the fuser assembly. Thermistor Service Manual 5-17...
  • Page 56: Fan

    Disassembly 5.12 Fan Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the top cover, see "5.5 Top Cover" on page 5-6. Remove the right cover, see "5.7 Side Cover (Left and Right)" on page 5-8. Disconnect the connector from the SMPS.
  • Page 57: Laser Scanner Unit (Lsu)

    Disassembly 5.13 Laser Scanner Unit (LSU) Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the top cover, see "5.5 Top Cover" on page 5-6. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8. Remove 1 screw to the control panel board and remove the board.
  • Page 58: Drive Assembly

    Disassembly 5.14 Drive Assembly Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the top cover, see "5.5 Top Cover" on page 5-6. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8. Remove the 6 screws securing the drive assembly.
  • Page 59: Transfer Assembly

    Disassembly 5.15 Transfer Assembly Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the toner cartridge. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the middle cover, see "5.6 Middle Cover" on page 5-7. Remove the top cover, see "5.5 Top Cover"...
  • Page 60: Tray 1/Mpt Assembly

    Disassembly 5.16.1 Tray 1/MPT Assembly Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the middle cover, see "5.6 Middle Cover" on page 5-7. Remove the top cover, see "5.5 Top Cover" on page 5-6. Remove the left and right covers, see "5.7 Side Cover (Left and Right)"...
  • Page 61: Feed Roller

    Disassembly 5.16.2 Feed Roller Remove the drive assembly, see "5.14 Drive Assembly" on page 5-20. Remove the Tray 1/MPT assembly, see "5.16.1 Tray 1/MPT Assembly" on page 5-22. Remove the 3 screws (gold) from the feed bracket. Note The feed bracket screws are numbered and need to be tightened down in the correct order when reassembling.
  • Page 62 Disassembly Remove the screw from the right idler bushing plate. Remove the plate, idler spring and bushing. Slide the feed shaft idler to the right and out of the printer. Remove the feed roller and feed roller 1 as shown below. Feed Roller Feed Roller1 5-24...
  • Page 63: Pick-Up Assembly, Solenoids, And Pick Roller

    Disassembly 5.17 Pick-Up Assembly, Solenoids, and Pick Roller Remove the front cover, see "5.2 Front Cover" on page 5-3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5. Remove the middle cover, see "5.6 Middle Cover" on page 5-7. Remove the top cover, see "5.5 Top Cover"...
  • Page 64 Disassembly Remove the pick roller as shown below on the right. Regi Solenoid Rubber Pickup Pick-up Solenoid 5-26...
  • Page 65: Alignment And Adjustments

    Alignment and Adjustments Alignment and Adjustments This chapter describes some of the main service procedures including: Using the DCU for diagnostics Clearing paper jam and test patterns Much of this chapter is also included in the user's guide. 6.1 How to Use the Diagnostic Control Unit (DCU) 6.1.1 DCU Setup You can use the DCU test unit as an aid to diagnosing printer problems.
  • Page 66: Status Monitoring Code

    Alignment and Adjustments 6.1.2 Status Monitoring Code The DCU can be used in 2 modes: Status Monitoring and Self Diagnostic. To use the DCU in Status monitoring mode, connect the DCU and turn printer power ON. The 7 segment LED display will show various codes that show the progress of the printer operation.
  • Page 67: Self Diagnostic Mode

    Alignment and Adjustments 6.1.3 Self Diagnostic Mode If an error appears, use the Self Diagnostic mode for fault finding as many safety features are disabled. To Enter Self Diagnostic Mode: Connect the DCU. Turn the printer ON while holding down the [Down], [Shift] and [Stop] at the same time. Code 78 will now appear on the display, continue to hold the buttons for approximately 3 seconds until 00 appears on the display, and then release the buttons.
  • Page 68 Alignment and Adjustments Feed and exit sensor test The OFF LED indicates the status of the exit sensor. The 3rd LED indicates the status of the feed sensor. Note: The feed sensor also detects the presensce of the toner cartridge. Cover open sensor test The ON LED indicates the status of the cover open sensor.
  • Page 69 Alignment and Adjustments Code Function Enter Stop Remark Motor Motor Run Motor Stop Mhv On Mhv off -1550 V THV(-) Thv Negative On Thv Negative Off THV(+) Thv On Thv Off +1300 V Dev On Dev Off +430 V LSU Run LSU Stop Ready PICK UP...
  • Page 70: Paper Path

    Alignment and Adjustments 6.2 Paper Path L S U Fuser Toner Cartridge EXIT Sensor MP Sensor MP Sensor Cassette Fuser Manual Feeder LSU(Laser Scan Unit) Transfer Roller Toner Cartridge After receiving the print command, the printer feeds paper from Tray 1, 2, or optional Tray 3. Jam0: L S U Fuser...
  • Page 71: Clearing Paper Jams

    Alignment and Adjustments 6.3 Clearing Paper Jams The leading causes of paper jams are: The tray is loaded improperly or overfilled. The tray has been pulled out during a print job. The front cover has been opened during a print job. Paper that does not meet specifications has been used.
  • Page 72: Jam0: Paper In The Feed Area

    Alignment and Adjustments 6.3.2 Jam0: Paper in the Feed Area Slide out the tray to expose the jammed paper. Remove any jammed paper by pulling the visible edge away from the tray. Make sure that all of the paper is properly aligned in the tray. Slide the tray back into the printer.
  • Page 73: Tips For Avoiding Paper Jams

    Alignment and Adjustments 6.3.4 Tips for Avoiding Paper Jams By selecting the correct paper types, most paper jams can be avoided. To help prevent paper jams always perform the following: Ensure that the adjustable guides are positioned correctly against the paper. Do not overload the tray.
  • Page 74: Consumables And Replacement Parts

    4 second intervals. Toner Cartridge Crum If the On Line/Error LED is blinking (red) [Error] and (orange) alternately, the printer has detected a non-Xerox toner cartridge. Toner Cartridge Empty The printer has stopped and the [Error] LED is blinking (orange). 6-10...
  • Page 75: Periodic Defective Image (Repeating Defects)

    Alignment and Adjustments 6.7 Periodic Defective Image (Repeating Defects) If a mark or other printing defect occurs at regular intervals down the printed page it may be caused by a damaged or contaminated roller. Measure the repeating defect and refer to the table below to identify the problem component. Roller Defective image Typical defect...
  • Page 76 Alignment and Adjustments 6-12...
  • Page 77: Troubleshooting

    Troubleshooting Troubleshooting 7.1 Print Quality Problems 7.1.1 Vertical Black Line and Band Example Possible Cause Sequence of Repair Actions There are straight, black, vertical lines or banding on the printed image. Damaged developer roller, Print a cleaning sheet. deformed doctor blade, or cleaning Replace the toner cartridge and re-test.
  • Page 78: Horizontal Black Band

    Troubleshooting 7.1.3 Horizontal Black Band Example Possible Cause Sequence of Repair Actions Dark or blurry horizontal stripes periodically appear on the printed image. Bad contacts on the toner cartridge Clean all HV contacts on the cartridge and high voltage terminals. primter frame.
  • Page 79: Light Image

    Troubleshooting 7.1.5 Light Image Example Possible Cause Sequence of Repair Actions The printed image is too light, with no ghosting. Toner Save mode is enabled. Turn Toner Save mode off. The developer roller is Replace the toner cartridge and re-test. Digital Printer contaminated or the toner cartridge Cycle power to the printer and wait...
  • Page 80: Uneven Density

    Troubleshooting 7.1.7 Uneven Density Example Possible Cause Sequence of Repair Actions Print density is uneven from left to right. The toner level is not even on the Remove the toner cartridge and gently toner cartridge roller due to a shake it to loosen toner. damaged blade or low toner.
  • Page 81: Ghosting 1

    Troubleshooting 7.1.9 Ghosting 1 Example Possible Cause Sequence of Repair Actions There is ghosting at 75.5 mm intervals from the OPC drum while printing on card stock, transparencies or using the MPT. When printing on card stock, thick Ensure supported media is being used and paper or transparenices a higher the correcy type is selected in the printer transfer voltage is required.
  • Page 82: Ghosting 3

    Troubleshooting 7.1.11 Ghosting 3 Example Possible Cause Sequence of Repair Actions Ghosting occurs at 78 mm intervals. Fuser contamination or Replace the fuser. termperature control problem. Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer...
  • Page 83: Stains On The Back Of The Page

    Troubleshooting 7.1.14 Stains on the Back of the Page Example Possible Cause Sequence of Repair Actions The back of the page is stained at 47 mm intervals. Transfer roller is contaminated. Run the OPC cleaning mode print 2 to 3 times then run the self test to remove Pressure roller is contaminated.
  • Page 84: Paper Feed Problems

    Troubleshooting 7.2 Paper Feed Problems 7.2.1 Wrong Print Position Printing begins at the wrong position on the paper. Possible Cause Solution Defective feed sensor. Replace the defective acutator/sensor. 7.2.2 Jam 0 Description: Paper does not leave the tray. Jam0 occurs if the paper is not fed into the printer. L S U Fuser Toner Cartridge...
  • Page 85: Jam 1

    Troubleshooting 7.2.3 Jam 1 Description: There is a paper jam in front of or inside the fuser. There is a paper jam stuck in the discharge roller and in the fuser, just after passing the feed actuator. L S U Fuser Toner Cartridge EXIT...
  • Page 86: Multiple Pick

    Troubleshooting 7.2.5 Multiple Pick Description: Multiple sheets of paper are picked from the tray at the same time. Possible Cause Solution The paper guides are set incorrectly. Adjust the guides so they fit snuggly against the paper in the tray. The paper has a rough surface.
  • Page 87: Printer Faults

    Troubleshooting 7.3 Printer Faults 7.3.1 All LEDs Blinking (Fuser Error) Description: All the lamps on the control panel blink. The fuser drive gear breaks or melts. When printing the motor skips or makes a noise due to a defective fuser drive gear. Possible Cause Sequence of Repair Actions The thermostat, fuser power cable or heat lamp has an...
  • Page 88: Paper Empty Error

    Troubleshooting 7.3.4 Paper Empty Error Description: The paper empty LED is lit even when paper is loaded in the tray. Possible Cause Sequence of Repair Actions The paper empty sensor or actuator is damaged or faulty. Use the DCU test 08. The main board is faulty.
  • Page 89: No Error Lamp When The Cover Is Open

    Troubleshooting 7.3.7 No Error Lamp When the Cover is Open Description: The error LED is not lit when the front cover is open. Possible Cause Sequence of Repair Actions The interlock may be stuck or damaged. Use the DCU test 09 and check for error code 64.
  • Page 90: Printed Vertical Lines Become Curved

    Troubleshooting 7.3.10 Printed Vertical Lines Become Curved Description: When printing the vertical lines are not straight. Possible Cause Sequence of Repair Actions The +24 V supply to the laser unit is faulty. Use the DCU test 05 to test the laser motor. If the voltage is stable, replace the laser unit.
  • Page 91: Toner Cartridge Servicing

    Troubleshooting 7.4 Toner Cartridge Servicing Use only Xerox toner cartridges in the printer. Non-Xerox toner or Third Party toner refills are not guaranteed to work with this printer and can cause malfunctions, print-quality problems, and jamming to occur. 7.4.1 Precautions for Toner Cartridges Excessive exposure to direct light for more than a few minutes can cause damage to the cartridge and degrade print quality.
  • Page 92: Software Problems

    Troubleshooting 7.5 Software Problems 7.5.1 The Printer is Not Responding to the Print Command The printer is on, but not operating in print mode. Print a Demo Page: When the Ready LED lights, press and hold the [Cancel] button until the LEDs flash then release. If the test print works, there are no hardware problems within the printer and the user should check the application settings.
  • Page 93: Spool Error

    Troubleshooting 7.5.3 SPOOL Error Simultaneous Peripheral Operations Online (SPOOL) is the process Windows uses to manage print jobs. Jobs are processed and then stored on the hard disk until the printer is ready to accept them. Insufficient space on the hard disk in the directory assigned for the basic spool. Delete any unnecessary files to provide more space for spool storage.
  • Page 94 Troubleshooting 7-18...
  • Page 95: Parts List

    Parts List Parts List Contents 8.1 Main Assembly 8.2 Frame Unit Assemly 8.3 MP Assembly 8.4 Fuser Unit Assembly 8.5 Main Drive Unit Assembly 8.6 Tray 2 (Cassette) Unit Assembly 8.7 Tray 3 (SCF - Optional Cassette) Unit Assembly Service Manual 8-1...
  • Page 96: Main Assembly

    Parts List 8.1 Main Assembly...
  • Page 97: Main Assembly Parts List 8.1

    Parts List Main Assembly Parts List 8.1 Part Name and (part description) Part number Remark ELA HOU-FRAME-220V, HB2 ELA HOU-FRAME-110V, HB2 MEA UNIT-COVER TOP 002N02314 COVER-M-TOP PMO-STACKER RX KEY-M-ON LINE SPRING-CS LENS LED-M-LED BUSH-M-F/DOWN COVER-M-SIDE L 002N02317 COVER-M-SIDE R 002N02318 MEA UNIT-COVER REAR 002N02319 COVER-M-REAR...
  • Page 98 Parts List Part Name and (part description) Part number Remark CBF HARNESS-ENGINE 152N02012 MEA UNIT-CASSETTE (PAPER TRAY) 109R00749 PLATE CHANNEL MOTOR HARNESS-DRIVE 152N11566 TONER CARTRIDGE 3.5k STANDARD CAP 109R00746 TONER CARTRIDGE 5k HIGH CAPACITY 109R00747...
  • Page 99: Frame Unit Assemly

    Parts List 8.2 Frame Unit Assemly Service Manual 8-5...
  • Page 100: Frame Unit Assembly Parts List 8.2

    Parts List Frame Unit Assembly Parts List 8.2 Part Name and (part description) Part number Remark ELA UNIT-FRAME 110V 110V ELA UNIT-FRAME 220V 220V FRAME-BASE R2 GUIDE-P-TR 038N00407 PLATE-P-SAW GUIDE-M-TR RIB 038N00408 PMO-GEAR_EXIT_DRV16 FOOT-BACK FOOT-FRONT GROUND-GUDIE TR R2 MEC-TERMINAL PLATE-TERMINAL CON R2 PLATE-TERMINAL CR R2 HOUSING-TERMINAL R2 002N02320...
  • Page 101 Parts List Part Name and (part description) Part number Remark SPRING ETC-TR L HAWK ROLLER-FEED 022N01607 BUSH-M-TR L GROUND-FUSER R2 SHAFT-FEED IDLE BUSH-M-FEED IDLE SPRING ETC-TR GROUND-DRIVE2 R2 SPRING-TS CAM-M-PICK_UP 008N01738 GROUND-DRIVE R2 SOLENOID-FEED ROCKY2 121N01074 SOLENOID-HB (MANUAL) 700N00094 MEA UNIT-GEAR PICKUP 007N01271 45-1 GEAR-PICK UP B_R2...
  • Page 102: Mp Assembly

    Parts List 8.3 MP Assembly...
  • Page 103: Mp Assembly Parts List 8.3

    Parts List MP Assembly Parts List 8.3 Part Name and (part description) Part number Remark ELA UNIT-MP 022N02085 FRAME-17-MP SOLENOID-MP 121N01075 CBF HARNESS-MPF SEN BUSH-M-PICK-UP R HOUSING-M-PICK UP2_R2 STOPPER-M-PICK UP_R2 HOLDER-M-PAD_MP HOUSING-M-PICK UP_MP HOLDER-M-SENSOR_MP PLATE-P-KNOCK UP_MP BRACKET-P-PICK UP_MP GEAR-IDLE 23 SHAFT-P-PICK_UP ROLLER-M-IDLE FEED GEAR-M-PICK UP_MP...
  • Page 104: Fuser Unit Assembly

    Parts List 8.4 Fuser Unit Assembly 8-10...
  • Page 105: Fuser Assembly Parts List 8.4

    Parts List Fuser Assembly Parts List 8.4 Part Name and (part description) Part number Remark ELA HOU-FUSER 110V 126N00229 110V ELA HOU-FUSER 220V 126N00230 220V COVER-FUSER R2 HOLDER-PLATE CLAW R2 SPRING ETC-CLAW PMO-ROLLER_EXIT SPRING ETC-FUSER EXIT THERMOSTAT-150 130N01265 PMO-GEAR_EXIT_DRV16 GEAR-IDLE 23 RING-E GEAR-RDCN 25/15 ROLLER-HEATER...
  • Page 106: Main Drive Unit Assembly

    Parts List 8.5 Main Drive Unit Assembly Main Drive Unit Assembly Parts List 8.5 Part Name and (part description) Part number Remark ELA UNIT- DRIVE 007N01270 BRACKET-GEAR MAIN GEAR-RDCN 53/26 GEAR-RDCN 113/33 GEAR-RDCN 57/18 WASHER-PLAIN BRACKET-MOTOR MAIN GEAR-RDCN GEAR-RDCN MOTOR STEP-HUMMINGBIRD 8-12...
  • Page 107: Tray 2 (Cassette) Unit Assembly

    Parts List 8.6 Tray 2 (Cassette) Unit Assembly Service Manual 8-13...
  • Page 108: Tray 2 (Cassette) Unit Assembly Parts List 8.6

    Parts List Tray 2 (Cassette) Unit Assembly Parts List 8.6 Part Name and (part description) Part number Remark MEA UNIT-CASSETTE, USA 109R00749 FRAME-M-CASSETTE GUIDE-M-EXTENSION LARGE GUIDE-EXTENSION SMALL PLATE-P-KNOCK_UP SPRING-CS MEA UNIT-HOLDER PAD HOLDER-M-PAD SHEET-HOLDER PAD R2 RPR-FRICTION PAD 019N00742 IPR-PLATE PAD SPRING ETC-EXIT ROLL FD COVER-SUB CASSETTE R2 INDICATOR-M-CST PAPER...
  • Page 109: Tray 3 (Scf - Optional Cassette) Unit Assembly

    Parts List 8.7 Tray 3 (SCF - Optional Cassette) Unit Assembly Service Manual 8-15...
  • Page 110: Tray 3 (Scf - Optional Cassette) Assembly Parts List 8.7

    Parts List Tray 3 (SCF - Optional Cassette) Assembly Parts List 8.7 Part Name and (part description) Part number Remark ELA HOU-SCF H2 097N01439 COVER-M-FRONT SCF H2 SPRING-ES ROLLER-IDLE FEED COVER-M-LEFT SCF H2 COVER-M-RIGHT SCF H2 COVER-M-REAR SCF H2 FRAME-M-SCF HOUSING-M-PICKUP _R2 HOUSING-M-PICKUP2 _R2 SPONGE-ROLLER PICK_UP...
  • Page 111: Xerox Options And Accessories

    39-10 SCREW-MACHINE 39-11 CORE-FERRITE 39-12 CABLE TIE BUSH CABLE SCREW-TAPTITE GUIDE-M-KNOCKUP MEA UNIT-CASSETTE 109R00749 Xerox Options and Accessories Part Name and (part description) Part number Remark POWER CORD, 110 V 117N01602 USB CABLE 117N01313 DCU Tool 600T80340 OPTIONAL TRAY 3...
  • Page 112 Parts List 8-18...
  • Page 113: Block Diagram

    Block Diagram Block Diagram Service Manual 9-1...
  • Page 114 Block Diagram...
  • Page 115: Connection Diagram

    Connection Diagram Connection Diagram ROMDIMM 100PIN CN13 NETWORK OPTION PI N RAMDIMM CN14 100PIN LSU_ CLK nLREADY POLYGON nPMOTOR MOTOR 24VS CN15 nHSYNC IE EE1284 COMPATIBLE nLD_ON CABLE HOST HOST 4PIN USB CABLE 3. 3V COMPUTER COMPUTER CN11 PTL LED ARRAY CON- CN16 NEC-...
  • Page 116 Connection Diagram 10-2...

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