Page 1 Phaser 3500 ® laser printer Service Manual...
Page 2 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 Unpublished rights reserved under the copyright laws of the United States.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.
Page 3: Service Terms
Service Terms Cautions, Notes, and Warnings Note: A note indicates an operating or maintenance procedure, practice or condition that is neccessary to efficiently accomplish a task. A note can provide additional information related to a specific subject or add a comment on the results achieved through a previous action.
Page 4: Symbols Marked On The Product
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. 30 min.
Page 5: Power Safety Precautions
Power Safety Precautions Power Source For 110 VAC printers, do not apply more than 140 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 VAC printers, do not apply more than 264 volts RMS between the supply conductors or between either supply conductor and ground.
Page 6: Electrostatic Discharge (Esd) Precautions
Electrostatic Discharge (ESD) Precautions Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic Discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated Circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.
Page 7: Service Safety Summary
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.
Page 8: Servicing Electrical Components
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...
Page 9: Table Of Contents
Jam At Duplex (Duplex Jam 2)......... 2-14 Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge, Replace Print Cartridge .
Page 10 Contents General Troubleshooting ........... 2-17 Control Panel Troubleshooting .
Page 11 Contents Covers ..............4-4 Right Cover .
Page 12 Contents Parts List Using the Parts List ............5-2 PL 8.1 Main Assembly .
Page 13 Overview of the Phaser 3500 Laser Printer........
Page 14: Service Call Procedures
Service Call Procedures This section includes the following: ■ Servicing Instructions on page 1-2 ■ Service Preventive Maintenance Procedure on page 1-3 Phaser® 3500 Laser Printer Service Manual...
Page 15: Servicing Instructions
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 Verify the problem reported and check for any error codes and write them down. Print normal customer prints and service test prints and look for any of the following: ■...
Page 16: Service Preventive Maintenance Procedure
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.
Page 17: Repair Analysis Procedures
Repair Analysis Procedures This section includes the following: Introduction on page 2-2 ■ ■ Service Diagnostics on page 2-4 ■ Troubleshooting Error Messages on page 2-10 General Troubleshooting on page 2-17 ■ ■ Power Supply Troubleshooting on page 2-18 Phaser® 3500 Laser Printer Service Manual...
Page 18: Introduction
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...
Page 19: Using The Troubleshooting Procedures
Repair Analysis Procedures Using the Troubleshooting Procedures 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.
Page 20: Service Diagnostics
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.
Page 21: Service Diagnostics Menu Map
Repair Analysis Procedures Service Diagnostics Menu Map Service Diagnostic Control Panel Button Descriptions 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. Scrolls up one menu item within a menu list.
Page 22 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...
Page 23 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.
Page 24 Repair Analysis Procedures Main Menu Sub Menu Description/Function Control 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...
Page 25 Repair Analysis Procedures Main Menu Sub Menu Description/Function Control Panel Display L Motor This tests if the laser unit is Laser Ready Test Ready ready and capable of Pass/Fail printing, or at a stable polygon motor speed. Fuser Fuser When the Target Temp is Target/Current Temp.
Page 26: Troubleshooting Error Messages
The leading edge of the paper passes the duplex sensor, but the leading edge of the ■ paper does not reach the registration sensor in the specified time. Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge page 2-14 A print cartridge is not detected.
Page 27: Jam At Tray [1] [2] [3] (Jam 0)
Repair Analysis Procedures Jam At Tray [1] [2] [3] (Jam 0) Step Actions and Questions Check the side guides for the Replace the Tray. Go to Step 2. inoperative tray for damage or improper seating. Are guides damaged or loose? Check the surface of the pick-up rollers Clean rollers with a Go to Step 3.
Page 28: Jam At Exit (Jam 2)
Repair Analysis Procedures Step Actions and Questions Use service diagnostics to test the exit Go to Step 4. Replace the exit sensor. sensor. Does the sensor operate correctly? Replace the Fuser Assembly and Complete. Replace the SMPS. retest. Did this correct the problem? Jam At Exit (Jam 2) Step Action and Questions...
Page 29 Repair Analysis Procedures Step Actions and Questions Inspect the Duplex Assembly. Is any Remove obstruction Go to Step 5. paper wrapped around the Duplex and clean rollers. rollers? Use service diagnostics to check the Go to Step 6. Replace the exit exit sensor.
Page 30: Jam At Duplex (Duplex Jam 2)
Replace the Duplex Assembly. Replace the Main Replace the Power Board. Supply Board. Does the problem still occur? Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge, Replace Print Cartridge Step Action and Questions Open the top cover and ensure that the Complete Go to Step 2.
Page 31: Close Top Cover
Repair Analysis Procedures Step Action and Questions 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 Visually inspec the top cover and the Replace the Top Go to Step 2.
Page 32: Output Tray Is Full
Repair Analysis Procedures Step Actions and Questions Use diagnostics to check the laser Replace the Laser Replace the Main motor function. Unit. Board. Did the laser motor fail? Output Tray Is Full Step Actions and Questions Check the Output Tray sensor and Replace the actuator.
Page 33: General Troubleshooting
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 Verify that power cord is securely plugged into both the printer and the grounded, three prong AC outlet with the appropriate power available.
Page 34: Power Supply Troubleshooting
Repair Analysis Procedures Power Supply Troubleshooting 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? Check the power cord for defects, damage, or a loose connection. Check the AC switch harness for continuity.
Page 35: Image-Quality Troubleshooting
Image-Quality Troubleshooting This section covers the following: Image-Quality Problems Overview on page 3-2 ■ ■ Control Panel (Internal) Test Print on page 3-4 ■ Image-Quality Troubleshooting on page 3-7 Phaser® 3500 Laser Printer Service Manual...
Page 36: Image-Quality Problems Overview
Note: See the approved media list, Media and Tray Specifications on page 6-9, for media that has been tested and approved for use with the Phaser 3500 Laser Printer. ■ Generate the Control Panel (Internal) Test Print on page 3-4, and see if the image- quality problem still exists ■...
Page 37: Repeating Defects
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 ■...
Page 38: Control Panel (Internal) Test Print
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.
Page 39: Resolution
image-quality Troubleshooting Resolution Observe the three resolution check points on several test prints. ■ Ensure that the 2 pixel horizontal, vertical, and diagonal lines are clear and continuous. The diagonal lines might appear to be narrower than the others. Characters in the text paragraphs should be uniform and equal in density. ■...
Page 40: Skips Or Smears
image-quality Troubleshooting Skips or Smears Check the test print in the indicated areas for loss, stretching, 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.
Page 41: Image-Quality Troubleshooting
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...
Page 42: Black Prints
image-quality Troubleshooting Image Defect Possible Causes Solutions Black Prints No charge voltage Verify the high-voltage ■ contacts are operational and Power Supply Board ■ The prints are completely black, make good contact with the Print Cartridge ■ has no visible image. print cartridge.
Page 43: Ghosting
image-quality Troubleshooting Image Defect Possible Causes Solutions Ghosting Operating environment Printer is installed in specified ■ environment? Media (paper) ■ Image from the previous page Verify that paper meets Print Cartridge ■ prints on consecutive pages. printer specifications. Print 20 Transfer Roller ■...
Page 44: Black Spots/Marks
image-quality Troubleshooting Image Defect Possible Causes Solutions Black Spots/Marks Print Cartridge Replace the Print Cartridge. ■ Fuser Assembly ■ There are spots and/or marks of NOTE: See Repeating Paper transports ■ toner on the printed side of the Defects on page 3-3 for defect page.
Page 45: Unfused Image
image-quality Troubleshooting Image Defect Possible Causes Solutions Unfused Image Paper quality (damp paper) Paper is too thick, damp or ■ contains a high percentage of Operating environment ■ Part or all of the image is cotton. Remote Control Panel ■ unfused.
Page 46: Repairs And Adjustments
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 ■...
Page 47: Overview
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.
Page 48: General Notes On 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.
Page 49: Covers
Repairs and Adjustments Covers Right Cover Disconnect the power cord. Remove the Duplex Unit. 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.
Page 50: Left Cover
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. Slide the left cover towards the rear of the printer to release the 3 tabs securing it to the printer.
Page 51: Rear Cover
Repairs and Adjustments Rear Cover Open the Rear Cover. Release the Restraining Strap (tie stopper). Tie Stopper s3500-081 Phaser® 3500 Laser Printer Service Manual...
Page 52 Repairs and Adjustments 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.
Page 53: Top Cover
Repairs and Adjustments Top Cover Remove the Print Cartridge and protect it from light exposure. Remove: ■ Covers on page 4-4 ■ Left Cover on page 4-5 Note: Open the Rear and Top Covers for access. Remove the 2 screws located on the front of the Top Cover. On the rear, left side of the printer, remove 1 screw securing the Top Cover.
Page 54 Repairs and Adjustments Release 3 tabs, one on the left, one on the right, and one on the rear of the Top Cover. s3500-085 Disconnect the Control Panel wiring harnesses from the Main Board, note the connector location and routing for reassembly. Phaser®...
Page 55: Control Panel And Lcd Display
Repairs and Adjustments Control Panel and LCD Display Remove: Top Cover on page 4-8 ■ Remove the 6 screws securing the LCD and control panel and remove from the top cover. ■ 2 screws to the LCD Board. ■ 4 screws on the key panel board. Note: DO NOT remove the 3 screws securing the plastic portion of the LCD display.
Page 56: Open Cover
Repairs and Adjustments Open Cover Remove: Covers on page 4-4 ■ ■ Left Cover on page 4-5 ■ Top Cover on page 4-8 Remove the 2 screws and stoppers from the Open Cover. Remove the Open Cover from the Top Cover by flexing the 2 tabs as shown below. Stopper s3500-087 Open Cover...
Page 57: Tray 1 (Mpt) Assembly
Repairs and Adjustments Tray 1 (MPT) Assembly Open Tray 1. 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. s3500-058 Note: In the next step, if you exert too much pressure you can break the tracks. Phaser®...
Page 58 Repairs and Adjustments 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 and are easy to lose. Tray Link s3500-059 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.
Page 59: Tray 1 Knock-Up Plate
Repairs and Adjustments Tray 1 Knock-Up Plate Follow all the steps for removing the Tray 1 (MPT) Assembly on page 4-12. 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. To free the Knock-Up Plate, carefully spread the slotted hinge piece to release the post, then remove the Knock-Up Plate.
Page 60: Tray 1 Pick-Up Rack
Repairs and Adjustments Tray 1 Pick-Up Rack Remove 2 screws securing the Pick-Up Rack and remove the rack. 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 s3500-118 Phaser®...
Page 61: Inner Cover
Repairs and Adjustments Inner Cover Remove: Tray 1 (MPT) Assembly on page 4-12 ■ ■ Top Cover on page 4-8 Open or remove Tray 2 for better access. Remove 2 screws securing the Inner Cover to the printer frame. Remove the Inner Cover. Inner Cover s3500-089 Phaser®...
Page 62: Transfer Roller
Repairs and Adjustments Transfer Roller 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.
Page 63: Retard Assembly
Repairs and Adjustments Retard Assembly Remove: Tray 1 (MPT) Assembly on page 4-12 ■ Squeeze the lock as shown below and take out the retard assembly. Retard Ass'y s3500-065 Reassembly Notes Note: When reassembling the retard roller, insert the left end of the retard shaft through the retard roller first.
Page 64: Tray 1 Separator (Holder) Pad Assembly
Repairs and Adjustments Tray 1 Separator (Holder) Pad Assembly Remove: ■ Tray 1 (MPT) Assembly on page 4-12 ■ Tray 1 Knock-Up Plate on page 4-14 ■ Retard Assembly on page 4-18 Disconnect the connector from the Separator Pad Assembly. Caution: Be careful not to break the actuator flag.
Page 65: Feed2 Idle Unit
Repairs and Adjustments Feed2 Idle Unit Remove: Tray 1 (MPT) Assembly on page 4-12 ■ ■ Retard Assembly on page 4-18 ■ Tray 1 Separator (Holder) Pad Assembly on page 4-19 Remove 4 screws, 2 for each of the feed idle units. Remove each idle unit.
Page 66: Registration Assembly
Repairs and Adjustments Registration Assembly Remove: Covers on page 4-4 ■ ■ Left Cover on page 4-5 ■ Top Cover on page 4-8 Remove the Gear Cap located on the right side of the Registration Assembly, the release is on the front of the cap. Gear Cap s3500-115 Phaser®...
Page 67 Repairs and Adjustments Remove the 4 screws securing the Registration Assembly to the printer. Remove the Registration Assembly from the printer. s3500-114 REGI Ass'y s3500-116 Phaser® 3500 Laser Printer Service Manual 4-22...
Page 68: Ptl Board
Repairs and Adjustments PTL Board Remove: ■ Covers on page 4-4 ■ Left Cover on page 4-5 ■ Top Cover on page 4-8 ■ Registration Assembly on page 4-21 Disconnect the wiring harness. Remove 1 screw and take out the PTL board. PTL Upper Terminal PTL PBA...
Page 69: Main Drive Assembly And Registration (Feed) Clutch
Repairs and Adjustments Main Drive Assembly and Registration (Feed) Clutch Remove: ■ Covers on page 4-4 Feed Clutch 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. Remove the e-ring securing the clutch to the feed roller shaft.
Page 70: Main Drive Assembly
Repairs and Adjustments Main Drive Assembly Disconnect 1 connector from the main motor assembly. Remove the 6 screws securing the Main Drive to the printer. Remove the Main Drive from the printer. Main Drive Ass'y s3500-074 Replacement Notes Note: There are numbers for replacing each of the 6 screws in the appropriate order when reassembling the Main Drive Assembly.
Page 71: Tray 1 Pick-Up Assembly And Pick Rollers
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.
Page 72: Pick Roller And Shaft Removal
Repairs and Adjustments Pick Roller and Shaft Removal 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.
Page 73 Repairs and Adjustments Remove 1 screw, on the right end of the shaft, securing the bracket, remove the bracket with the bearing. Bracket Gear ass'y Bearing s3500-120 Remove the right side gear from the shaft. Lift the latch on the idle cam and slide the shaft to the right, throught the cam, to free it from the printer.
Page 74: Tray 2 Pick-Up Assembly And Rollers
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. Remove: ■ Covers on page 4-4 ■ Left Cover on page 4-5 ■ Top Cover on page 4-8 ■...
Page 75 Repairs and Adjustments Remove the e-clip from the feed shaft. Remove the locking bearing, rotating in the direction of the arrow as shown below. Bearing Feed2 Gear s3500-125 Remove the gear by sliding off the shaft. Turn the printer onto its left side. Remove the front crossbar secured by 2 screws.
Page 76 Repairs and Adjustments Slide the actuator down and remove it from the printer. Actuator s3500-128 Remove the 4 screws securing the pick assembly and manuever the pick assembly out of the printer. Pick Up Unit s3500-129 Phaser® 3500 Laser Printer Service Manual 4-31...
Page 77: Feed 2 Unit
Repairs and Adjustments Feed 2 Unit 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. Remove the 4 screws securing the Feed 2 Unit to the printer and remove the assembly. Bearing Pick Up Gear s3500-126...
Page 78: Developer Drive Assembly
Repairs and Adjustments Developer Drive Assembly Remove: Covers on page 4-4 ■ Disconnect the connector from the developer drive assembly. Remove 4 screws securing the developer drive to the printer. DEVE Drive Ass'y s3500-075 Replacement Notes Note: There are numbers for replacing each of the 4 screws in the appropriate order when reassembling the Developer Drive Assembly.
Page 79: Connector Board
Repairs and Adjustments Connector Board Remove: Covers on page 4-4 ■ Disconnect all connectors to the connector board. Remove 1 screw securing the board to the chassis. Remove the connector board. Connector s3500-076 Phaser® 3500 Laser Printer Service Manual 4-34...
Page 80: Tray 1 (Mpt) Solenoid
Repairs and Adjustments Tray 1 (MPT) Solenoid Remove: Covers on page 4-4 ■ Disconnect the connector to the Tray 1 Solenoid. Remove 1 screw securing the Tray 1 Solenoid. MP Solenoid s3500-078 Phaser® 3500 Laser Printer Service Manual 4-35...
Page 81: Main Solenoid
Repairs and Adjustments Main Solenoid Remove: Covers on page 4-4 ■ ■ Feed Clutch on page 4-24 Disconnect the connector to the Main Solenoid. Remove 1 screw securing the Main Solenoid. Main Solenoid s3500-079 Phaser® 3500 Laser Printer Service Manual 4-36...
Page 82: Fuser Assembly
Repairs and Adjustments Fuser Assembly Remove: ■ Rear Cover on page 4-6 Pull the locking lever and take out the Fuser Assembly. Fuser Ass'y Thermistor Connector s3500-090 Phaser® 3500 Laser Printer Service Manual 4-37...
Page 83: Exit Solenoid Assembly
Repairs and Adjustments Exit Solenoid Assembly Remove: Covers on page 4-4 ■ ■ Left Cover on page 4-5 ■ Top Cover on page 4-8 Disconnect the connector running to the main board. Remove 3 screws securing the solenoid to the printer. Remove the solenoid assembly.
Page 84: Exit And Duplex Rollers
Repairs and Adjustments Exit and Duplex Rollers Remove: ■ Covers on page 4-4 ■ Left Cover on page 4-5 ■ 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.
Page 85: Exit Gear
Repairs and Adjustments Exit Gear Remove the bearing in order to remove the gear. Bearing Exit Gear s3500-102 Tray Full Actuator Remove the actuator from the exit roller. Actuator s3500-100 Phaser® 3500 Laser Printer Service Manual 4-40...
Page 86: Duplex Roller
Repairs and Adjustments Duplex Roller Using a small flatblade screwdriver, spread apart the bearings on both side of the duplex roller and remove from the printer. Duplex Exit Roller Holder s3500-103 Phaser® 3500 Laser Printer Service Manual 4-41...
Page 87: Laser (Lsu) Assembly And Lower Cover
Repairs and Adjustments Laser (LSU) Assembly and Lower Cover Remove: Covers on page 4-4 ■ ■ Left Cover on page 4-5 ■ 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.
Page 88: Lsu Lower Cover
Repairs and Adjustments LSU Lower Cover 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. Disconnect all the connectors running to the LSU Cover. LSU Lower Cover s3500-113...
Page 89: Left Side Cooling Supply Fan And Duct
Repairs and Adjustments Left Side Cooling Supply Fan and Duct Remove: Covers 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 Disconnect the connector to the Toner Sensor Board. Remove 1 screw to remove the fan from the printer.
Page 90: Toner Sensor Board And Crum
Repairs and Adjustments Toner Sensor Board and CRUM Remove: Covers 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 Disconnect all connectors running to the toner sensor board. Remove 2 screws securing the toner sensor board to the LSU cover.
Page 91: Cover Open Board And Harness Cover
Repairs and Adjustments Cover Open Board and Harness Cover Remove: ■ Covers 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.
Page 92: Main Board And Shield
Repairs and Adjustments Main Board and Shield 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.
Page 93: Power Supply And Shield
Repairs and Adjustments Power Supply and Shield 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.
Page 94 Repairs and Adjustments Remove 5 screws from the power supply shield. Remove 1 grounding screw from the rear of the power supply shield. Engine Shield Ass'y s3500-135 Pull out the shield slightly and disconnect all connectors to the power supply board. Remove the power supply from the printer.
Page 95: Fuser Gear Assembly
Repairs and Adjustments Fuser Gear Assembly 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 ■ Exit Solenoid Assembly on page 4-38 ■...
Page 96: Paper Size Sensor
Repairs and Adjustments Paper Size Sensor Note: If the optional Tray 3 Feeder is installed, it must be removed before perfoming this procedure. Remove: ■ Print Cartridge Tray 2 and Tray 3 (if installed) ■ ■ Left Cover on page 4-5 Disconnect CN 1 from the Paper Size Sensor.
Page 97: Parts List
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 ■...
Page 98: Using The Parts List
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.
Page 99: Pl 8.1 Main Assembly
Parts List PL 8.1 Main Assembly 39(Network only) 39-2 39-1 20-1 20-3 20-2 21-3 21-2 21-1 Phaser® 3500 Laser Printer Service Manual...
Page 100: Pl 8.1 Parts List Table
Parts List PL 8.1 Parts List Table Main Assembly Item No. Description Part Number ELA UNIT FRAME BASE ELA HOU BASE HOUSING MEA UNIT KNOCK UP MP 050N00475 PLATE M KNOCK UP MP MPR PAD KNOCK UP MP PMO SIDE GUIDE MP R PMO SIDE GUIDE MP L GEAR PINION SHAFT REINFORCEMENT...
Page 101 Parts List Main Assembly (Continued) Item No. Description Part Number ELA UNIT EXIT SOLENOID 121N01100 ELA UNIT DEVE MOTOR 127N07389 ELA UNIT MAIN MOTOR 127N07390 PBA MAIN (Main Board) 140N63016 MEA UNIT GEAR PICK UP 007N01361 20.1 GEAR M PICK UP CAM 20.2 GEAR M PICK UP 20.3...
Page 102 Parts List Main Assembly (Continued) Item No. Description Part Number 39.1 BRACKET NIC 39.2 PBA SUB (NIC BOARD) STOPPER M NETWORK Phaser® 3500 Laser Printer Service Manual...
Page 103: Pl 8.2 Cover Assembly
Parts List PL 8.2 Cover Assembly 1-14 1-13 1-11 1-12 1-10 Phaser® 3500 Laser Printer Service Manual...
Page 104: Pl 8.2 Parts List Table
Parts List PL 8.2 Parts List Table Cover Assembly Item No. Description Part Number 1 (1-X) AS UNIT COVER TOP 002N02411 COVER M TOP COVER M OPEN XRX PMO STACKER RX 002N02418 LEVER M STACKING 38 036N00030 STOPPER M HINGE OPEN COVER M OP PANEL XRX SHEET OVERLAY BUTTON MEC BRUSH ANTISTATIC...
Page 105: Pl 8.3 Frame Assembly
Parts List PL 8.3 Frame Assembly Phaser® 3500 Laser Printer Service Manual...
Page 106 Parts List 48-2 48-9 48-7 48-4 48-8 48-6 48-1 48-5 48-3 47-5 47-2 47-3 47-4 47-1 49-1 49-11 49-8 49-9 49-10 50-6 50-9 49-7 50-4 50-8 50-3 49-4 49-5 50-5 49-3 50-7 49-6 50-1 49-7 50-2 49-2 59-10 59-9 59-5 60-1 59-6 59-5-1...
Page 107: Pl 8.3 Parts List Table
Parts List PL 8.3 Parts List Table Frame Assembly Item No. Description Part Number FRAME M BASE MEA UNIT PICK UP MP 022N02172 SHAFT M PICK UP MP PMO IDLE PICK UP MP ELA UNIT ROLLER P/UP MP 022N02182 2-4-1 HOLDER M PICKUP MP 2-4-2 HOUSING M PICK UP MP...
Page 108 Parts List Frame Assembly (Continued) Item No. Description Part Number SPRING EXIT ROLL FD ROLLER EXIT F/DOWN 006N01264 HOLDER M BUSHING EXIT 013E25770 PMO ACTUATOR OUT FULL 120N00479 GEAR M EXIT Z17 007N01364 HOLDER BUSHING EXIT (F/DOWN) 013E25770 MEA UNIT ROLL EXIT DUPLEX 006N01265 11-1 SHAFT M EXIT DUPLEX...
Page 109 Parts List Frame Assembly (Continued) Item No. Description Part Number GROUND P SCF MAIN GROUND P MOTOR MAIN GROUND P GUIDE DUP CAP M GUIDE HARNESS PMO DUMMY DEVE ELA HOU VARISTOR FOOT ML80 PMO REMOVE LOCK CST SHAFT M GEAR RETARD SHAFT M COUPLING RETARD PMO BEARING SHAFT GEAR REGI Z25...
Page 110 Parts List Frame Assembly (Continued) Item No. Description 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 ELA UNIT FEED2 IDLE 022N02176 50-1...
Page 111 Parts List Frame Assembly (Continued) Item No. Description Part Number 59-5 AS FEED 1 ROLL ASSY 022N02187 59-5-1 HOUSING 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 ELA UNIT FEED2...
Page 112 Parts List Frame Assembly (Continued) Item No. Description Part Number ELA UNIT FUSER 110V 126N00242 ELA UNIT FUSER 220V 126N00243 PMO GUIDE DEVE L PMO GUIDE DEVE R SPRING ETC GUIDE DEVE TERMINAL P TR KESTREL TERMINAL SPRING TR PBA MAIN ZENER CBF HARNESS EARTH GROUND P ZENER GROUND P FUSER...
Page 113: Pl 8.4 Fuser Assembly
Parts List PL 8.4 Fuser Assembly 1-14 1-14 1-26 1-11 1-15 1-10 1-12 1-18 1-27 1-28 1-21 1-29 1-19 1-19 1-17 1-22 1-16 1-20 1-25 1-17 1-13 1-24 1-23 3-15 3-14 3-10 3-13 3-11 3-12 3-14 Phaser® 3500 Laser Printer Service Manual 5-17...
Page 114: Pl 8.4 Parts List Table
Parts List PL 8.4 Parts List Table Fuser Assembly Item No. Description Part Number ELA UNIT FUSER 110V 126N00242 ELA UNIT FUSER 220V 126N00243 COVER M FUSER UPPER THERMOSTAT (ELECTRODE P FU L) THERMISTOR PMO GUIDE CLAW GREEN SPRING TS SPRING SEPARATION MEC BRUSH ANTISTATIC ELECTRODE P FU R...
Page 115 Parts List Fuser Assembly (Continued) Item No. Description Part Number 1-29 PEX ROLLER F/UP(2) ELA UNIT ASSY HEAT ROLL MEA UNIT BRK GEAR FU BRACKET P FUSER GEAR IDLE 23 GEAR M IDLE 25 RING-E MEA UNIT FUSER LOWER ROLLER PRESSURE BUSH M PR SPRING PR ROLL COVER M FUSER LOWER...
Page 116: Pl 8.9 Tray 2 Cassette
Parts List PL 8.9 Tray 2 Cassette Phaser® 3500 Laser Printer Service Manual 5-20...
Page 117: Pl 8.9 Parts List Table
Parts List PL 8.9 Parts List Table Tray 2 Assembly Item No. Description Part Number ELA UNIT CASSETTE FRAME M CASSETTE GUIDE M HANDLE INDICATOR EMPTY PLATE P KNOCK UP SPRING PLAT K/UP GEAR PINION CAP M GUIDE SIDE L GUIDE P SIDE L GUIDE M SIDE LOCK GUIDE P SIDE R...
Page 118: Pl 8.10 Tray 3 Cassette
Parts List PL 8.10 Tray 3 Cassette Phaser® 3500 Laser Printer Service Manual 5-22...
Page 119: Pl 8.10 Parts List Table
Parts List PL 8.10 Parts List Table Tray 3 Cassette Item No. Description Part Number ELA UNIT SCF FRAME M SCF COVER M RIGHT SCF COVER M LEFT SCF COVER M DUMMY SCF PBA SCF 140N63018 CBF HARNESS OPE BUSH CABLE CBF HARNESS SCF INTERFACE 152N11620 SOLENOID MAIN...
Page 120 Parts List Tray 3 Cassette (Continued) Item No. Description 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 HUB IN RETARD 22-11 FRAME M RETARD 22-12...
Page 121: Pl 8.11 Duplex Assembly
Parts List PL 8.11 Duplex Assembly 32 30 19 20 Phaser® 3500 Laser Printer Service Manual 5-25...
Page 122: Pl 8.11 Parts List Table
Parts List PL 8.11 Parts List Table Duplex Assembly Item No. Description Part Number ELA UNIT DUPLEX FRAME M DUPLEX GUIDE M UPPER DUP COVER M REAR DUP MEA ETC ALIGN DUP GUIDE M ALIGN DUP SHAFT IDLE ROLL DUP ROLLER M IDLE DUP PCT SLIP WASHER SPRING ETC DUP...
Page 123 Parts List Duplex Assembly Item No. Description Part Number BRACKET P MOTOR DUP PULLEY M 30 DUP BELT TIMING GEAR PULLEY M 30 DUMMY DUP RING E CBF HARNESS D JOINT Phaser® 3500 Laser Printer Service Manual 5-27...
Page 124: General Information And Specifications
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 ■...
Page 125: Printer Configurations
General Information and Specifications Printer Configurations 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 Default Resolution 600 x 600 dpi Maximum Resolution 1200 x 1200 dpi...
Page 126: Consumable And Service Part Life Expectancy
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...
Page 127: Parts Of The Printer
General Information and Specifications Parts of the Printer Front View Output Tray Print Cartridge Paper Output Support Control Panel Control Board cover Tray 1 (MPT) Tray 1 (MPT) Release Tray 2 On/Off Switch Paper Gauge s3500-013 Rear View Rear Door Network Port (optional for 3500B) Duplex Unit...
Page 128: Control Panel
General Information and Specifications Control Panel The Control Panel has three components: ■ Multi-colored Light Emitting Diode (LED) light Alphanumeric display ■ ■ Six-button cluster Cancel Button Return Button On-line/Data/Error LED Menu Button Status/Error Messages and Menus Up Arrow Button OK Button Down Arrow Button s3500-012...
Page 129: Printer Specifications
General Information and Specifications Printer Specifications Printer Location and Clearance ■ Place the printer in a dust-free area where the temperature 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%.
Page 130: Printer Physical Specifications
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 lbs) Functional Specifications Characteristic Specification Printing process Non-Impact Electrophotography Color medium Monochrome...
Page 131: Electrical Specifications
General Information and Specifications Electrical 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...
Page 132: Media And Tray Specifications
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 lb. ~ 28 lb. Labels, Transparency. Executive, ISO and JISB5, (60 ~ 176 gsm) Tray 2 Paper, Cardstock A4, Letter, Legal, Folio,...
Page 133: Wiring Data
Wiring Data Phaser® 3500 Laser Printer Service Manual...
Page 134: Block Diagram
Wiring Data Block Diagram DG N D CA R T D A T A CA RT CL K +3 . 3V 1 . H O T 2 .N e u t r a l 1 . H O T 2 . N eu t r a l Phaser®...
Page 135 Wiring Data Phaser® 3500 Laser Printer Service Manual...
Page 136 Wiring Data Phaser® 3500 Laser Printer Service Manual...
Page 137 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 ■...
Page 138: Theory Of Operation
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 following:...
Page 139: Print Modes
Theory of Operation Print Modes The Phaser 3500 Laser Printer provides four print modes: ■ Draft mode: Uses a combination of reduced toner output and the lowest resolution (300 x 300 dpi) to extend print cartridge life. 300: Used for printing with a resolution of 300 x 300 dpi.
Page 140: Printer Paper Path
Theory of Operation Printer Paper Path Imaging Drum (OPC) Exit Roller Exit/Duplex Roller Heat Roller Registration Sensor Idler Tray 1 Pick Roller Idler Tray 1 Fuser Exit Roller No Paper Sensor Fuser Exit Sensor Pressure Roller Feed 2 Idler Feed 2 Roller Registration Roller Transfer Retard Roller...
Page 141: Paper Feed Sequence
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.
Page 142: Major Assemblies And Functions
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.
Page 143: Laser Scan Unit (Lsu)
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.
Page 144: Sensor Functions
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}”...
Page 145: Printer Controls
Theory of Operation 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.
Page 146: Main Board
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.
Page 147: Power Supply
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 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.
Page 148: Paper Size Control
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.
Page 149: Laser Light Intensity Control
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.
Page 150 071-0877-00...

Xerox Phaser 3500 Service Manual

1 Service Call Procedures

2 Repair Analysis Procedures

3 Image-Quality Troubleshooting

4 Repairs and Adjustments

5 Parts List

6 General Information and Specifications

7 Wiring Data

8 Theory of Operation

Quick Links

Troubleshooting

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Summary of Contents for Xerox Phaser 3500

Table of Contents