Phaser® 3150

laser printer

Service
Manual
manuals4you.com
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
so.

First Printing: July 2004

721P58540
1 Precautions
1.1 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Safety Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2.1 Toxic Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2.2 Electric Shock and Fire Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2.3 Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.4 Assembly and Disassembly Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.5 Bodily Injury Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3 ESD Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2 Reference Information
2.1 Tools for Troubleshooting the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Selecting a Location for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3 Specifications
3.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Controller/Software Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Environmental Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6 Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6.1 Approved Paper Size and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6.2 Print Margins and Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

4 Product Summary
4.1 Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.2 Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.3 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Printer Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.1 System Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.2 System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.3 Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.4 Transfer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.5 Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.6 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.7 Laser Scanner Unit (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.8 Toner Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3 Main Controller Board (PBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.1 ASIC (SPGPm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3.2 Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3.3 Flash Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3.4 SDRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.3.5 Sensor Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.4 Switching Mode Power Supply (SMPS) and High Voltage Power Supply (HVPS)4-12
4.4.1 High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.4.2 Switching Mode Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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 4.5 Engine F/W. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.5.1 Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

5 Disassembly
5.1 Precautions for Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Precautions When Removing Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Tray 1/MPT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6 Middle Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.7 Side Cover (Left and Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.8 Exit Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.9 Engine Shield Assembly and Exit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.10.1 SMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.2 Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.10.3 Removing the Network Card or Optional Memory Modules . . . . . . . . . . . . . . 5-14
5.11 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.12 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.13 Laser Scanner Unit (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.14 Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.15 Transfer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.16.1 Tray 1/MPT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.16.2 Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.17 Pick-Up Assembly, Solenoids, and Pick Roller . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

6 Alignment and Adjustments

6.1 How to Use the Diagnostic Control Unit (DCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1 DCU Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.2 Status Monitoring Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Normal Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.3 Self Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2 Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3 Clearing Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.1 Jam2: Paper in the Exit Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.2 Jam0: Paper in the Feed Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.3 Jam1: Paper Around the Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.4 Tips for Avoiding Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4 Sample Patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.1 Printing a Demo or Configuration Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.2 Printing a Cleaning Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.5 Consumables and Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.6 The LED Display Status for Each Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.7 Periodic Defective Image (Repeating Defects) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
7 Troubleshooting
7.1 Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 Vertical Black Line and Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.2 Vertical White Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.3 Horizontal Black Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.4 Black/White Spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.5 Light Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1.6 Dark Image or Completely Black Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1.7 Uneven Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.1.8 Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.1.9 Ghosting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.1.10 Ghosting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.1.11 Ghosting 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.1.12 Ghosting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.1.13 Stains on the Front of the Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.1.14 Stains on the Back of the Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.1.15 Blank Page is Printed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.1.16 Blank Page is Printed 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.2 Paper Feed Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.2.1 Wrong Print Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.2.2 Jam 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.2.3 Jam 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.2.4 Jam 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.2.5 Multiple Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.2.6 Paper Rolled in the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.2.7 Paper Rolled in the OPC Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.3 Printer Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.3.1 All LEDs Blinking (Fuser Error) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.3.2 All LEDs Blinking (Scan Error) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.3.3 Fuser Gear Melted Due to Overheating, Causing a Paper Jam . . . . . . . . . 7-11
7.3.4 Paper Empty Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.3.5 Paper Empty Error Without Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.3.6 Cover Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.3.7 No Error Lamp When the Cover is Open . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.3.8 Defective Motor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.3.9 No Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.3.10 Printed Vertical Lines Become Curved . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.4 Toner Cartridge Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.4.1 Precautions for Toner Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.4.2 Toner Cartridge Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.4.3 Redistributing Toner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.5 Software Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.5.1 The Printer is Not Responding to the Print Command . . . . . . . . . . . . . . . . 7-16
7.5.2 The Printer is Not Responding to a Print Command or
Strange Fonts are Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.5.3 SPOOL Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

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8 Parts List
8.1 Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Main Assembly Parts List 8.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2 Frame Unit Assemly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Frame Unit Assembly Parts List 8.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.3 MP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
MP Assembly Parts List 8.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.4 Fuser Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Fuser Assembly Parts List 8.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.5 Main Drive Unit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Main Drive Unit Assembly Parts List 8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.6 Tray 2 (Cassette) Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Tray 2 (Cassette) Unit Assembly Parts List 8.6. . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.7 Tray 3 (SCF - Optional Cassette) Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Tray 3 (SCF - Optional Cassette) Assembly Parts List 8.7 . . . . . . . . . . . . . . . . . 8-16
Xerox Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

9 Block Diagram

10 Connection Diagram
 Precautions

1 Precautions

In order to prevent accidents and to prevent damage to the printer, please read the precautions listed below carefully
before servicing the printer.

1.1 Safety Warnings

1. Only to be serviced by appropriately qualified service engineers.
High voltages and lasers inside this product are dangerous. This printer should only be serviced by a suitably
trained and qualified service engineer.
2. 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.
3. Laser Safety Statement
The Printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, chapter 1 Subchapter J for
Class 1 laser products, and elsewhere, it is certified as a Class 1 laser product conforming to the requirements of
IEC 825. Class 1 laser products are not considered to be hazardous. The laser system and printer are designed so
there is never access to laser radiation above a Class 1 level during normal operation, user maintenance, or
prescribed service condition.

Warning
Never operate or service the printer with the protective cover removed from Laser assembly. The reflected
beam, although invisible, can damage your eyes. When using this product, these basic safety precautions
should always be followed to reduce the risk of fire, electrical shock, and bodily injury.
CAUTION - INVISIBLE LASER RADIATION
WHEN THIS COVER OPEN.
DO NOT OPEN THIS COVER.
VORSICHT - UNSICHTBARE LASERSTRAHLUNG,
WENN ABDECKUNG GEÖFFNET.
NICHT DEM STRAHL AUSSETZEN.
ATTENTION - RAYONNEMENT LASER INVISIBLE EN CAS
D’OUVERTURE. EXPOSITION DANGEREUSE
AU FAISCEAU. CAUTION - INVISIBLE LASER RADIATION
WHEN THIS COVER OPEN.
ATTENZIONE - RADIAZIONE LASER INVISIBILE IN CASO DI DO NOT OPEN THIS COVER.
VORSICHT - UNSICHTBARE LASERSTRAHLUNG,
APERTURA. EVITARE L’ESPOSIZIONE AL WENN ABDECKUNG GEÖFFNET.
FASCIO. NICHT DEM STRAHL AUSSETZEN.
ATTENTION - RAYONNEMENT LASER INVISIBLE EN CAS
PRECAUCION - RADIACION LASER IVISIBLE CUANDO SE ABRE. D’OUVERTURE. EXPOSITION DANGEREUSE
AU FAISCEAU.
EVITAR EXPONERSE AL RAYO. ATTENZIONE - RADIAZIONE LASER INVISIBILE IN CASO DI
APERTURA. EVITARE L’ESPOSIZIONE AL
ADVARSEL. - USYNLIG LASERSTRÅLNING VED ÅBNING, NÅR FASCIO.
PRECAUCION - RADIACION LASER IVISIBLE CUANDO SE ABRE.
SIKKERHEDSBRYDERE ER UDE AF FUNKTION. EVITAR EXPONERSE AL RAYO.
UNDGÅ UDSAETTELSE FOR STRÅLNING. ADVARSEL. - USYNLIG LASERSTRÅLNING VED ÅBNING, NÅR
SIKKERHEDSBRYDERE ER UDE AF FUNKTION.
ADVARSEL. - USYNLIG LASERSTRÅLNING NÅR DEKSEL UNDGÅ UDSAETTELSE FOR STRÅLNING.
ÅPNES. STIRR IKKE INN I STRÅLEN. ADVARSEL. - USYNLIG LASERSTRÅLNING NÅR DEKSEL
ÅPNES. STIRR IKKE INN I STRÅLEN.
UNNGÅ EKSPONERING FOR STRÅLEN. UNNGÅ EKSPONERING FOR STRÅLEN.
VARNING - OSYNLIG LASERSTRÅLNING NÄR DENNA DEL
VARNING - OSYNLIG LASERSTRÅLNING NÄR DENNA DEL ÄR ÖPPNAD OCH SPÄRREN ÄR URKOPPLAD.
BETRAKTA EJ STRÅLEN. STRÅLEN ÄR FARLIG.
ÄR ÖPPNAD OCH SPÄRREN ÄR URKOPPLAD. VARO! - AVATTAESSA JA SUOJALUKITUS OHITETTAESSA
BETRAKTA EJ STRÅLEN. STRÅLEN ÄR FARLIG. OLET ALTTIINA NÄKYMÄTTÖMÄLLE LASER-
SÄTEILYLLE ÄLÄ KATSO SÄTEESEEN.
VARO! - AVATTAESSA JA SUOJALUKITUS OHITETTAESSA
OLET ALTTIINA NÄKYMÄTTÖMÄLLE LASER-
SÄTEILYLLE ÄLÄ KATSO SÄTEESEEN.

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1.2 Safety Cautions

1.2.1 Toxic Material

This product contains toxic materials that could cause illness if ingested.
1. Please keep toner cartridges away from children. The toner powder contained in the toner cartridge may be
harmful and if swallowed you should contact a doctor immediately.

1.2.2 Electric Shock and Fire Safety Precautions

Failure to follow the following instructions could cause electric shock or potentially cause a fire:
1. Use only the correct voltage, failure to do so could damage the printer and potentially cause a fire or electric
shock.
2. Use only the power cable supplied with the printer. Use of an incorrectly specified cable could cause the cable to
overheat and potentially cause a fire hazard.
3. Do not overload the power socket, this could lead to overheating of the cables inside the wall and could lead to a
fire hazard.
4. Do not allow water or other liquids to spill into the printer, this can cause electric shock. Do not allow paper
clips, pins, or other foreign objects to fall into the printer as these could cause a short circuit leading to electric
shock or fire hazard.
5. Never touch the plugs on either end of the power cable with wet hands, this can cause electric shock. When
servicing the printer, remove the power plug from the wall socket.
6. Use caution when inserting or removing the power connector. The power connector must be inserted completely
otherwise poor contact could cause overheating possibly leading to a fire. When removing the power connector,
grip it firmly and pull.
7. Do not allow the power cable to become twisted, bent sharply round corners or otherwise damaged. Do not place
objects on top of the power cable. If the power cable is damaged, it could overheat and cause a fire or exposed
cables could cause an electric shock. Replace a damaged power cable immediately, do not reuse or repair the
damaged cable. Some chemicals can eat through the coating on the power cable, weakening the cover, or
exposing cables causing fire and shock risks.
8. Ensure that the power sockets and plugs are not cracked or broken in any way. Any defects should be repaired or
replaced immediately. Take care not to cut or damage the power cable or plugs when moving the printer.
9. 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.
10. Avoid damp or dusty areas, install the printer in a clean well ventilated location. Do not position the printer near
a humidifier. Damp and dust build up inside the printer can lead to overheating and cause a fire.
11. Do not position the printer in direct sunlight. This will cause the temperature inside the printer to rise leading to
the printer failing to work properly and in extreme conditions could lead to a fire.
12. Do not insert any metal objects into the printer through the ventilator fan or other parts of the casing, it could
come into contact with a high voltage conductor inside the printer and cause an electric shock.

1-2
 Precautions

1.2.3 Handling Precautions

The following instructions are for personal safety, to avoid injury, and to avoiddamage the printer
1. Ensure the printer is installed on a level surface, capable of supporting its weight. Failure to do so could cause the
printer to tip or fall.
2. The printer contains many rollers, gears, and fans. Take great care to ensure that you do not catch your fingers,
hair, or clothing in any of these rotating devices.
3. Do not place any small metal objects, containers of water, chemicals, or other liquids close to the printer which if
spilled could get into the printer and cause damage, electric shock, or a fire hazard.
4. Do not install the printer in areas with high dust or moisture levels, beside an open window, or close to a
humidifier or heater.
5. 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.
Please carry out the following procedures before disassembly or replacing any parts:
1. Check the contents of the printer memory and make a note of any user settings. These will be erased if the
mainboard or network card is replaced.
2. Ensure that power is disconnected from the wall socket before servicing or replacing any electrical parts.
3. Disconnect printer interface cables and power cables before servicing or replacing any parts.
4. Only use approved spare parts. Ensure that part number, product name, any voltage, current, or temperature
rating are correct.
5. When removing or re-fitting any parts do not use excessive force, especially when fitting screws into plastic.
6. Take care not to drop any small parts into the printer.

Handling of the OPC Drum

The OPC Drum can be irreparably damaged if:
■ Exposed to light. Take care not to expose
the OPC Drum either to direct sunlight or to
fluorescent or incandescent room lighting.
Exposure for as little as 5 minutes can
damage the surface photoconductive "HOT CAUTION" LABEL
properties and will result in print quality
degradation. Take extra care when servicing
the printer. Remove the OPC Drum and
store it in a black bag or other lightproof
container.
■ Take care when working with the covers
(especially the top cover) open as light is
admitted to the OPC area and can damage
the OPC Drum.
■ Take care not to scratch the green surface of
OPC Drum Unit. 110V "HOT CAUTION" LABEL
■ If the green surface of the Drum Cartridge
is scratched or touched, the print quality
will be compromised. 220V

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1.2.5 Bodily Injury Warnings

1. 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.
2. 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.). Remove jewelry and loose clothing before servicing the printer.
3. When you moving the printer.
This printer weighs 12.7 kg including the toner cartridge and tray. Use safe lifting and handling techniques. Use
the lifting handles located on each side of the printer. Back injury could result if you do not lift the printer
properly.

4. Ensure the printer is installed properly.

Ensure the printer is installed on a flat, level surface, capable of supporting its weight. Failure to do so could
cause the printer to tip or fall possibly causing personal injury or damaging the printer.
Do not install the printer on a sloping or unstable surface. After installation, double check that the printer is
stable.

1-4
 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.
Be sure the power is off to the chassis or circuit board, and observe all other safety precautions.
■ Immediately 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 under test 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. These can generate electrical charges sufficient to damage some devices.
■ Do not remove a replacement component or electrical sub-assembly from its protective package until you are
ready to install it.
■ Immediately 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. Motion, such as your clothes brushing
together, or lifting a foot from a carpeted floor, can generate enough static electricity to damage an electro-
statically sensitive device
■ 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).

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 Reference Information

2 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.
■ Digital Voltage Meter (DVM) standard: indicating more than 3 digits
■ Screwdrivers
■ Tweezers
■ Cotton swabs
■ Cleaning equipment: dry, lint-free cloth and/or mild detergent
■ Toner Type II Vacuum
■ Soft bristle brush
■ Printer Installer and Utilities CD-ROM
■ Diagnostic Control Unit (DCU)

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2.2 Acronyms and Abbreviations

Definition Definition

ADC Analog-to-Digital Conversion F/W Firmware

AP Access Point FCF/FCT Tray 1 or First Cassette Feeder

AC Alternating Current FISO Front In, Side Out

ASIC Application Specific Integrated Circuit FPOT First Print Out Time

Ass’y Assembly GDI Windows Graphic Device Interface

BIOS Basic Input Output Sytem GIF Graphic Interchange Format

BLDC Motor Brushless Dc Motor GND Ground

CMOS Complementary Metal Oxide HBP Host Based Printing

Semiconductor

CMYK Cyan, Magenta, Yellow, Black HDD Hard Disk Drive

CN Connector HTML Hyper-text Transfer Protocol

CON Connector HV High Voltage

CPU Central Processing Unit HVPS High Voltage Power Supply

CTD Sensor Color Toner Density Sensor I/F Interface

dB Decibal I/O Input/Output

dBA A Weighted Decibel lb Pound(s)

dBm Decibel Milliwatt IC Integrated Circuit

DC Direct Current ICC International Color Consortium

DCU Diagnostic Control Unit IDE Intelligent/integrated Drive Electronics

DIMM Dual In-line Memory Module IEEE Institute of Electrical and Electronics
Engineers, Inc.

DPI Dots Per Inch IOT Image Output Terminal (Color Printer,
Copier)

DRAM Dynamic Random Access Memory IPA Isopropyl Alcohol

DVM Digital Voltmeter IPC Inter Process Communication

ECP Enhanced Capability Port IPM Images Per Minute

ECU Engine Control Unit ITB Image Transfer Belt (Transfer Belt)

EEPROM Electronically Erasable LAN Local Area Network

Programmable Read Only Memeory

EMI Electro Magnetic Interference LBP Laser Beam Printer

EP Electro Photographic LCD Liquid Crystal Display

EPP Enhanced Parallel Port LED Light Emitting Diode

LSU Laser Scanner Unit

2-2
 Reference Information

Definition Definition

LVPS Low Voltage Power Supply Or SMPS

MB Megabyte Q’ty Quantity

MHz Megahertz RAM Random Access Memory

MPBF Mean Prints Between Failure ROM Read Only Memory

MPF/MPT Multi-Purpose Tray SCF/SCT Tray 2 Or Second Cassette Feeder

NIC Network Interface Card SMPS Switching Mode Power Supply or LVPS

NPC Network Printer Card SPGPm Samsung Printer Graphic Processor

NVRAM Non-volitale Random Access Memory SPL Samsung Printer Language

OPC Organic Photo Conductor Spool Simultaneous Peripheral Operation Online

PBA Print Board Assembly SW Switch

PCI Peripheral Component Interconnect SURF Surface Rapid Fusing

PCL Printer Command Language Sync Synchronous

PDF Portable Document Format T1 ITB or Transfer Belt Imaging

PDL Page Description Language T2 Transfer Roller Imaging

Ping Packet Internet or Inter-network TRC Toner Reproductive Curve

Grouper

PPD PostScript Printer Description PnP Universal Plug-n-Play

PPM Pages Per Minute URL Uniform Resource Locator

PS PostScript USB Universal Serial Bus

PTL Pre-Transfer (Erase) Lamp

PWM Pulse Width Moduration

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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.
■ Clean, dry, and free from excessive dust.

100 mm

(3.9 in.)

100 mm 100 mm

954.6 mm(37.5 in.)

(3.9 in.) (3.9 in.)
482.6 mm(18.8 in.)

552 mm(21.7 in.)

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 Specifications

3 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) Thermal rollers fusing with pressure (heat lamp: 600 Watts)

Resolution True: 600 x 600 dpi

Addressable: 1200 x 1200 dpi
Grayscale level: 128 Gray

Print Speed* A4: 20 ppm

Letter/Executive: 22 ppm
Legal: 18 ppm

Warm-up time Cold warm-up and sleep mode: 42 seconds

FPOT < 10 seconds

Feed Method Tray 1/MPT (Multi-Purpose Tray), Tray 2 (Cassette), Optional Tray 3, 250-sheet
feeder

Dimensions Width: 358 mm (14.1 in.)

Depth: 452 mm (17.8 in.)
Height: 278 mm (10.9 in.)

Weight Printer: 10.2 kg (22 lb.) with consumables

Optional Tray 2: 3 kg (6.6 lb.) with packaging

Acoustic Noise** Standby: 39 dBA

Printing: 53 dBA

Power Saver Mode Available, user settings enabled

* Print speed will be affected by the operating system used, computing performance, application
software, connection method, media type, media size, and job complexity.
** Sound pressure level, ISO 7779

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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

Network Optional: 10/100 Base TX

Test Print Demo Mode: Press the Cancel key for 2 seconds.
Configuration Mode: Press the Cancel key for 6 seconds.
Cleaning Mode: Press the Cancel key for 10 seconds.

Operating System Windows 98/NT4/2000/Me/XP

Compatibility Linux OS including Red Hat, Caldera, Debian, Mandrake, Slakware, SuSE, and
Turbo Linux

3.3 Electrical Specifications

Item Description

Input Voltage Low voltage: 100-127 VAC High voltage: 220-240 VAC

Input Range 90-135 VAC 180-270 VAC

Input Frequency: 50/60 Hz 50/60 Hz

Frequency tolerance +3 Hz +3 Hz

Power Consumption Ready: 70 Watts

Average: 400 Watts
Maximum: 700 Watts
Power Saver: 15 Watts

Power Saver Mode User settings available Off or 5, 10, 15, 30, 45, and 60 min.

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 Specifications

3.4 Environmental Range

Items Operating Storage Optimum

Temperature 10 ~ 32o C (50 ~ 90o F) 0 ~ 40 o C (32 ~ 104o F) 20 - 25o C

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

The supported media types for this printer include, but are not limited to: labels, envelopes, cardstock, plain paper,
transparency, letterhead and colored paper.

Tray Support Media Types / Capacity Sizes Weight

Tray 2 Plain Paper - 250 sheets A4, A5, A6, Letter, Legal, Folio, 16 ~ 24 lb.
Oficio, Executive, ISO and JIS B5
Optional Tray 3 60 ~ 90 g/m2

Plain Paper - 50 sheets A4, A5, A6, Letter, Legal, Folio, 16 ~ 43 lb.
OHP film, Label Oficio, Executive, ISO and JIS B5
60 ~ 163 g/m2
Tray1 / MPT Envelope -10 Monarch No. 10, C5, C6, DL
Card stock; International Postcard, Letter/A4
Custom Min. 75 x 125 mm

3.6.2 Print Margins and Skew

Print Area Margin

Guaranteed Paper Width (A+B) A = Left Margin 4.23 mm

Print Quality Area B = Right Margin 4.23 mm
Paper Length (C+D) C = Top Margin 4.23 mm
D = Bottom Margin 4.23 mm

Printable area Paper Width (A+B) A = Left Margin 3 mm

B = Right Margin 3 mm
Paper Length (C+D) C = Top Margin 3 mm
D = Bottom Margin 3 mm

Registration Tolerance +2.5 mm in the scan direction

+3.0 mm in the process direction

Skew Tray 1, 2 Tray 3 Length

A. Vertical Skew < 2.0 mm (0.08 in.) < 2.5 mm (0.10 in.) 244.3 mm

B. Horizontal Skew < 1.5 mm (0.06 in.) < 2.0 mm (0.08 in.) 177.8 mm

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 Summary of Product

4 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

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Summary of Product

4.1.2 Rear View

Rear Output Tray Top Output Tray

(Face up) (Face down)

Power
Receptacle

USB Port

Parallel Port

4.1.3 Control Panel

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 Summary of Product

ON Line/Error and Toner Save LED’s

LED Description

The On Line/Error LED is green, when the printer is Ready to Print.

The On Line/Error LED slowly blinks green when the printer is receiving data,
and blinks rapidly while printing.

The On Line/Error LED is red if an error occurs in the printer.

The On Line/Error LED will blink red if:

■ The user presses the Cancel button to cancel a print job.
■ The printer is in manual feed mode and there is no paper in the
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.

If the On Line/Error and Toner Save LEDs all blink at the same time, an
internal or hardware malfunction is present.
Refer to Section 6.6 for troubleshooting procedures.

The Toner Save LED comes on when Toner Save mode is enabled. This can be
set in the printer driver.

Cancel Button Functions

Printing the Demo Page In Ready mode, press and hold the Cancel button until all LEDs blink slowly
and then release, (approximately 2 seconds).

Printing the In Ready mode, press and hold the Cancel button until all LEDs blink quickly
Configuration Page and then release, (approximately 6 seconds).

Cleaning inside the In Ready mode, press and hold the Cancel button until all LEDs turn on and
printer then release (approximately 10 seconds).
After cleaning, one cleaning sheet is printed.

Canceling a print job To cancel a print job, press the Cancel button.
The On Line/Error LED blinks while the print job is cleared from both the
printer and the computer. The printer then returns to Ready mode. This may
take some time depending on the size of the print job.
Note
In Manual Feed mode it is not possible to cancel the print job by pressing
this button.

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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

1. Engine Frame
2. 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. The rollers and sensors in the paper feed path control paper
registration and guide the paper through the image transfer, image development, image fusing and exit
assemblies. The paper path has an anti-static connection to ground to eliminate problems due to static charge on
the paper.
3. Main drive mechanism
The main drive is a bi-polar, two phase motor. It drives the drum, paper pick, and paper feed rollers using a gear
train mechanism.
4. Image development unit
Using a Laser Scanner Unit (LSU), this portion of the mechanism creates the image on the OPC drum (part of the
integrated toner cartridge).
5. Image transfer unit
This unit uses the high voltages supplied by the HVPS to move the image from the OPC drum onto the paper.
6. Image fusing unit
This unit permanently fixes the toner image onto the paper. This is achieved using a temperature controlled
heating unit (the fuser).
7. Electronic boards include:
a. The Main control board, consisting of:
■ Main processor asic (166 MHz SPGPm)
■ Memory (Flash ROM containing the control program and DRAM for working memory)
■ Engine interface parts (motor control, fuser control, HVPS control, and sensors)
■ PC Interface (USB , Parallel, Network)
■ Bus, DMA and I/O handling
b. Control panel
c. PC Interface

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 Summary of Product

4.2.2 System Layout

5 LSU
4
Fuser Toner Cartridge
CR

PR
6 OPC
DR
SR

EXIT
Sensor
2
FR
3 TR

MP Sensor MP Sensor

K/R
PIC

1 Cassette 4 Fuser
2 Manual Feeder 5 LSU(Laser Scan Unit)
3 Transfer Roller 6 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. The rollers and sensors in the paper feed path control paper registration and
guide the paper through the image transfer, image development, image fusing and exit assemblies. The paper path has
an anti-static connection to ground to eliminate problems due to static charge on the paper.
1. Paper separation method
Individual sheets are separated in the tray using the ‘friction pad’ method. When paper feeds into the printer it
passes over a spring loaded friction pad that separates the sheets of paper.
2. Paper tray (cassette)
The paper trays use a ‘center loading’ method. There are no paper size sensors, instead a software process is used
to detect the size of the first sheet of paper as it is fed through the printer. Both the rear and side paper guides are
adjustable for various paper sizes.
There is a ‘Paper Empty’ sensor which detects the presence of paper (Capacity: 250 sheets).
There is an indicator flag on the front of the tray which indicates the amount of paper remaining.
3. Pick-up roller
The pick-up roller is used to pick and feed paper into the printer. It also is used to remove any static charge on the
paper.
4. Tray1/MPT
The multi-purpose tray is used to hold non-standard or custom paper sizes and special media (envelopes,
transparencies, etc.). There is an MPT paper empty sensor. The MPT uses a friction pad method to ensure paper
separation and can hold a maximum of 50 sheets of paper or envelopes.
5. SCF (Second Cassette Feeder) or Tray 3
The optional third tray unit is universal with the second main tray and also has a capacity of 250 sheets.

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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.
The transfer assemblies life span is 60,000 sheets.

4.2.5 Drive Assembly

The drive assembly receives power from the main controller board. The main motor powers the paper feed, toner
cartridge, fuser unit and all pick-up, feed, and exit rollers.

4.2.6 Fuser Assembly

The fuser assembly uses a heat lamp process. This consists of a heat lamp, heat roller, pressure roller, thermistor, and
thermostat. By use of heat and pressure, toner is melted to adhere to the paper surface in order to complete the
printing process.

4.2.6.1 Thermistor and Thermostat

The thermistor is used to detect the temperature of the heating unit and feeds this information into the main processor.
If the heat lamp becomes too hot, the thermostat cuts off the power to the lamp in order to prevent overheating and
any potential fire hazard is removed.

4.2.6.2 Heat roller

The heat roller transfers the heat from the heat lamp to the paper. The surface of the heat roller is coated with Teflon
so that toner does not stick to the surface.

4.2.6.3 Pressure roller

A pressure roller, mounted under the heat roller, is made of a silicon resin and the surface is also coated with Teflon.
When paper passes between the heat roller and the pressure roller the toner powder is melted and permanently fixed
to the surface of the paper.

4.2.6.4 Safety features

To prevent overheating:
■ 1st protection device: Hardware cuts off when overheated.
■ 2nd protection device: Software cuts off when overheated.
■ 3rd protection device: Thermostat cuts off main power to the lamp.
Safety device
■ Fuser power is cut off when the front cover is opened.
■ Laser power is cut off when the front cover is opened.
■ The temperature of the fuser cover's surface is maintained at less than 80º C to protect the user. A caution
label is attached where the customer can see it easily when the rear cover is opened.

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 Summary of Product

4.2.7 Laser Scanner Unit (LSU)

This is the core of the laser printer. It converts the video data received from the computer into an electrostatic latent
image on the surface of the OPC drum. This is achieved by controlling the laser beam and exposing the surface of the
OPC drum to the laser light. A rotating polygon mirror reflects the laser light onto the OPC. Each face of the mirror
produces one scan line. As the OPC drum turns, the laser scans, to create the full page image.
The HSYNC signal is created when the laser beam from the laser unit reaches the end of the polygon mirror and this
signal is sent to the controller. The controller detects the HSYNC signal to adjust the vertical line of the image on
paper. In other words after the HSYNC signal is detected the image data is sent to the laser unit to adjust the left
margin on the paper.

4.2.8 Toner Cartridge

The toner cartridge is an integral unit containing the OPC unit and toner unit. The OPC unit consists of the OPC drum
and charge roller. The toner cartridge unit consists of the toner, supply roller, developing roller, and blade (doctor
blade).

Developing Method Non magnetic 1 element contacting method

Toner Non magnetic 1 element shatter type toner

Toner Life 3,500 sheets / 5,000 sheets (ISO19752 standard)

Toner remaining sensor No

OPC Cleaning Film OPC using an electro-static cleaning process

Management of waste toner Collected using an electro-static process and retained within the toner
cartridge. No waste toner to dispose of.

OPC Drum protecting Shutter No

Toner CRUM Reader Identifies whether toner is Xerox branded toner or whether a Non-Xerox toner
cartridge is installed in the printer

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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.
Circuits on the main board drive the main motor (paper feed, cartridge, fuser), clutch, pre-transfer lamp, heat-lamp
and fan. The signals from the paper feed jam sensor and paper empty sensor are inputted to the main board from the
power supply board.

1 12 2 3 4 7

17
6
16 8 5

15

14 13 11
10 9

1. U1 Low drop fixed and adjustable positive voltage regulators (LD1117DT)

2. U2 Low power, dual bi-polar comparators (LM393D)

3. U4 Spread spectrum clock generator (CY25811)

4. OSC1 CPU X-TAL (12 MHz)

5. U6, U15 SDRAM (K4S641632H)

6. U7 Low voltage HEX inverter with 5 V tolerant Schmitt trigger inputs (74LCX14)

7. U9 Motor driver (A3977SLP)

8. U11 Graphics processor ASIC (SPGPm)

9. U24 Low voltage HEX inverter with 5V tolerat Schmitt trigger inputs (74LCX14)

10. U23 Parallel port single termination network (ST1284)

11. U22 Low voltage IEEE translating transceiver (161284)

12. OCS3 Video X-TAL (19.6 MHz)

13. U25 USB 2.0 (NET2270)

14. OSC4 USB X-TAL (30 MHz)

15. U14, U19 Low voltage octal D-type flip-flop (74LVX273)

16. U10 Low voltage, bi-directional transceiver (74LCX245)

17. U13 Flash Memory (29LV160DB)

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 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
■ Graphic Execution Unit for banding support of printer languages
■ Printer Video Controller for LBP engines
■ PVC: Printer Video Controller without RET Algorithm
■ HPVC: Printer Video Controller with RET algorithm

(Line Memory and Lookup Table Memory: 512 x 8, 4096 x 16)

■ Engine Controller
■ Motor control unit
■ Motor speed lookup table memory (128 x 16 x 2)
■ Pulse width modulation unit
■ 4 channels are supported
■ ADC interface unit
■ 3 ADC Channels are available
■ ADC Core (ADC8MUX8) maximum clock frequency: 3 MHz
■ USB 2.0 Interface
■ Package: 272 pins PBGA
■ Power: 1.8 V(Core), 3.3 V(IO) power operation
■ Speed: 166 MHz core (ARM946ES) operation, 60 MHz bus operation

4.3.2 Memory
The board has Flash ROM and DRAM memory units. There are 2 SODIMM sockets to enable extra DRAM or Flash
ROM (PostScript option, not available in all countries) to be fitted.

4.3.3 Flash Memory

Flash memory stores the system software code. This can be updated by downloading the system program through the
PC Interface. PCL fonts are also stored in the flash memory.
■ Capacity: 2 MB
■ Access Time: 70 nsec

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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. Paper Empty Sensing

The Paper Empty sensor (Photo Interrupter) on the engine board is monitored by the CPU. When the tray is empty the
printer flashes the red error LED.

4.3.5.2. Tray 1/MPT Sensing

Presence of paper in Tray 1 is detected by the MP sensor (photo interrupter) on the frame. The CPU monitors this
sensor to recognize paper in Tray 1, and paper is fed if there is paper present.

4.3.5.3. Paper Feeding

When paper passes the actuator on the feed sensor, it is detected by the photo interrupter. The CPU monitors the
signal and starts the process of creating the image after a specified delay time. If the feed sensor is not detected within
one second after paper is fed, a paper jam0 occurs. (red error LED is lit).

4.3.5.4. Toner Remaining Sensing

The printer does not have a toner remaining sensor.

4.3.5.5. Paper Exit Sensing

This detects that paper exits cleanly from the printer using an exit sensor on the engine board and actuator on the
frame. The CPU detects the on/off time of the exit sensor and normal operation or a jam status is reported. If a Jam2
error occurs, the red error LED is lit.

4.3.5.6. Cover Open Sensing

The cover open sensor is located on the power supply board. It is operated by a molded tab on the front cover. When
the front cover is open the +24 V and +5 V supplies to the DC fan, solenoid, main motor, polygon motor in the laser
unit, HVPS and laser diode are cut off.

4.3.5.7. DC Fan/Solenoid Driving Circuit

A fan driving circuit is controlled by the CPU via a transistor. It is automatically turned off when the printer enters
sleep mode. There are two solenoids, these are driven by signals from the CPU (tray paper pick).

4.3.5.8. Motor Driving Circuit

The main motor drives the paper feed, developing unit, fuser, and exit assembly. The circuit is driven by software
which controls the acceleration, constant speed, and deceleration profiles. The Motor is driven using an A3977 driver
IC.

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 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. The resistance value of the transfer roller changes due to the
environment of the room or within the printer. This change in resistance in turn changes the value of the voltage due
to loading. This voltage is fed back into the printer through the A/D converter. Based on the value fed back the PWM
cycle is changed to maintain the required transfer voltage.

4.3.5.10 Fusing
The temperature of the heat roller's surface is detected according to the resistance value of the thermistor. The
thermistor resistance is measured using the A/D converter and thus the CPU can determine the temperature of the heat
roller. The AC power is controlled by comparing the target temperature to the value from the thermistor. If the value
from the thermistor is out of the controlled range while controlling the fusing process, an error is reported.
See the error table below to identify fuser temperatur errors.

Error Description DCU LED Display

Open heat error Lower than 680 C for more than 25 seconds while 60 All LEDs blinking
warming up.

Low heat error Standby: 62 All LEDs blinking

Lower than 1000 C for more than 20 seconds.
Printing:
From 2 consecutive pages; the fixed fusing
temperature has been lower than 300 C for more
than 5 seconds.
Higher than 2200 C for over 3 seconds.

Over heat error It has been higher than 2200 C for over 3 seconds. 68 All LEDs blinking

4.3.5.11 Laser Scanner Unit (LSU)

The Laser Unit consists of the laser diode and the polygon motor control. When the printing signal occurs, the laser
diode is turned on and the polygon motor is enabled. When the light sensor detects the beam, H-SYNC occurs. When
the polygon motor speed becomes steady, Ready mode occurs. If these two conditions are satisfied the laser unit is
judged to be ready. If the two conditions are not satisfied, one of two errors are reported as shown in the table below.

Error Description DCU

Polygon motor error When the polygon motor speed is not steady. 95

H-SYNC error The polygon motor speed is steady but the H-SYNC 96
is not generated.

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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.
The HVPS creates the high voltage for the THV/MHV/Supply/Dev and supplies it to the toner cartridge. The CPU is
used to modify some of these voltage settings to provide the ideal voltages to create the image.
The HVPS uses the 24 V and outputs the high voltage for THV/MHV/BIAS and the outputted high voltage is then
supplied to the toner, OPC cartridge, and transfer roller.

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 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 ± 5 % (fluctuating input 21.6 V~26.4 V)
Loading contrast : ± 5% or less
Output Voltage Rise Time: 100 ms Max
Output Voltage Fall Time: 100 ms Max
Transfer voltage range as environment varies: +650 V(Duty 10%) ~ 5K V (Duty 90%)
Environment Recognition Control Method:
The THV-PWM ACTIVE is the transfer active signal. It detects the resistance by recognizing the voltage
value, F/B, while permitting the environmental recognition voltage.
Output Voltage Control Method:
Transfer output voltage is output and controlled by changing the duty cycle of the THV PWM Signal.
10% duty: +650 V; 90% duty: +5K V±5%

2) Charge Voltage (MHV)

Input Voltage: 24 VDC ± 15%
Output Voltage: -1.3K V ~ -1.8K VDC ± 50V
Output Voltage Rise Time: 50 ms maximum
Output Voltage Fall Tim: 50 ms maximum
Output Loading range: 30 Mž ~1000 Mž
Output Control Signal (MHV-PWM): CPU is HV output when PWM is low

3) Cleaning Voltage (THV-)

The (+)Transfer Voltage is not output because the THV PWM is controlled with high.
The (-)Transfer Voltage is output because the THV-Enable Signal is controlled with low.
The output fluctuation range is big because there is no Feedback control.

4) Developing Voltage (DEV)

Input Voltage: 24 VDC ± 15%
Output Voltage: -200 V ~ -600 VDC ±20V
Output Voltage Fluctuation range: PWM Control
Input contrast of the output stability degree: ±5 % or less
Loading contrast: ± 5 % or less
Output Voltage Rise Time: 50 ms maximum
Output Voltage Fall Time: 50 ms maximum
Output Loading range: 10 Mž ~ 1000 Mž
Output Control Signal (BIAS-PWM): the CPU output is HV output when PWM is low.

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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 ~ 1000 Mž
Output Control Signal (BIAS-PWM): the CPU is HV output when PWM is low.

4.4.2 Switching Mode Power Supply

The SMPS is the power source for the entire printer system. The SMPS supplies DC power for driving the printer, and
the AC heater control which supplies power to fuser. The SMPS has two output channels: 3.3 V and +24 V.

1) AC Input
Input Rated voltage: AC 220 V ~ 240 V, AC 120 V ~ AC 220 V (EXP version)
Input Voltage range: AC 198 V ~ 264 V, AC 90 V ~ 135 V, AC 198 V ~ 264 V (EXP version)
Rated Frequency: 50/60 Hz
Frequency range: 47 ~ 63 Hz
Input Current: Under 4.0A RMS/2.0A RMS (When the fuser lamp is off and input / output voltages are in range)

2) Rated Output Power

No Item CH1 CH2 CH3 Remark

1. Channel name +3.3 V +5 V +24.0 V
2. CONNECTOR PIN CON 3 CON 3 CON 3
3.3 V PIN: 3, 4 5 V PIN: 8 24 V PIN: 11, 12, 13
GND PIN: 5, 6 GND PIN: 7 GND: 9, 10
3. Rated output 3.3 V ± 5% +5 V ± 5% +24 V ± 10%
(3.2 ~ 3.4 V) (4.75 ~ 5.25 V) (21.6 ~ 26.4 V)
4. Max output current 1.0 A 0.14A 2.0 A
5. Peak loading current 1.5 A 0.14A 2.5 A 1ms
6. Ripple noise voltage Under 100mVp-p 100mVp-p Under 500mVp-p
7. Maximum output 3.3 W 0.35 W 48 W
8. Peak output 4.95 W 0.7 W 60 W 1ms
9. Protection for loading
shortage and overflowing
current - -

3) Consumption Power

No Item CH1 +3.3 V CH2 +5 V CH3 +24.0 V Remark

1. Standby 1.0 A 0.07 A 0.4 A AVG: 55 Wh
2. Printing 1.0 A 0.14 A 2.0 A AVG: 280 Wh

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 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.

Jam Description

This is an indcation that the leading edge of the paper did not pass the feed sensor.
■ After paper pick, paper does not enter the printer.
■ After paper pick, the paper enters the printer but it does not reach the feed sensor in the
Jam 0 specified amount of time.
■ If paper has been picked, and the feed sensor is not ON, the printer will re-pick. If after re-
picking the feed sensor is still not reported as ON, this error will occur.
■ Even though the paper reaches the feed sensor, the feed sensor is not ON.

This is an indication that the leading edge of the paper has already passed the feed sensor.
■ After the leading edge of the paper passes the feed sensor, the trailing edge of the paper
does not pass the feed sensor within the specified time. (The feed sensor cannot be OFF
Jam 1
during this time.)
■ After the leading edge of the paper passes the feed sensor, the paper does not reach the exit
sensor within the specified time. (The exit sensor cannot be ON during this time.)

The paper is between the feed sensor and the exit sensor.
Jam 2 ■ After the trailing edge of the paper passes the feed sensor, the trailing edge of the paper does
not pass the exit sensor within the specified time.

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Summary of Product

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 Disassembly

5 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.
■ Do not make any unauthorized changes or additions to the printer, this could cause the printer to malfunction and
create electrical shock or fire hazards.
■ When disassembling the printer, note where each screw goes. Using the wrong screw could lead to printer failure,
short circuits, or electrical shock.
■ Do not disassemble the laser unit. Once it is disassembled dust is admitted to the mirror chamber and will
seriously degrade print quality. There are no serviceable parts inside.
■ Regularly check the condition of the power cord, plug and socket. Bad contacts
could lead to overheating and fire. Damaged cables could lead to electric shock or
component malfunctions.

Caution
Many of the parts are held in place with plastic latches. The latches break easily;
Remove them carefully. To remove such parts, gently pull the hook end of the
latch away from the part where it is latched.

Caution
To prevent damaging the toner cartridge and degrading print quality, protect the toner cartridge from light when
removing it from the printer.

5.1.1 Precautions When Removing Circuit Boards

Static electricity can damage a board, follow the ESD precautions in Section 1 of this manual when handling or
storing a board.
Precautions when moving and storing boards:
■ Place boards in an approved anti-static discharge bag.
■ Do not store a board where it is exposed to direct sunlight.
Precautions when replacing boards:
■ Disconnect power connectors first, before disconnecting other cables.
■ Do not touch any soldered connections, connector terminals, or other electronic parts when handling
insulated parts.
Precautions when checking boards:
■ Before touching a board, touch a grounded area on the printer chassis to discharge any static electrical
charge on the body or wear an anti-static wrist strap.

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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. Check for hidden screws. Always ensure that the correct screw
is used. When toothed washers are removed, ensure they are refitted in their original positions

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 Disassembly

5.2 Front Cover

1. Remove the paper tray.
2. Open the front door and remove the toner cartridge.

Cassette Front Cover

3. With the front cover fully open, carefully release the plastic hinge supports from the guide hooks by pulling
inward.
4. Pull the front cover away from the printer to remove.

Latch

Front Cover

Latch Holder

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Disassembly

5.3 Tray 1/MPT Assembly

1. Open the Tray1/MPT assembly.

2. With the tray at a 45o angle, carefully release the plastic hinge supports from the guide hooks.
3. Lift the Tray1/MPT assembly off the hinge pins on the front cover.

45°

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 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.

1. Remove 2 screws securing the rear open cover and remove.

Rear Open

2. Open the face up cover.

3. Remove the 2 screws as shown below.
4. Using a screwdriver, carefully release the 2 tabs securing the rear cover.

Rear Cover

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5.5 Top Cover

1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
3. 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.

Exit Roller

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 Disassembly

5.6 Middle Cover

1. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
2. Remove the top cover, see "5.5 Top Cover" on page 5-6.
3. Open the front cover.
4. Remove 4 screws securing the middle cover.
5. Disconnect and free the wiring harness from the middle cover.
6. Lift up on the left side of the middle cover to release it from the retaining pin.

Middle Cover

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Disassembly

5.7 Side Cover (Left and Right)

1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
3. Remove the top cover, see "5.5 Top Cover" on page 5-6.
4. Remove the 2 screws securing the right or left cover.
5. Slide the cover towards the rear of the printer while releasing the top latch, as shown below, to remove the right
or left cover.

Top Latch
Side Cover(LH)

Bottom
Latches

Top Latch

Side Cover(RH)

Bottom Latches

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 Disassembly

5.8 Exit Roller

1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
3. Remove the top cover, see "5.5 Top Cover" on page 5-6.
4. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8.
5. 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
removed from the printer.

Exit Gear Bearing

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Disassembly

5.9 Engine Shield Assembly and Exit Board

1. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
2. Remove the top cover, see "5.5 Top Cover" on page 5-6.
3. Remove the right cover, see "5.7 Side Cover (Left and Right)" on page 5-8.
4. Remove the paper tray.
5. Remove 1 screw securing the SMPS shield and remove the shield.

SMPS
Shield

Screw

6. Disconnect the following wiring harnesses from the SMPS; on the right side printer, the fan (CN3) and the
control panel (CN4). On the rear of the printer disconnect the fuser (CN1) and exit sensor (CN6).
7. Disconnect the following wiring harnesses connected to the main board.

CN 5 Laser Unit CN 10 Manual Solenoid

CN 6 Motor CN 11 PTL
CN 8 Pickup Sol CN 17 MP sensor
CN 9 Regi Sol CN 18 CRUM

Caution
Be sure all 12 wiring harnesses are diconnected from the assembly.

Caution
In the next step you will be turning the printer over, use caution when working on the printer in
order to avoid damaging the exit rollers.

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 Disassembly

8. 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

9. 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.

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Disassembly

5.10.1 SMPS
1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
3. Remove the top cover, see "5.5 Top Cover" on page 5-6.
4. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8.
5. Remove the engine shield assembly, see "5.9 Engine Shield Assembly and Exit Board" on page 5-10.
6. Remove the 3 screws (one is to ground) securing the inlet bracket and remove the bracket.

Inlet Bracket

7. Unplug 1 connector from the main board.

8. Remove the 6 screws securing the SMPS to the shield.

Connector SMPS

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 Disassembly

5.10.2 Main Board

1. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
2. Remove the SMPS shield, see step 5 in "5.9 Engine Shield Assembly and Exit Board" on page 5-10.
3. Disconnect all harnesses from the main board.
4. 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.

Main PBA

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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

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 Disassembly

5.11 Fuser Assembly

Warning
The fuser assembly is HOT. Let the fuser cool before removing.

1. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
2. Unplug 2 connectors, one from the main board and one from the SMPS.
3. Remove 4 screws securing the fuser assembly.

Fuser Ass'y

Caution
When removing the thermostat, the 2 screws are secured by nuts that are not captured. These can
fall out and get lost if you tip the fuser assembly.

4. Remove the 2 screws securing the thermostat and lift the thermostat out.

Thermostat

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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.

5. Remove the 2 screws securing the Halogen lamp. Then remove the lamp from the heat roller as shown below.

Halogen Lamp

Caution
When disassembling the fuser, note the orientation of the spring loaded stripper fingers (claws). If
reassembled improperly the claws will damage the heat roller causing the fuser to malfunction.

6. Remove the 4 screws securing the fuser cover and 2 screws securing the guide to disassemble the fuser.

Claw

Fuser Cover

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 Disassembly

7. Free the thermister harness as shown below.

Thermistor Harness

8. Remove 1 screw securing the thermister and remove from the fuser assembly.

Thermistor

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5.12 Fan
1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
3. Remove the top cover, see "5.5 Top Cover" on page 5-6.
4. Remove the right cover, see "5.7 Side Cover (Left and Right)" on page 5-8.
5. Disconnect the connector from the SMPS.
6. Remove 1 screw securing the fan.

Fan

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 Disassembly

5.13 Laser Scanner Unit (LSU)

1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
3. Remove the top cover, see "5.5 Top Cover" on page 5-6.
4. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8.
5. Remove 1 screw to the control panel board and remove the board.
6. Remove the 4 screws securing the LSU.

Caution
Be careful not to get fingerprints on the window of the laser unit (bottom of assembly).

Note
The laser unit securing screws are numbered and need to be tightened down in the correct order
when reassembling.

7. Disconnect the two connectors to the LSU, and remove the laser unit

LSU
Connector

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5.14 Drive Assembly

1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
3. Remove the top cover, see "5.5 Top Cover" on page 5-6.
4. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8.
5. Remove the 6 screws securing the drive assembly.

Drive Ass'y

Note
The drive assembly screws are numbered and need to be tightened down in the correct order
when reassembling.

6. Disconnect 1 connector from the drive assembly to remove the drive.

Drive Ass'y

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5.15 Transfer Assembly

1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the toner cartridge.
3. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
4. Remove the middle cover, see "5.6 Middle Cover" on page 5-7.
5. Remove the top cover, see "5.5 Top Cover" on page 5-6.
6. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8.
7. Remove the LSU, see "5.13 Laser Scanner Unit (LSU)" on page 5-19.
8. Using a screwdriver, unlatch the transfer roller as shown below.
9. Pull the transfer roller up and to the right in order to remove it from the printer.

Transfer Roller

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Disassembly

5.16.1 Tray 1/MPT Assembly

1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
3. Remove the middle cover, see "5.6 Middle Cover" on page 5-7.
4. Remove the top cover, see "5.5 Top Cover" on page 5-6.
5. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8.
6. Disconnect the MP solenoid and MP sensor connectors from the main board.
7. Remove the 4 screws from the front of the assembly and remove.

MP Ass’y

Caution
There is a flexible, mylar paper guide that needs to rest between the metal idler shaft and the feed
rollers when reassembling the Tray 1/MPT assembly.

Place photos here.

MP Ass’y

Metal Idler Shaft

Mylar Fingers

Feed Roller

5-22
 Disassembly

5.16.2 Feed Roller

1. Remove the drive assembly, see "5.14 Drive Assembly" on page 5-20.
2. Remove the Tray 1/MPT assembly, see "5.16.1 Tray 1/MPT Assembly" on page 5-22.
3. 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.

Feed Bracket

4. Remove the feed gear 2 (lower) and then feed gear 1 (upper) as shown below.

Feed Gear2

Feed Gear1

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Disassembly

5. Remove the screw from the right idler bushing plate.

6. Remove the plate, idler spring and bushing.
7. Slide the feed shaft idler to the right and out of the printer.

8. Remove the feed roller and feed roller 1 as shown below.

Feed Roller

Feed Roller1

5-24
 Disassembly

5.17 Pick-Up Assembly, Solenoids, and Pick Roller

1. Remove the front cover, see "5.2 Front Cover" on page 5-3.
2. Remove the rear cover, see "5.4 Rear Cover" on page 5-5.
3. Remove the middle cover, see "5.6 Middle Cover" on page 5-7.
4. Remove the top cover, see "5.5 Top Cover" on page 5-6.
5. Remove the left and right covers, see "5.7 Side Cover (Left and Right)" on page 5-8.
6. Remove the engine shield assembly, see "5.9 Engine Shield Assembly and Exit Board" on page 5-10.
7. Remove the drive assembly, see "5.14 Drive Assembly" on page 5-20.
8. Remove the feed bracket, see "5.16.2 Feed Roller" on page 5-23
9. Remove the pick-up gear, and then the pick-up assembly as shown below.

Note
Note the orientation of the gear for reassembly.

Pick-Up Gear Ass'y

1
2

Pick-Up Ass'y

10. Disconnect the main clutch and registration clutch harness’s from the main board.
11. Remove the 2 screws securing the solenoids (2).
12. Unroute the harness’s through the printer frame to remove the solenoids.

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Disassembly

13. Remove the pick roller as shown below on the right.

Regi Solenoid
Rubber Pickup

Pick-up Solenoid

5-26
 Alignment and Adjustments

6 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. To connect the DCU to the printer, open the
rear access cover and then connect the DCU harness wire (10 pin/4 pin) to CN2 on the main controller board.

ML SERIES DIAGNOSTIC CONTROL UNIT

04 DEV 300 DEV 350 DEV 350
05 LSU READY LSU MT & LD LSU MOTOR
07 PAPER EMPTY PAPER WIDTH NEW CRU SELF
08 EXIT SENSOR FEED SENSOR TEST
09 COVER OPEN
STATUS
10 COER HEATING PRINTING TEMP READY HEAT

DIAGNOSTIC
ON OFF

DIAGNOSTIC CODE NORMAL STATUS CODE

00 MAIN MOTOR OPERATING SYSTEM 61 WARM UP
01 MAIN HIGH-VOLTAGE ON
02 TRNSFER HIGH-VOLTAGE (-)ON
03 THV(+) REFERANCE VOLTAGE 00 READY (REGAL)
04 DEV/SUPPLY HIGH-VOLTAGE ON/PTL ON 01 READY (LETTER)
05 LSU OPERATING SYSTEM 02 READY (A4)
06 PICKUP CLUTCH ON 03 READY (EXECUTIVE)
07 PEEMPTY/PWITH/NEW CRU TEST 04 READY (B5)
08 FEED & EXIT SENSOR TEST
09 COVER OPEN SENSOR TEST 20 PRINT START
10 FUSER TEST 30 FEED SENSOR ON
11 HOT BURN TEST 40 FEED SENSOR OFF
12 CLEAN MODE PRINT 50 PAPER OUT
13 THV(+)TRIGGER, ALL HV & FAN ON
14 THV(+) REFERENCE ON 69 SLEEP MODE

ERROR STATUS CODE

60 OPEN FUSER ERROR
62 LOW TEMPERATURE ERROR
68 OVER HEATING ERROR
64 COVER OPEN ERROR
70 NO PAPERR
71 PAPER JAM 0
72 PAPER JAM 1
73 PAPER JAM 2
95 LSU NOT READY

DIAGNOSTIC DOWN SHIFT STOP

MODE UP ENTER

TO ENTER DIAGNOSTIC MODE, PUSH THREE BUTTONS SIMUL ANEOUSL

AND TURN THE PRINTER POWER ON.
SEC CODE : ML+5000 KC/XRX

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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.

Normal Code Table

When the printer is warming up, or during a print job, the display indicates the papers postion in the printer.

Code State Description

78 System initialization The main processor is starting up.

61 Warming up The printer is ON, the cover is open or closed.

00 - 05 Ready (code dependent on The printer is Ready. The paper is detected when the first
paper size) page is printed.
00: Legal, 01: Letter, 02: A4, 03: EXEC, 04: B5, 05: Other

20 Print start The engine controller received the print order from the video
controller.
20: Tray 2, 21: Tray 1/MPT, 22: Optional Tray 3

30 Feed sensor ON The paper is passing out of the feed sensor.

40 Feed sensor OFF The paper has passed out of the feed sensor.

50 Paper out The paper has passed out of the exit sensor.

69 Sleep Mode The fuser power is turned OFF to minimize power

consuption.

Error Codes

If a problem is detected during the print process, printing is stopped and an error code is displayed.

Code State Description

60, 62, 68 Fuser Error An error has occured in the fuser, see section "4.3.5.10
Fusing" on page 4-11.
60: Open fuser error, 62: Low heat error, 68: Overheat error

64 Cover open The printer cover is open.

65 CRU Error The toner cartridge is not installed.

70 No paper There is no paper loaded in the tray.

71 Paper Jam0 Paper is jammed between the pick rollers and the feed
sensor.

72 Paper Jam1 Paper is jammed between the exit sensor and feed sensor.

73 Paper Jam2 Paper is jammed just after passing through the exit sensor.

95 Laser Unit no ready The LSU motor is not ready or the Hsync signal was not
output.

6-2
 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:

a. Connect the DCU.
b. Turn the printer ON while holding down the [Down], [Shift] and [Stop] at the same time.
c. 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.

Running Tests from the DCU:

■ Use the [Up] or [Shift][Up] buttons to select the required test.
■ To start the test, press the [Enter] button.
■ To stop the test, press the [Shift] and [Enter] buttons together.

Code Description

00 Main motor operating system

The main motor is tested.

01 Main high voltage ON (MHV-)

-1550 voltage output to MHV terminal

Note
High voltage probe should not be used.

02 Transfer high voltage (-) on (THV-)

-1200 voltage output to THV terminal
Note
High voltage probe should not be used.

03 Transfer high voltage (+) on (THV-)

+1300 voltage output to THV terminal

Note
High voltage probe should not be used.

04 DEV/Supply high voltage

-430 voltage output to DEV terminal
Note
High voltage probe should not be used.

05 Laser operating system

The laser scanning motor is started and the ON LED is lit. When the laser motor is ready the 3rd
LED is lit.

06 Pickup clutch ON
Tests the Tray 2 solenoid.

07 Paper empty sensor test

The ON LED indicates the status of Tray 2’s paper empty sensor.

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Alignment and Adjustments

08 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.

09 Cover open sensor test

The ON LED indicates the status of the cover open sensor.

10 Fuser test
When [Enter] is pressed, the heat lamp is turned ON. The ON and OFF LEDs indicate the lamp
status.

11 Hot burn test

When the [Enter] button is pressed, the printer continuously prints without detection. Turn the
power OFF to stop this test.

12 Cleaning mode print

This causes the cleaning cycle to be repeated continously. Turn the power OFF to stop this test.

13 THV(+) Trigger All HV

High voltage is output to each high voltage terminal. The laser unit and fan are started. In this
mode the electronic resistance of the transfer roller is detected and the THV is checked.

14 PTL Test
Tests the pre-transfer lamp. The ON and OFF LEDs indicate the lamp status.

15 Fan test
Tests the fan. The ON and OFF LEDs indicate the fan status.

16 Regi clutch test

Tests the registration clutch. The ON and OFF LEDs indicate the clutch status.

17 Regi sensor test

Tests the registration sensor. The ON and OFF LEDs indicate the sensor status.

18 MP pickup test
Tests the Tray 1/MPT pick clutch. The ON and OFF LEDs indicate the clutch status.

19 MP sensor test
Tests the Tray 1/MPT sensor. The ON and OFF LEDs indicate the sensor status.

6-4
 Alignment and Adjustments

Code Function Enter LED Stop Remark

00 Motor Motor Run Motor Stop

01 MHV Mhv On Mhv off -1550 V

02 THV(-) Thv Negative On Thv Negative Off

03 THV(+) Thv On Thv Off +1300 V

04 DEV Dev On Dev Off +430 V

05 LSU LSU Run ● ● ● LSU Stop

On Off Ready

06 PICK UP Pick Up On Pick Up Off

07 P EMPTY ● ● ●
Paper Empty

08 SENSOR ● ● ●
Exit Feed

09 COVER ● ● ●
Cover Open

10 Fuser Fuser On Fuser Off 160 C

11 HotBurn HotBurn On

12 Clean Print Clean Printing

13 Thv ● ● ●
Reference Low Adequate High

14 PTL PTL On PTL Off

15 Fan Fan On Fan Off

16 Regi Clutch Regi Clutch Regi Clutch Off

17 Regi ● ● ●
Sensor Manual Sensor

18 MP Pickup MP Pickup On MP Pickup Off

19 MP Sensor ● ● ●
MP Empty

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Alignment and Adjustments

6.2 Paper Path

5 LSU
4
Fuser Toner Cartridge
CR

PR
6 OPC
DR
SR

EXIT
Sensor
2
FR
3 TR

MP Sensor MP Sensor

K/R
PIC

1 Cassette 4 Fuser
2 Manual Feeder 5 LSU(Laser Scan Unit)
3 Transfer Roller 6 Toner Cartridge

After receiving the print command, the printer feeds

paper from Tray 1, 2, or optional Tray 3.

LSU
Jam0:
Fuser Toner Cartridge
CR

EXIT
PR OPC
DR
SR
If the paper does not pass the feed senosr in the
Sensor
TR

Empty Sensor
FR
specified amount of time a Jam0 occurs. See the first
illustration to the left.

Jam1
A Jam 1 will occur if after passing the feed sensor,
LSU the paper does not reach the exit sensor in the
Fuser
CR
Toner Cartridge specified amount of time. See the second illustration
DR

EXIT
Sensor
PR OPC

TR
SR

FR
to the left.
Empty Sensor

Jam2
A Jam 2 occurs if the paper does not leave the exit
sensor in the specified amount of time while exiting
LSU

Fuser
the printer. See the third illustration to the left.
Toner Cartridge
CR
DR
OPC SR
PR
EXIT
Sensor
TR FR

Empty Sensor

6-6
 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.
■ Paper that is outside of the supported size range has been used.
If a paper jam occurs, the On Line/Error LED on the control panel lights red. Find and remove any jammed paper in
the printer. If there is no paper visible, look inside the printer.

Caution
Do not use tweezers or other sharp metal tools when removing a paper jam. You can damage the toner cartridge,
fuser rollers, or potentially damage wiring leading to the potential for electric shock.

Note
If the paper tears while removing a jam, ensure that ALL fragments of paper are removed from
within the printer, otherwise jamming will still occur.

6.3.1 Jam2: Paper in the Exit Area

Warning
Paper jammed in this area is very close to the fuser and burns can occur.

1. If the paper jams as it exits to the output tray and a long portion of the paper is visible, pull the paper straight out.
When pulling the jammed paper, if there is any resistance and the paper does not move immediately, stop pulling
and continue with the next step.
2. Open the rear output tray.
3. Loosen the paper if it is caught in the feed rollers, then pull the paper gently out.

Warning
Be careful when you open the rear cover as the inside of the printer is still hot.

4. Close the rear output tray. Open and close the front cover. Printing can now resume.

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Alignment and Adjustments

6.3.2 Jam0: Paper in the Feed Area

1. Slide out the tray to expose the jammed paper.

2. Remove any jammed paper by pulling the visible edge away from the tray.
3. Make sure that all of the paper is properly aligned in the tray.
4. Slide the tray back into the printer. Open and close the front cover. Printing can now be resumed.

6.3.3 Jam1: Paper Around the Toner Cartridge

1. Open the front cover and remove the toner cartridge.

2. Gently pull the paper toward you. Check that there is no other paper left in the printer.
3. Reinstall the toner cartridge, and then close the cover. Printing can now be resumed.

6-8
 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. Ensure that the paper is below the paper capacity mark located on the inside right
of the tray.
■ Do not remove the paper or paper tray from the printer while printing.
■ Flex, fan, and straighten the paper before loading.
■ Do not use creased, damp or highly curled paper.
■ Do not mix paper types in the input tray.
■ Use only recommended print media.
■ Ensure that the recommended print side is correctly oriented when loading paper into the tray(s).

6.4 Sample Patterns

This product has the several sample patterns to aid in verifying the existence of abnormalities within the printer. The
patterns help to regularly maintain the product. The following patterns are available:
■ Demo Page
■ Configuration Page
■ Cleaning Sheet

6.4.1 Printing a Demo or Configuration Page

Print a Demo Page or a Configuration Sheet to make sure that the printer is operating correctly. The Demo Page or
Configuration Page shows the printer’s current configuration.
1. Hold down the Cancel button for about 2 seconds to print a Demo Page.
2. Hold down the Cancel button for about 6 seconds to print the printer Configuration Page.

6.4.2 Printing a Cleaning Sheet

If you are experiencing blurred, faded, or smeared prints, printing a cleaning sheet cleans the drum inside the toner
cartridge. This process will produce a page with toner debris, which should be discarded.
1. Ensure the printer is turned ON and in Ready mode with paper loaded in the tray.
2. Press and hold down the Cancel button on the control panel for about 10 seconds.
3. The printer automatically picks a sheet of paper from the tray and prints out a cleaning sheet with dust or toner
particles on it.

Note
The cleaning process takes some time. To stop printing, turn the power OFF.

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Alignment and Adjustments

6.5 Consumables and Replacement Parts

The life cycle outlined below is a general guideline for maintenance purposes and is for reference only.
Environmental conditions (temperature, humidity, dust, etc.) and actual use can cause these figures to vary.

Component Replacement Cycle

Transfer Roller 60,000 pages

Fuser 80,000 pages

Toner Cartridges 3,500 Standard / 5,000 High-Capacity pages

6.6 The LED Display Status for Each Error

DCU
Error LED Status Code
Open Fuser Error The [Error] LED (red) and the [Toner Save] LED 60
are simultaneously flashing at 1 second intervals.
Over Heat Error The [Error] LED (orange) and the [Toner Save] 68
LED are simultaneously flashing at 1 second
intervals.
Low Heat Error The [Error] LED (red) and the [Toner Save] LED 62
are simultaneously flashing at 4 second intervals.
Laser not Ready Error The [Error] LED (green) and the [Toner Save] LED 95
are simultaneously at 1 second intervals.
(Motor Error)
Laser Not Ready Error 6 The printer has stopped and the [Error] LED 96
(green) and the [Toner Save] LED are
(HSYNC Error)
simultaneously flashing at 4 second intervals.
Toner Cartridge Crum If the On Line/Error [Error] LED is blinking (red)
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
 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.

No Roller Defective image Typical defect

1 OPC Drum 75.5 mm white spot on black image or black spot
2 Charge Roller 37.7 mm black spot
3 Supply Roller 44.9 mm light or dark horizontal image band
4 Developing Roller 35.3 mm horizontal image band
5 Transfer Roller 47.1 mm image ghost
6 Heat Roller 78 mm black spot and image ghost
7 Pressure Roller 75.5 mm black spot on the backside

PTL

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Alignment and Adjustments

6-12
 Troubleshooting

7 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.

1. Damaged developer roller, a. Print a cleaning sheet.

deformed doctor blade, or cleaning b. Replace the toner cartridge and re-test.
Digital Printer blade within the toner
c. Replace the transfer roller and re-test.
Digital Printer cartridge.Scratched surface on the
charge roller within the toner d. Replace the fuser.
Digital Printer cartridge.
Digital Printer 2. Depression or deformation on the
Digital Printer surface of the transfer roller.
3. Contaminated Fuser.

7.1.2 Vertical White Lines

Example Possible Cause Sequence of Repair Actions

There are white, vertical voids in the printed image.

1. Contamination on the window or a. Clean the laser window with a

internal lens of the laser mirror. recommended cleaner (IPA) and a clean
Digital Printer 2. Foreign object inside the toner cotton swab.
Digital Printer cartridge. b. If dirt is inside the laser unit, replace it.
3. Low toner. c. Replace the toner cartridge.
Digital Printer
4. If the fuser is defective, voids occur d. Open the front cover and check/remove any
Digital Printer periodically at the top of a black contamination inside the printer that
Digital Printer image. corresponds to the position of the voids.
5. Contamination on the OPC drum. e. If the problem is not solved, replace the
6. Depression or deformation on the toner cartridge.
surface of the transfer roller. f. Replace the transfer roller.

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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.

1. Bad contacts on the toner cartridge a. Clean all HV contacts on the cartridge and
high voltage terminals. primter frame.
Digital Printer 2. The rollers in the toner cartridge b. Ensure all toner or paper dust particles are
Digital Printer may be contaminated. removed.
■ Charge roller = 37.7 mm c. Clean the Gear that has a relatively small
Digital Printer tooth gap on the OPC drum.
■ Supply roller = 44.9 mm
Digital Printer d. If the problem persists replace the toner
■ Develop roller = 35.3 mm
Digital Printer ■ Transfer roller = 47.1 mm
cartridge.

7.1.4 Black/White Spot

Example Possible Cause Sequence of Repair Actions

Dark or blurry spots are randomly spread on the page, or white spots are randomly on the page.

1. If dark or blurry black spots appear, a. Print several OPC cleaning mode prints and
the rollers in the developer may be then run the self-test 2 or 3 times.
Digital Printer contaminated. b. 75.5 mm repeating defect: Examine the
Digital Printer ■ Charge roller: 37.7 mm surface of the OPC drum and clean with a
■ OPC drum: 75.5 mm soft, lint free cloth.
Digital Printer c. 37.7 mm repeating defect: Replace the
2. If faded areas or voids appear
Digital Printer every 75.5 mm or if black spots toner cartridge.
Digital Printer occur elsewhere, the OPC drum d. If the transfer roller is at its end of life,
surface is damaged. replace the transfer roller.
3. If a black image is partially broken, e. 78 mm defect: Replace the fuser.
the transfer voltage is incorrect or NOTE: Cleaning the inside of the printer to remove
the transfer roller is at its end of life. excess toner or paper dust will reduce the
4. If the spots appear at 78 mm, the occurrence of this problem.
fuser heat roller is contaminated.

7-2
 Troubleshooting

7.1.5 Light Image

Example Possible Cause Sequence of Repair Actions

The printed image is too light, with no ghosting.

1. Toner Save mode is enabled. a. Turn Toner Save mode off.

2. The developer roller is b. Replace the toner cartridge and re-test.
Digital Printer contaminated or the toner cartridge c. Cycle power to the printer and wait
Digital Printer is almost empty. 30 minutes then try printing again.
3. The ambient temperature is below d. Clean the cartridge and printer contacts.
Digital Printer
10o C. e. Clean the inside of the printer.
Digital Printer 4. Bad contact caused by dirty f. Replace the HVPS if none of the above
Digital Printer terminals on the toner cartridge or procedures fix the problem.
inside the printer.
5. Abnormal output voltage from the
HVPS.

7.1.6 Dark Image or Completely Black Print

Example Possible Cause Sequence of Repair Actions

The printed image is dark or the page is entirely black.

1. Charge voltage fault due to bad a. Clean the high voltage contact terminals.
contact between the toner cartridge b. Check the state of the connector between
Digital Printer and printer contacts. the main board and the HVPS.
Digital Printer 2. No charge voltage in the engine c. Replace the HVPS.
board.
Digital Printer 3. VD0 signal on the main board is in
d. Replace the laser unit.
e. Replace the main board.
Digital Printer a LOW state.

Digital Printer

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Troubleshooting

7.1.7 Uneven Density

Example Possible Cause Sequence of Repair Actions

Print density is uneven from left to right.

1. The toner level is not even on the a. Remove the toner cartridge and gently
toner cartridge roller due to a shake it to loosen toner.
damaged blade or low toner. b. Replace the toner cartridge and retest.
2. The life of the toner cartridge has c. Replace the left and right bushings and
expired. spring assemblies.
3. The pressure force on the left and d. Clean the laser window.
right springs of the transfer roller
are not even or the springs are
damaged.
4. The transfer roller is improperly
installed.
5. The transfer roller bearings or
holders are damaged.
6. Laser window is dirty.

7.1.8 Background Contamination

Example Possible Cause Sequence of Repair Actions

Light or dark background contamination appears all over the paper.

1. Using unsupported media. a. Use only approved media.

2. Printing large quantities of low b. The toner cartridge is designed to print
Digital Printer coverage (2%) pages or not using 5,000 sheets at 5% coverage. If 2% is
Digital Printer the printer for a long period of time. consistently used, background
3. The toner cartridge life has expired. contamination can occur.
Digital Printer c. Replace the toner cartridge.
4. The transfer rollers up/down
Digital Printer movement is off. d. Clean the transfer roller bushings.
Digital Printer 5. There is a problem with the HVPS. e. Clean the high voltage terminals.
f. Replace the HVPS.

7-4
 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.

1. When printing on card stock, thick a. Ensure supported media is being used and
paper or transparenices a higher the correcy type is selected in the printer
Digital transfer voltage is required. driver and software application.
Digital Printer
Printer
Digital Printer
Digital Printer
Digital
Digital Printer
Printer
Digital Printer
Digital Printer
Digital
Digital Printer
Printer

7.1.10 Ghosting 2

Example Possible Cause Sequence of Repair Actions

Ghosting appears at 75.5 mm on the whole print.

1. Bad contacts caused by a. Clean all high voltage contacts.

contamination from toner particles b. Replace the HVPS.
Digital between the high voltage terminals,
Digital Printer
Printer the printer, and the electrodes of
c. Replace the toner cartridge.
Digital Printer
Digital Printer the toner cartridge. d. Replace the transfer roller.
Digital
Digital Printer
Printer 2. Bad contacts caused by e. Replace the main board.
Digital Printer contamination from toner particles
Digital Printer between the high voltage terminals
Digital
Digital Printer
Printer the printer, and the one on the high
voltage supply board.
3. The toner life has expired.
4. The transfer life has expired.
5. The ambient temperature is too
low.
6. There is a damaged cleaning blade
in the toner cartridge.

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Troubleshooting

7.1.11 Ghosting 3

Example Possible Cause Sequence of Repair Actions

Ghosting occurs at 78 mm intervals.

1. Fuser contamination or a. Replace the fuser.

termperature control problem.
Digital
Digital Printer
Printer
Digital Printer
Digital Printer
Digital
Digital Printer
Printer
Digital Printer
Digital Printer
Digital
Digital Printer
Printer

7.1.12 Ghosting 4

Example Possible Cause Sequence of Repair Actions

White ghosting occurs every 32 mm on a black image.

1. The life of the toner cartridge may a. Replace the toner cartridge.
be expired. b. Check the HVPS supply voltage.
Digital
Digital Printer
Printer 2. Abnormal output from the HVPS. c. Clean all high voltage terminals on the
Digital Printer
Digital Printer cartridge and in the printer.
Digital d. Replace the HVPS.
Digital Printer
Printer
Digital
Digital Printer
Printer
Digital Printer
Digital Printer

7.1.13 Stains on the Front of the Page

Example Possible Cause Sequence of Repair Actions

1. Toner leakage due to an improperly a. Run the PC cleaning mode print 2 to 3 times
sealed toner cartridge. and perform the self test 2 to 3 times to
Digital Printer 2. The charge roller may be remove contamination.
Digital Printer contaminated. b. Replace the toner cartridge.

Digital Printer
Digital Printer
Digital Printer

7-6
 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.

1. Transfer roller is contaminated. a. Run the OPC cleaning mode print 2 to 3

2. Pressure roller is contaminated. times then run the self test to remove
Digital contamination from the transfer roller.
Digital Pri b. Replace the transfer roller.
c. Replace the fuser.
Digital Printer
Digital Printer
Digital Printer

7.1.15 Blank Page is Printed 1

Example Possible Cause Sequence of Repair Actions

The printed page is blank.

1. Bad ground contacts in the OPC a. Clean the ground terminals on the toner
and/or toner cartridge. cartridge and inside the printer.
Digital Printer b. Check the OPC ground or the OPC diode
Digital Printer for defects or an open circuit (inside left side
of printer).
Digital Printer
Digital Printer
Digital Printer

7.1.16 Blank Page is Printed 2

Example Possible Cause Sequence of Repair Actions

Blank page is printed, one or several blank pages are printed, or when the printer is first powered on several blank
pages are printed.

1. Bad ground contacts in the OPC a. Delete all print jobs in the queue and cycle
and/or toner cartridge. power to the printer and try printing again.
2. Defective solenoid. b. Clean the ground terminals on the toner
cartridge and inside the printer.
c. Check the OPC ground or the OPC diode
for defects or an open circuit (inside left side
of printer).
d. Run the engine self test using the DCU
(refer to code 6) to check the solenoid.
e. Replace the main board.

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Troubleshooting

7.2 Paper Feed Problems

7.2.1 Wrong Print Position

Printing begins at the wrong position on the paper.

Possible Cause Solution

1. Defective feed sensor. a. 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.
LSU

Fuser CR
Toner Cartridge
DR
OPC SR
EXIT
Sensor PR
PTL MP Sensor
TR FR
Feed
Sensor
K/R

PIC
Empty Sensor

Possible Cause Solution

1. Defective solenoid. 1. Use diagnostics to test the solenoid. Replace

2. Defective feed sensor. the solenoid if defective.
3. Problem with the MP lift plate and springs. 2. Test the feed sensor. Replace if defective.
4. Defective paper separator pad. 3. Replace the tray if defective.
5. Contaminated or defective pick roller. 4. Clean the pick roller. Replace if defective.
5. Ensure all rollers are free from debris and
rotating freely.
6. Check the SMPS, main board and all
connections. Replace any defective parts.

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 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
LSU and in the fuser, just after passing the feed actuator.
Fuser CR
Toner Cartridge
DR
OPC SR
EXIT
Sensor PR
PTL MP Sensor
TR FR
Feed
Sensor

K/R
PIC
Empty Sensor

Possible Cause Solution

1. Defective exit sensor/actuator. a. Replace the exit sensor, SMPS, or main

2. Defective feed actuator. board.
b. Replace the feed actuator and spring if
defective.

7.2.4 Jam 2

Description:
There is an accordian jam in front of or inside the
fuser.
LSU There is an accordian jam stuck in the discharge
Fuser Toner Cartridge
roller and in the fuser, just after passing the feed
CR

OPC
DR
SR
actuator.
EXIT
Sensor PR
PTL MP Sensor
TR FR
Feed
Sensor
K/R

PIC
Empty Sensor

Possible Cause Solution

1. If the paper has exited the printer and a Jam2 occurs the a. Look for debris or contamination around the
exit sensor is defective: exit sensor and actuator.
■ After paper passes the exit sensor, the flag should b. Check the exit sensor and actuator for
return to its normal position. The flag may stick or damage.
return too slowly due to contamination or foreign c. Replace if defective.
objects obstructing its path.
d. Replace the fuser.
2. If there is an accordian paper jam in the fuser:
■ The guide claw is damaged.
■ The spring on the guide is damaged.
■ The heat roller or pressure roller is contaminated with
toner.

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Troubleshooting

7.2.5 Multiple Pick

Description: Multiple sheets of paper are picked from the tray at the same time.

Possible Cause Solution

1. The paper guides are set incorrectly. a. Adjust the guides so they fit snuggly against
2. The paper has a rough surface. the paper in the tray.
3. The friction pad is damaged or contaminated. b. Make sure the paper size selected in the
print driver is the same as the paper in the
4. The solenoid is not functioning properly.
tray.
c. Use the appropriate supported paper type
for this printer.
d. Clean the friction pad or replace if
damaged.
e. Replace the solenoid.

7.2.6 Paper Rolled in the Fuser

Description: There is an accordian jam in the fuser.

Possible Cause Solution

1. The pressure roller or heat roller is damaged or not a. Replace the fuser.
functioning properly.
2. The paper guides or springs are damaged.

7.2.7 Paper Rolled in the OPC Drum

Description: Paper is caught or rolled up in the OPC.

Possible Cause Solution

1. The paper is too thin. a. Use the appropriate supported paper type
2. The paper is curled. for this printer.
b. Load a fresh ream of paper.
NOTE: To remove paper rolled up in the OPC:
■ Remove the toner cartridge from the printer,
take care not to touch the green surface. use
the gerar on the side to rotate the OPC drum
and pull the paper from the toner cartridge.
■ Clean any fingerprints on the OPC gently with
a soft, lint free cloth, using caution not to
scratch the surface.

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 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

1. The thermostat, fuser power cable or heat lamp has an a. Use the DCU to test the fuser.
open circuit. b. Replace the fuser.
2. The thermistor is faulty.
3. The drive gear melted.

7.3.2 All LEDs Blinking (Scan Error)

Description: All LEDs are blinking on the control panel.

Possible Cause Sequence of Repair Actions

1. The laser cable or connector is faulty. a. Replace the laser unit or cable.
2. The laser motor is faulty. b. Replace the main board if the error persists
3. The HSYNC signal. after replacing the laser unit.

7.3.3 Fuser Gear Melted Due to Overheating, Causing a Paper Jam

Description: Constant jam where paper is entering the fuser unit or the fuser rollers are not turning.

Possible Cause Sequence of Repair Actions

1. The heat lamp, thermistor, thermostat, or fuser rollers are a. Use the DCU to check the fuser. Codes: 60,
damaged. 62, 0r 68.
b. Replace the fuser unit.
c. Replace the main board.

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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

1. The paper empty sensor or actuator is damaged or faulty. a. Use the DCU test 08.
2. The main board is faulty. b. Replace the defective actuator or sensor.
3. Faulty cable or connector. c. Replace the main board.

7.3.5 Paper Empty Error Without Indication

Description: The paper empty LED does not light when the paper tray is empty.

Possible Cause Sequence of Repair Actions

1. The paper empty sensor or actuator is damaged or faulty. a. Use the DCU test 08.
2. The main board is faulty. b. Replace the defective actuator or sensor.
3. Faulty cable or connector. c. Check and replace the wiring to the control
panel if faulty.
d. Replace the main board.

7.3.6 Cover Open

Description: The error LED is lit even though the

cover is closed.

Possible Cause Sequence of Repair Actions

1. The interlock may be stuck or faulty. a. Use the DCU test 09 and check for error
2. The interlock tab on the front cover may be damaged. code 64.
3. The sensor switch on the main board may be defective. b. Replace the interlock if faulty.
c. Replace the front cover.
d. Replace the main board.

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 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

1. The interlock may be stuck or damaged. a. Use the DCU test 09 and check for error
2. The control panel LED may be faulty. code 64.
3. The sensor switch on the main board may be faulty. b. Replace the interlock if faulty.
c. Replace the front cover.
d. Replace the cabling or control panel.
e. Replace the main board.

7.3.8 Defective Motor Operation

Description: The main motor is faulty and paper does not feed into the printer, resulting in a Jam0.

Possible Cause Sequence of Repair Actions

1. The main motor harness or motor board may be faulty. a. Use the DCU test 00 to test the main motor.
2. The main board may be faulty. b. Replace the motor or harness if faulty.
3. The SMPS may be faulty. c. Replace the main board.
d. Replace the SMPS.

7.3.9 No Power

Description: When the printer is powered ON the LEDs on the control panel do not come on.

Possible Cause Sequence of Repair Actions

1. The SMPS or power input are faulty. a. Replace the power supply cable.
2. Lamps don’t come on, but other normal start-up sounds b. Check the power fuse on the SMPS, replace
are heard. the SMPS if necessary.
3. After replacing the SMPS, the lamps do not come on and c. Check the control panel wiring. Replace the
no start up sounds are heard. harness or control panel if faulty.
d. Replace the main board.

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Troubleshooting

7.3.10 Printed Vertical Lines Become Curved

Description: When printing the vertical lines are not straight.

Possible Cause Sequence of Repair Actions

1. The +24 V supply to the laser unit is faulty. a. Use the DCU test 05 to test the laser motor.
b. If the voltage is stable, replace the laser
unit.
c. If the voltage is not 24 volts, replace the
SMPS.
d. Replace the main board.

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 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.

7.4.2 Toner Cartridge Life

If the printed image is light due low toner life remaining, you can temporarily improve the print quality by
redistributing the toner (shake the toner cartridge); however, you should replace the toner cartridge to solve the
problem.

7.4.3 Redistributing Toner

When toner is low, faded or light areas may appear on a printed page. You may be able to temporarily improve the
print quality by redistributing the toner. The following procedures can allow you to finish the current print job before
replacing the toner cartridge.
1. Grasp the front cover and pull it toward you to open.
2. Remove the toner cartridge from the printer.

Warning
Avoid reaching too far into the printer. The fuser area may be hot.

3. Gently shake the toner cartridge from side to side five or six times to redistribute the toner.
4. Reinsert the toner cartridge into the printer. Ensure that the toner cartridge snaps into place.
5. Close the front cover. Make sure that the cover is securely closed.

Note
If the toner gets on your clothing, wipe it off with a dry cloth and wash clothing in cold water. Hot water sets
the toner in the fabric.

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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.
1. Print a Demo Page:
a. When the Ready LED lights, press and hold the [Cancel] button until the LEDs flash then release.
b. If the test print works, there are no hardware problems within the printer and the user should check the
application settings.
c. If the test print did not print, use the DCU in diagnostic mode to continue troubleshooting.
2. Check that the computer and the printer are properly connected.
a. Reconnect or replace the connection from printer to computer if faulty or damaged.
b. If the connection is sound, continue troubleshooting.
3. The printer is not printing from Windows.
a. If you use windows, check that the printer driver in the is set up correctly, the correct port is selected and Use
On-line is selected in the driver.
b. If the printer driver is properly set up, try printing a test page from the driver properties window.
c. Verify which program is not printing.
d. If no programs can print, try opening Notepad and printing from there.
e. If the problem is within a single application, adjust the printing properties within that program.
f. If changing the properties in the application print dialog box does not solve the problem, uninstall and
reinstall a new driver.
g. If the printer is not printing from all programs, and the user is printing using the parallel port, check the port
settings. Ensure the following settings:
■ CMOS is on ECP
■ the address is IRQ 7
■ 378 (for parallel port 1).
h. Try using USB instead.

7.5.2 The Printer is Not Responding to a Print Command or Strange Fonts are
Printing
After receiving a print command, there is no reponse from the printer.
1. Ensure there is sufficient hard disk space for the termporary work files created during printing.
a. The message “ insufficient printer memeory” means there is a hard disk space problem, rather than a printer
RAM problem. Free up space on the hard disk. Use the disk utilities program to delete unnecessary files.
2. The error occurs even though there is plenty of hard disk space.
a. The connection or communication between the printer port and computer is incorrect.
b. Verify the cable is properly connected and configured for printing. Make sure the CMOS settings are
correctly set. For the printer port:
■ Select ECP which supports 12-bit data transfer or SPP which supports 8-bit data transfer.

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 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.
1. Insufficient space on the hard disk in the directory assigned for the basic spool.
a. Delete any unnecessary files to provide more space for spool storage.
2. If previous printing errors were not solved.
a. There may be files from previous failed print jobs on the hard disk with the name in the form ‘*.jnl’. Delete
these files and reboot Windows to restart the printer.
3. There may be a conflict with other drivers or programs.
a. Shut down all other programs except the current one, if possible.
4. When an application program or the printer driver is damaged.
a. Delete the printer driver completely and reinstall it.
5. When some files related to the OS are damaged or virus infected.
a. After rebooting the computer, check for viruses, restore the damaged files and reinstall the application
program which is not working properly.
6. Computer memory is insufficient to support printing.
a. Add up more memory to the PC.

How to delete the data in the spool manager.

In the spool manager, the installed drivers and the list of the documents waiting to be printed are shown. Select the
document to be deleted and check delete in the menu.
If the job you are deleting is the current job any job data that has already been transferred to the printer’s memory will
still be printed. If there is a problem with the printer (out of toner, offline, out of paper, etc.) the job may take a long
time to delete as it must wait for a time out.

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Troubleshooting

7-18
 Parts List

8 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

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8-2
2-6
2-2
2
Parts List

5
0

5-2

2-1 5-3

2-3
2-4
2-5 18

3
8.1 Main Assembly

16
5-1

23 22

21
Toner Cartridge 17 8
15

7 9

7-1
6
14

14-2
19 14-1
6-4 6-3

6-5 6-1 6-11

6-2 10
7-3
7-2
6-6

11
6-7

6-8 13
20

6-10

6-10
12

6-9

Opt Tray 3
 Parts List

Main Assembly Parts List 8.1

No. Part Name and (part description) Qty Part number Remark
0 SET
1 ELA HOU-FRAME-220V, HB2 1
1 ELA HOU-FRAME-110V, HB2 1
2 MEA UNIT-COVER TOP 1 002N02314
2-1 COVER-M-TOP 1
2-2 PMO-STACKER RX 1
2-3 KEY-M-ON LINE 1
2-4 SPRING-CS 1
2-5 LENS LED-M-LED 1
2-6 BUSH-M-F/DOWN 1
3 COVER-M-SIDE L 1 002N02317
4 COVER-M-SIDE R 1 002N02318
5 MEA UNIT-COVER REAR 1 002N02319
5-1 COVER-M-REAR 1
5-2 COVER-FACE UP 1
5-3 COVER-M-REAR OPEN 1
6 MEA UNIT-COVER FRONT 1 002N02316
6-1 COVER-M-FRONT 1
6-2 KNOB-M-LOCKER 1
6-3 HOLDER-M-LOCKER 1
6-4 TRAY-EXIT-MP 1
6-5 ADJUST-M-MP L 1
6-6 ADJUST-M-MP R 1
6-7 TRAY-M-COVER-MP 1
6-8 GEAR-PINION 1
6-9 TRAY-M-CASE-MP 1
6-10 TRAY-M-LINK-MP 2
6-11 SPRING-CIS(C2) 1
7 MEA UNIT-COVER MID 1 002N02315
7-1 COVER-M-MIDDLE 1
7-2 PMO-M-SUB ACTUATOR 1
7-3 CAP-M-SUB ACTUATOR 1
8 COVER-M-SMPS REAR 1
9 PBA MAIN-PANEL 1 101N01330
10 PBA MAIN-CONTROLLER 1 140N62926
11 SMPS-V2_220V 1 105N02039 220V
SMPS-V1_110V 1 105N02038 110V
12 MEA UNIT-SHIELD 1
13 BRACKET-P-INLET 1
14 NETWORK OPTION (ELA HOU-NPC3_PRT ) 1 097N01438
14-1 BRACKET-NPC 1
14-2 PBA SUB-NPC3_PRT 1
14 ELA HOU-WLAN NPC 1
15 MEA ETC-TR 1 022N02079
16 UNIT-LSU 1 122N00235
17 ELA UNIT-RX-DRIVE 1 007N01270
18 CBF HARNESS-LSU 1 152N02010

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Parts List

No. Part Name and (part description) Qty Part number Remark
19 CBF HARNESS-ENGINE 1 152N02012
20 MEA UNIT-CASSETTE (PAPER TRAY) 1 109R00749
21 PLATE CHANNEL 1
22 MOTOR HARNESS-DRIVE 1 152N11566
23 TONER CARTRIDGE 3.5k STANDARD CAP 1 109R00746
23 TONER CARTRIDGE 5k HIGH CAPACITY 1 109R00747

8-4
 62
61
63
63-1
63-2
49
34 Transfer Roller
29
73
56 32 38 61
48
37

65-2 65-3
30 36
65
31 65-4 65-1

28 23 49

5
51 72 35
42 5
3
46 5
39

46-1
8.2 Frame Unit Assemly

43
46-2 2
41
17 70
44 40

47 45-1
47-1 45-2
45
47-2 45-3
47-3

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47-4
16
18 15 4
50
47-5

26
60
66
8

21-2 9
11
25 12

24 21-1
10
20 13
21-3
21
7 6
14
27-1 25
27-3

27-2

27-4
33 19-2
58
27-5
19-1
27-4 22
27
19

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Parts List
Parts List

Frame Unit Assembly Parts List 8.2

No. Part Name and (part description) Qty Part number Remark
0 ELA UNIT-FRAME 110V 1 110V
ELA UNIT-FRAME 220V 1 220V
1 FRAME-BASE R2 1
2 GUIDE-P-TR 1 038N00407
3 PLATE-P-SAW 1
4 GUIDE-M-TR RIB 1 038N00408
5 PMO-GEAR_EXIT_DRV16 3
6 FOOT-BACK 2
7 FOOT-FRONT 2
8 GROUND-GUDIE TR R2 1
9 MEC-TERMINAL 4
10 PLATE-TERMINAL CON R2 3
11 PLATE-TERMINAL CR R2 1
12 HOUSING-TERMINAL R2 1 002N02320
13 PMO-LOCKER CST 2 120N00427
14 PMO-ACTUATOR CVR OPEN 1 120N00423
15 PMO-PLATE GUIDE DEVE_R 1 032N00390
16 SPRING ETC-GUIDE DEVE 2
17 GROUND-PUSH BUSHING 1
18 PMO-PLATE GUIDE DEVE_L 1 032N00391
19 MEA UNIT-ACT FEED 1
19-1 PMO-ACT FEED R2 1 120N00444
19-2 SPRING-TS 1
20 PMO-ACTUATOR EMPTY 1 120N00425
21 MEA UNIT-ACT MANUAL 1
21-1 PMO-ACT MANUAL R2 1 120N00446
21-2 HOLDER-ACT MANUAL R2 1
21-3 SPRING-TS 1
22 GROUND-EARTH TR R2 1
23 GROUND-TERMINAL TR 1
24 ROLLER-FEED ROLLER 1 1 022N02080
25 PMO-BUSHING FEED 5 016N00274
26 SHAFT-FEED 1
27 MEA UNIT-PICKUP 1 022N02084
27-1 BUSH-M-PICK_UP L 1
27-2 SHAFT-P-PICK_UP 1
27-3 STOPPER-PICK UP_R2 2
27-4 PMO-IDLE PICK_UP 2
27-5 SPONGE-ROLLER PICK_UP 1
27-6 BUSH-M-PICK_UP R 1
27-7 HOUSING-PICK UP_R2 1
27-8 HOUSING-PICK UP2_R2 1
27-9 SHAFT-CORE 2
28 IPR-P-EARTH TRANSFER 1 117N01616
29 HOLDER-PTL R2 1
30 LENS-PTL 1 062N00246
31 PMO-BUSHING_TR(L) 1

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 Parts List

No. Part Name and (part description) Qty Part number Remark
32 SPRING ETC-TR L HAWK 1
33 ROLLER-FEED 1 022N01607
34 BUSH-M-TR L 1
35 GROUND-FUSER R2 1
36 SHAFT-FEED IDLE 1
37 BUSH-M-FEED IDLE 2
38 SPRING ETC-TR 2
39 GROUND-DRIVE2 R2 1
40 SPRING-TS 1
41 CAM-M-PICK_UP 1 008N01738
42 GROUND-DRIVE R2 1
43 SOLENOID-FEED ROCKY2 1 121N01074
44 SOLENOID-HB (MANUAL) 1 700N00094
45 MEA UNIT-GEAR PICKUP 1 007N01271
45-1 GEAR-PICK UP B_R2 1
45-2 GEAR-PICK UP A_R2 1
45-3 SPRING-CS 1
46 MEA UNIT-BRACKET FEED 1 030N00690
46-1 BRACKET-FEED R2 1
46-2 GEAR-Z35 IDLE 1
47 MEA UNIT-CLUTCH 1 022N01609
47-1 GEAR-FEED 1 1
47-2 PMO-COLLAR_SPRING 1
47-3 SPRING-TS 1
47-4 PMO-HUB CLUTCH 1
47-5 SHAFT-FEED 1
48 ELA HOU-FUSER 110V 1 126N00229 110V
ELA HOU-FUSER 220V 1 126N00230 220V
49 PLATE-PUSH BUSHING 2
50 GEAR-FEED 2 1
51 GEAR-IDLE 23 1
52 SPRING-TS 1
54 IPR-P-TERMINAL DEVE KEY 3
56 PBA SUB -PTL 1
58 HOLDER-TERMINAL R2 1
60 FAN-DC 1 127N07328
61 MEC-BEARING,EXIT 2
62 GEAR-EXIT F/DOWN 1
63 ROLLER-EXIT F/DOWN 1
64 RMO-RUBBER EXIT 4
65 MEA RACK-EXIT ROLLER 4 022N02081
65-1 PMO-HOLDER EXIT ROLL 1
65-2 PMO-ROLLER FD F 1
65-3 PMO-ROLLER FD R 1
65-4 SPRING ETC-EXIT ROLL FD 1
66 GUIDE-SUB FRONT 1
70 PBA SUB-EXIT SENSOR 1 130N01360
72 LABEL(R)-HOT CAUTION,KME 1
73 HARNESS-FUSER 1

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8.3 MP Assembly

26

11

12

28

14
2 23
14
23
25

21 1
7
25
3
30
18
9
24
31
29
16 10 20
17

13 6
15 8
22

27

19 4
5
19

8-8
 Parts List

MP Assembly Parts List 8.3

No. Part Name and (part description) Qty Part number Remark
0 ELA UNIT-MP 1 022N02085
1 FRAME-17-MP 1
2 SOLENOID-MP 1 121N01075
3 CBF HARNESS-MPF SEN 1
4 BUSH-M-PICK-UP R 1
5 HOUSING-M-PICK UP2_R2 1
6 STOPPER-M-PICK UP_R2 2
7 HOLDER-M-PAD_MP 1
8 HOUSING-M-PICK UP_MP 1
9 HOLDER-M-SENSOR_MP 1
10 PLATE-P-KNOCK UP_MP 1
11 BRACKET-P-PICK UP_MP 1
12 GEAR-IDLE 23 1
13 SHAFT-P-PICK_UP 1
14 ROLLER-M-IDLE FEED 2
15 GEAR-M-PICK UP_MP 1
16 GEAR-M-HOLDER_MP 1
17 CAM-M-PICK UP_MP 1
18 PMO-ROLLER CAM_MP 1
19 PMO-IDLE PICK UP 2
20 PMO-M-ACT EMPTY MP 1
21 RPR-FRICTION PAD 1 019N00742
22 RUBBER-PICK UP_MP 1
23 SPRING-ETC-EXIT ROLL FD 2
24 RPR-PAD CASSETTE 1
25 SPRING-ES 2
26 SHEET GUIDE PAPER R2 1
27 SHAFT-P-CORE 2
28 SHEET GUIDE MP 1
29 SPRING-CS 1
30 SPRING-ES 1
31 PHOTO INTERRUPTER 1

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Parts List

8.4 Fuser Unit Assembly

36 0

12 6
14

17

34
4 38
1
5

29 3
37 2
31

29

37
32 13

35 15
30
11

16

33

20
23 19
18

21
22 25
9 28
8 24
36
10
7

27

38
26

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 Parts List

Fuser Assembly Parts List 8.4

No. Part Name and (part description) Qty Part number Remark
0 ELA HOU-FUSER 110V 1 126N00229 110V
0 ELA HOU-FUSER 220V 1 126N00230 220V
1 COVER-FUSER R2 1
2 HOLDER-PLATE CLAW R2 4
3 SPRING ETC-CLAW 4
4 PMO-ROLLER_EXIT 2
5 SPRING ETC-FUSER EXIT 2
6 THERMOSTAT-150 1 130N01265
7 PMO-GEAR_EXIT_DRV16 1
8 GEAR-IDLE 23 1
9 RING-E 1
10 GEAR-RDCN 25/15 1
11 ROLLER-HEATER 1
12 ELECTRODE-LFET R2 1
13 THERMISTOR-NTC 1 130N01266
14 ELECTRODE-RIGHT R2 1
15 CBF HARNESS-FUSER 110V 1 WHITE
CBF HARNESS-FUSER 220V 1 BLACK
16 BUSH-HR R_R2 1
17 LABEL(P)-CAUTION, HOT_FUSER 1
18 RMO-RUBBER_EXIT 2
19 ROLLER-M-EXIT F/UP 1
20 ROLLER-PRESSURE 1
21 BEARING-PRESSURE/R 2
22 SPRING-CS 2
23 PMO-BUSHING TX 3
24 HOLDER-ACTUATOR 1
25 PMO-ACTUATOR EXIT R2 1
26 FRAME-FUSER R2 1
27 GUIDE-INPUT R2 1
28 SPRING-TS 1
29 NUT-HEXAGON 5
30 BUSH-HR L_R2 1
31 PLATE-P-CLAW 4
32 GEAR-FUSER R2 1
33 LAMP-HALOGEN 110V 1 122N00231 110V
LAMP-HALOGEN 220V 1 122N00229 220V
34 LABEL(R)-HV FUSER 1
35 SCREW-TAPTIEE 1
36 SCREW-ASS'Y MACH 6
37 SCREW-TAPTIEE 6
38 BRUSH-ANTISTAIC 1

Service Manual 8-11

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Parts List

8.5 Main Drive Unit Assembly

0

4
2
5

4 5

Main Drive Unit Assembly Parts List 8.5

No. Part Name and (part description) Qty Part number Remark
0 ELA UNIT- DRIVE 1 007N01270
1 BRACKET-GEAR MAIN X
2 GEAR-RDCN 53/26 1
3 GEAR-RDCN 113/33 1
4 GEAR-RDCN 57/18 2
5 WASHER-PLAIN 2
6 BRACKET-MOTOR MAIN 1
7 GEAR-RDCN 1
8 GEAR-RDCN 1
9 MOTOR STEP-HUMMINGBIRD 1

8-12
 Parts List

8.6 Tray 2 (Cassette) Unit Assembly

12

14 13

16
4
6-4

6-3
6-2

6-1 15
5
3
7
5

10

11
1

Service Manual 8-13

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Parts List

Tray 2 (Cassette) Unit Assembly Parts List 8.6

No. Part Name and (part description) Qty Part number Remark
0 MEA UNIT-CASSETTE, USA 1 109R00749
1 FRAME-M-CASSETTE 1
2 GUIDE-M-EXTENSION LARGE 1
3 GUIDE-EXTENSION SMALL 1
4 PLATE-P-KNOCK_UP 1
5 SPRING-CS 2
6 MEA UNIT-HOLDER PAD 1
6-1 HOLDER-M-PAD 1
6-2 SHEET-HOLDER PAD R2 1
6-3 RPR-FRICTION PAD 1 019N00742
6-4 IPR-PLATE PAD 1
7 SPRING ETC-EXIT ROLL FD 1
8 COVER-SUB CASSETTE R2 1
9 INDICATOR-M-CST PAPER 1
10 PMO-PLATE_LOCKER 1
11 SPRING ETC-LOCKER,PLATE 1
12 ADJUST-M-CASSETTE_L 1
13 ADJUST-M-CASSETTE_R 1
14 GEAR-PINION 1
15 RPR-PAD CASSETTE 1
16 CAM-KNOCK UP 1

8-14
 0

27 4

39
38

39-2 30
39-5

39-11
25
39-12

39-10

39-4 19
39-1 18
39-7 39-9 17 32 26
39-3
39-6 22 27 40
23 33
39-8 37
20
21
28
24

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34
29
5

41
1-1
42
1-2
1 31 3
35
11 10

6
13
43 14
9

15 34
8
7
16 12 36
8.7 Tray 3 (SCF - Optional Cassette) Unit Assembly

Service Manual 8-15

Parts List
Parts List

Tray 3 (SCF - Optional Cassette) Assembly Parts List 8.7

No. Part Name and (part description) Qty Part number Remark
0 ELA HOU-SCF H2 1 097N01439
1 COVER-M-FRONT SCF H2 1
1-1 SPRING-ES 2
1-2 ROLLER-IDLE FEED 2
2 COVER-M-LEFT SCF H2 1
3 COVER-M-RIGHT SCF H2 1
4 COVER-M-REAR SCF H2 1
5 FRAME-M-SCF 1
6 HOUSING-M-PICKUP _R2 1
7 HOUSING-M-PICKUP2 _R2 1
8 SPONGE-ROLLER PICK_UP 1
9 SHAFT-P-CORE 2
10 STOPPER-M-PICK_UP_R2 2
11 BUSHING-PICK_UP L 1
12 BUSHING-PICK_UP R 1
13 SHAFT-P-PICK_UP 1
14 PMO-IDLE PICK_UP 2
15 ROLLER-FEED 1
16 PMO-BUSHING FEED 2
17 PMO-GEAR PICK_UP A 1
18 PMO-GEAR PICK_UP B 1
19 SPRING-CS 1
20 RING-CS 1
21 CAM-M-PICK_UP 1
22 SHAFT-FEED 1
23 GEAR-FEED 2 1
24 SPRING-TS 1
25 PCB-SENSOR 1
26 PBASUB-SCF 1
27 CBF HARNESS-SCF GND 2
28 CBF HARNESS-SCF 1
29 COVER-M-SIMM R2 1
30 SHEET-COVER SENSOR 1
31 PMO-ACTUATOR EMPTY 1
32 IPR-GND TOP 1
33 SOLENOID-HB (MANUAL) 1
34 PMO-LOCKER CST 2
35 FOOT-BACK 2
36 FOOT-FRONT 2
37 SCREW-ASS'Y TAPT 1
38 SCREW-TAPTITE 4
39 ELAHOU-MOTOR SCF 1
39-1 BRKT-P-MOTOR SCF 1
39-2 BRKT-P-GEAR SCF 1
39-3 BRKT-M-FEED SCF 1
39-4 GEAR 61/47 IDLE 1
39-5 GEAR 59 IDLE 1

8-16
 Parts List

No. Part Name and (part description) Qty Part number Remark
39-6 GEAR 35 IDLE 1
39-7 GEAR-RDCN 57/18 1
39-8 GEAR-IDLE 23 1
39-9 MOTOR STEP(SCF) 1
39-10 SCREW-MACHINE 5
39-11 CORE-FERRITE 1
39-12 CABLE TIE 1
40 BUSH CABLE 1
41 SCREW-TAPTITE 14
42 GUIDE-M-KNOCKUP 1
43 MEA UNIT-CASSETTE 1 109R00749

Xerox Options and Accessories

Part Name and (part description) Qty Part number Remark
POWER CORD, 110 V 1 117N01602
USB CABLE 1 117N01313
DCU Tool 1 600T80340
OPTIONAL TRAY 3 1 097N01439
MEMORY 1
32 MB 097N01434
64 MB 097N01435
128 MB 097N01436
NETWORK CARD 1 097N01438
POSTSCRIPT OPTION 1 097N01437

Service Manual 8-17

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Parts List

8-18
 PO WER
POWE
COR
CORD 9
FUSER
USER ASSY THERMISTOR To Controller
IN-LET F.G

-+
+24V
+5V
+3.3V
GND

HEATER-AC SMPS Bloc

lock

EXIT - SENSOR LSU

LS

Controller Block
Co HVPS
PS Block
ock
Crystal
MAIN MOTOR A3977
A3977
12MHz
Motor
Motor Driver MHVPWM
Main MHV
SPGPm
SPG Pm Clock
Freq.

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OPCGND
Solenoid Spread FAN
PTL Power
SDRAM
SDRAM SUPPLY
On
Voltage Reset (16MB) EEPROM BIASPWM
Block Diagram

Detector DEV

THVPWM
FLASH
FLA SH THV
USB2.0
MEMORY
IEEE1284 (2MB) PANE
ANEL
FEED-SENSOR
+24V
CART
ARTRID
RID GE
IN FO. P/ EMPTY SENSOR

SCF
SC MP- SENSOR Cover- Open Switch
ption)
( Opt ion)
NIC
NI

Service Manual 9-1

Block Diagram
Block Diagram

9-2
 Connection Diagram

10 Connection Diagram

ROMDIMM 100PIN CN13

NETWORK
CN7 PI30N OPTION
RAMDIMM 100PIN CN14
LSU_CLK
1 nLREADY
1
2 nPMOTOR
2 POLYGON
3 3
4
GND 4 MOTOR
24VS 5
36 CN15 CN5 56 nHSYNC
LSU
IE EE1284 1
PIN 7 5V
2
COMPATIBLE 8 GND
3
CABLE 9
nLD_ON
4 LD
VDO
10 5
GND 6
11
HOST
4PIN
USB CABLE 1
3. 3V
1
COMPUTER CN11 2 PTL
2 PTL LED ARRAY
CON-
NEC- CN16
TOR 24VS
for CN10 1 1
2 M_Clutch
2 MANUAL SOLENOID
USB2.0

SCF
SC 1 24VS 1
8PIN J1 CN8 2 CASSETTE CLUTCH
C_Cl utc h
(O IO N)
(OPTIO 3 2

Main
CARTRIDGE
INFO.
INFO
4PIN B oa
oa r d 1 P_EMPTY
FEED 1
2 2
CN18 4 layer 3 5V
5V 3
4 4
GND
THERM FR4 5 5
THERMISTOR 12
HERMI THERM2 1
CN4 6 GND
6
2 7 NC
GND
7 SMPS
8 8
GND
9 9
10 GND
1
A
1 10
11 24VS
2
A/
2 11
MOTOR 3 B CN6 12 24VS 12
3 13 MP_EMPTY
4
B/
4 24V
13
CN1 14
15 THV_READ 14
THV_PWM
15 HVPS
16 16
THV_EN
17 17
BIAS_PWM
3. 3V 18 18
1 1 19 MHV_P WM
19
2 DCU_DATA 2
DCU DCU_CLK CN2 20 FAN
20
3 3 21 FUSER
21
4 GND 4 22 P_EX IT SENSOR
LED_READY
22
23 23
24 LED_ERROR
24
25 LED_TONERLOW
1 3. 3V 1 KEY_CONTINUE
25
2 RXD 2 26 26
UART TXD CN3
3 3
GND
4 4
1 24V 1
CN9 2 2 REGI SOL
REGI SOL
3 3

1 MP SENSOR 1
GND MP SENSOR
CN17 2
SV
2
3 3

Service Manual 10-1

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Connection Diagram

10-2