MB 4550 General Information

Page 1

Chapter

General Information

This service manual contains information useful for troubleshooting, repairing, adjusting, and maintaining a Tektronix Phaser Printers. This manual includes troubleshooting guides, adjustment procedures, a ﬁeld replaceable units (FRU) list and assembly/disassembly procedures for selected FRUs. To ensure complete understanding of the product, we recommend participation in Phaser 540 service training.

540 and Phaser

540 Plus Color

Figure 1-1 The Phaser 540 Color Printer

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General Information

The Phaser 540 Color Printers

The Phaser 540 and Phaser 540 Plus Color Printers both combines a color laser, continuous-tone print engine with an image processor supporting Adobe’s PostScript Level 2 page description language (version 2015). The image processor features a bi-directional parallel interface for host communication. Optional network adapter cards to the image processor allow the printer to communicate on networks using LocalTalk, serial, Ethernet or Token Ring protocols. The Ethernet network card supports EtherTalk, Novell and TCP/IP. With the Token Ring network card, the Phaser 540 Plus supports Toten Ring protocols. The network cards are sometimes referred to as “smart cards” because each houses its own processor for executing speciﬁc on-board protocols; only data is transferred from the installed smart card to the printer’s image processor board.

The printers each comes standard with 20 Mbytes of RAM which can be supplemented with one or two additional 16-Mbyte RAM SIMMs. The printer contains 39 standard, built-in fonts. The printer features a SCSI-compatible interface to connect to an external hard disk drive for additional font storage. An orderable option, the Phaser CopyStation can also be connected to the printer’s SCSI port to give the printer the ability to optically copy color images.

The printer supports printing on A- and A4-sized paper and transparency ﬁlm from an A or A4-size tray. An optional two-tray second feeder (called the Lower Tray Assembly) is available. The printer also supports manual feeding. The Phaser 540 Plus also supports Legal-size paper in its Legal-size tray.

The printer prints at a user-selectable resolution of 300 dots-per-inch or 600 dots-per-inch. Color printing is at either 4 or 16 levels of color depending on the amount of memory installed in the printer. After being idle for one hour the printer switches into its Energy Star mode where it consumes less than 45 watts of power. It “awakens” upon receiving data at any of its ports. The printer also features a closed-loop image density sensor system that allows it to auto-calibrate its color imaging so printing output remains consistent over the life of the print engine and its consumable supplies.

RAM and printer capabilities

With additional RAM memory the printer’s capabilities increase:

■

With standard 20 Mbytes of RAM, the printer has a frame buffer of 16 Mbytes, an I/O buffer of 100 kbytes, an image pipeline color cache of 500 kbytes, and PostScript virtual memory of 3.6 Mbytes. With standard 20 Mbytes of RAM, the printer can print 300 dpi continuous-tone and 600 dpi bi-level images.

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Phaser 540 Color Printer

Page 3

With 36 Mbytes of RAM, the printer has a frame buffer of 32 Mbytes,

■

an I/O buffer of 100 kbytes, an image pipeline color cache of 500 kbytes, and PostScript virtual memory of 3.6 Mbytes. With 36 Mbytes of RAM the printer can print 300 or 600 dpi continuous-tone images and has faster data throughput. With the additional RAM in the Phaser 540 Plus, the scan-to-print start time of the Phaser CopyStation is reduced to about 65 seconds.

■

With a maximum 52 Mbytes of RAM, the printer has a frame buffer of 32 Mbytes, an I/O buffer of 1 Mbytes, and image pipeline color cache of 2 Mbytes, and PostScript virtual memory of 16.8 Mbytes.

Print engine assemblies

Toner level sensor board

General Information

Pre-exposure lamp

Imaging unit

Paper feeder

Black toner cartridge

Yelllow toner cartridge

Magentatoner cartridge

Cyan toner cartridge

Pre-transfer lamp



Ozone filter



Fuser

Laser scanner

Toner cartridge selector/paper exit unit

Paper tray

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Figure 1-2 Print engine major components

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General Information

Toner cartridge drive unit

Power supply fan

Power supply unit

Engine control board

Fuser fan

Charger sensor board

Cleaning board

Toner  cartridge motor

Ozone fan

Laser driver board

Image processor board

High voltage board

Main motor

Paper feed motor

Engine driver board

Figure 1-3 Print engine components (continued)

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Phaser 540 Color Printer

Page 5

Manual feed sensor

Registration sensor

Transparency sensor (transmitter)

Transparency sensor (receiver)

Toner level sensors (transmitters)

Accumulator belt home position sensor

Image density sensor

Scorotron charger sensor

Pre-transfer charger sensor

General Information

Toner level sensors (receivers) are mounted inside the toner cartridge driver unit

Front right door opened switch

Transfer waste bin sensor

Transfer roller position sensor

Fuser-installed switch

Left door opened switch

Paper low sensor*

Paper tray type sensors

Paper jam sensor

*Unused by image processor

Power switch

Figure 1-4 Print engine sensor, switch and solenoid locations

These sensors are not illustrated:

■

The photoconductive belt position sensor. This optical sensor marks the home position of the photoconductive belt. It is mounted inside the customer-replaceable imaging unit.

The photoconductive belt toner disposal bin full sensor. It is mounted

■

inside the customer-replaceable imaging unit. This ultrasonic sensor determines if one of the imaging unit’s two waste toner bins is full which, if true, would impair print quality. Under ordinary circumstances, neither waste toner bin should ﬁll up before the imaging unit’s life is expired.

Paper-exit sensor

Fuser-exit sensor

Paper-empty sensor

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The logic state of paper low sensor is not monitored or used by the image processor.

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General Information

Front panel

These front panel features are found on the printer:

■

A two-line, 24-character LCD and two LEDs

Four push buttons

■

LCD

The LCD serves two purposes: displaying current controller and print engine status information and displaying an interactive menu. Status information includes controller status such as

Printing . Print engine status includes messages such as Out of paper , Paper Jam , and Out of toner . The interactive menu can only be entered

while the print engine and controller are idle. The interactive menu allows the user to review and change certain NVRAM, I/O ports and peripheral parameters. Using the front panel to review and change parameters is discussed in Chapter 9, “Checks and Adjustments.”

Ready , Receiving data and

Buttons

cancel an operation while in the interactive menu. The functions of Buttons 2, 3 and 4 are deﬁned by the particular menu or function being displayed on the LCD display. The bottom row of the LCD labels the current function of each button.

In addition, pressing the buttons as you turn on the printer enables certain diagnostic modes:

■

The Chapter 9 topic, “Resetting NVRAM” on page 9-9 explains how to use the front panel buttons to reset the NVRAM to its factory default values.

Button 1, the left-most button, is labeled the Exit key and is used to

Pressing and holding Button 1, as you turn on the printer, skips power-up diagnostics (except for a brief kernel test) and proceeds to PostScript startup.

Pressing and holding Button 2, as you turn on the printer, executes extended diagnostics.

Pressing and holding Button 3, as you turn on the printer, executes interactive service tests. These are described in “Printer self-diagnostics” on page 9-6.

1-6

Phaser 540 Color Printer

Page 7

General Information

LEDs

The Power LED indicates the printer has +5 VDC available for its logic

control boards.

The

Error LED has three indications:

■

Off indicates that no errors have been detected.

■

indicates a warning to the user. An explanatory message, such as

Low Paper , is displayed on the LCD.

Blinking indicates an error has been detected. An error message, such

■

Paper Jam at Output , is displayed on the LCD. Error codes

as, are listed and explained in the Section 6 topic, “Error messages” on page 6-19.

Exit

Button 1

Button 2

Button 3

Button 4

Figure 1-5 The front panel and its functions

Power Error

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General Information

Rear panel

Connectors

The rear panel of the Phaser 540 printer features the host interface connectors to the printer. It includes the following connectors:

Standard parallel (high-density connector).

■

SCSI high-density connector (font hard disk drive or Phaser CopyStation only).

With the addition of a network card, the printer can feature either of these groups of connectors:.

■

ThinNet (10base2) and Twisted Pair (10baseT) Ethernet connectors. This is Option P1 and P2.

■

RS-232 serial and LocalTalk connectors. This is Option P2

Unshielded Twisted Pair (10baseT) and shielded Twisted Pair (DB-9)

■

Token Ring connectors. This is Option P4.

The ﬁgure below illustrates the rear panel.

Parallel

Smart card slot for network card

Phaser™ Share

Ethernet Card

10Base2

Link

RX

10Base-T

LocalTalk/Serial Card

Phaser™ Share

Serial LocalTalk®

RS-232 serial

LocalTalk

1-8

Figure 1-6 The Phaser 540 rear panel

Phaser 540 Color Printer

SCSI

Option P1 P2

Option P3

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Network card LEDs

The Ethernet network card has two LED indicators:

■

Note

General Information

TX indicator (yellow); blinks while data is transmitted to the host. The LED is off while no data is being sent.

Twisted Pair (10baseT). RX indicator (green); blinks while the

network card is receiving data. The LED is being received. If the LED is hardware) has occurred at the network hub.

ThinNet (10base2). RX indicator (green); blinks while the network

card is receiving data. The LED is received. If the LED is has occurred at the network hub.

Do not use both Ethernet connectors at the same time. If both are used the 10base2 line is ignored.

on steady , then a problem (probably hardware)

off steady , then a problem (probably

off stead y while no data is being

on steady while no data is

Test print button

The Token Ring network card has two LED indicators:

■

Connection (yellow); off when the printer is not inserted into the Token

blinks while the printer is attemping to insert itself into the Token

Ring, Ring,

Ring Speed (green); off when the card is set for 4 megabits per second

■

(MBPS),

When both LEDs blink, a network card failure has occured.

■

In the center of the rear cabinet panel is the test print button. Pressing this button while the printer is idle causes the print engine to print a built-in test print. The print is made independently of the image processor board.

when the printer is properly inserted in the ring.

when the card is set for 16 MBPS.

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General Information

Health LED

A health LED indicates the status of the image processor board. The health LED is mounted on the image processor board and is viewable through the grill behind the manual feed tray. (The grill is the removable RAM SIMM options cover.) Once the PostScript code is loaded into memory and the image processor is initialized and running, the image processor blinks the LED at a one-second rate.

Blinking (at a steady rate): The printer is operating normally. The LED

■

blinks irregularly during power-up self-diagnostics.

If a soft error occurs, the image processor board operates, but in a reduced capacity. Soft failures include failure of expansion memory SIMMs or any of the interface ports. When a soft error occurs, the printer automatically prints a startup page listing the error.

■

or Off : A hard error condition has occurred that would keep the

image processor board from operating.

Media tray type sensing

The combinations of the three tray sensors “tell” the print engine what type of paper tray is installed. The tray sensors are located on the left-side interior of the paper tray slot. Sensor actuators are attached to the bottom end of the tray to close the appropriate sensor. There are four tray types:

■

Letter (A-size) paper

Letter (A-size) transparency ﬁlm

■

Metric Letter (A4-size) paper

■ Metric Letter (A4-size) transparency ﬁlm

■ Legal-size paper (Phaser 540 Plus)

Table 1-1 Tray switch sensor combinations

Left switch Middle switch Right switch Tray type

Closed Open Open Letter (A-size) paper

1-10

Closed Closed Open Letter (A-size) transparency ﬁlm Open Open Closed Metric Letter (A4-size) paper Closed Open Closed Metric Letter (A4-size) transparency ﬁlm Open Closed Open Legal-size paper

Phaser 540 Color Printer

Page 11

General Information

Sensor actuators

Middle

Left

Right

Tray sensors

Figure 1-7 Tray switch sensors and actuators

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General Information

Speciﬁcations

Table 1-2 Physical dimensions

Dimensions Speciﬁcation

Height: Width: 48.3 cm (19 in.) With output tray: 69.6 cm (27.4 in.) Depth: 48.3 cm (19.5 in.)

45.7 cm (18 in.) With Lower Tray Assembly: 68.6 cm (27 in.)

Weight: Approximately 53.3 kgs (117 lbs.) with Lower Tray Assembly

and consumables installed. Approximately 39.1 kgs (86.2 lbs.) without Lower Tray Assembly.

Table 1-3 Printer clearances

Clearances Speciﬁcation

Top: 7.6 cm (3 in.) Left: 7.6 cm (3 in.) Right: 10.2 cm (4 in.) for handling the output tray Front: Unlimited for removal of consumable Rear: 15.3 cm (6 in.) for connecting computer cable and pow er cord Bottom: No obstruction under printer that could block its cooling vents. Mounting surface

ﬂatness:

Within 2 degrees of horizontal with all four feet in contact with the table surface.

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Phaser 540 Color Printer

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General Information

Table 1-4 Functional specifications

Characteristic Speciﬁcation

Printing process Electro-photographic, four color (CMYK) transfer printing

Color medium Four toner cartridges each contain one of four colors: cyan,

Addressability Standard mode: 300 x 300 dots-per-inch text and graphics

Printing speed Time from paper-load to paper-eject:

Minimum printing margins

Usable paper A-size (letter) and A4-size (Metric letter) and Legal-size of a

Paper tray capacity 250 sheets using 20-lb. paper. 100 sheets of transparency

magenta, yellow or black. The toner is a nonmagnetic, monocomponent contact medium.

Enhanced mode: 600 x 600 dpi text and graphics

Four-color 3.5 pages per minute at 300 dpi paper: 1.75 pages per minute at 600 dpi Monochrome: 14 pages per minute at 300 dpi 7 pages per minute at 600 dpi Four-color transparency: 1.3 pages per minute at 300 dpi

Print times do not include image processing time, which can vary depending on image complexity.

All sides, 5 mm (0.2 ins.).

good quality, or premium laser printer or copier paper.

ﬁlm. The optional Lower Tray Assembly also uses trays with the same capacity.

Table 1-5 Electrical specifications

Characteristic Speciﬁcation

Primary line voltages 87 to 128 VAC (115 VAC or 100 VAC nominal); 174 to 260

Primary voltage frequency range

Power consumption 60 watts (fuser off), 850 watts (fuser on) during Ready state,

Primary voltage fusing 110 VAC conﬁguration – 10 amp

Secondary DC voltages Image processor:

RF emissions Both 110 and 220 VAC-conﬁgured instruments pass these

VAC (220 VAC nominal) 47 to 63 Hz

950 watts during Warm-up state, 45 watts during Energy Star state

220 VAC conﬁguration – 6.3 amp

+ 5 VDC ± 0.25 (1A minimum, 6 A maximum) ± 12 VDC ± 0.6 (100 mA max)

Print engine: + 5V ± .25 (2.2 A max) + 12V ± .25 (0.4 A max)

- 12V ± .25 (0.1 A max) + 24V ± .25 (3.0 A max)

standards: FCC Part 15 Class B VDE Class B EN55022 (CISPR 22) Class B VCCI (CISPR 22) Class B

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General Information

Table 1-6 Environmental specifications

Characteristic Speciﬁcation

Temperature Operating Non-operating Storage

Humidity Operating Non-operating

10o to 32.5o C (50oto 91oF)

to 40o C (32o to 104o F)

-20

to 60o C (-4

to 140o F)

Media should be acclimated 24 hours before using in the printer.

10 to 80% relative humidity, non-condensing 10 to 90% relative humidity, non-condensing

Media should be acclimated 24 hours before using in the printer.

Altitude Operating Non-operating

Vibration/shock Operating

Non-Operating (vibration)

Non-operating (shock) Acoustic Noise

(operating)

0 to 2500 m (8,000 ft.) at 25

0 to 15000 m (50,000 ft.) (Fuser maximum 4000 m (13,300 ft.)

May drop any side or corner 50 mm (2 in.) without impairment of subsequent operation. On ﬁve mutually perpendicular axes: 0.5 g, 25-minute sweep, 5 to 200 to 5 Hz, 100 to 200 sec./sweep cycle. No resonant frequencies below 50 Hz. 30 g, trapezoidal ﬂared pulse, 20 msec each axis.

Aver age sound le vel (LEQ) is less than 53 dbA. Peak noise in standby mode is 47 dbA.

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Phaser 540 Color Printer

Page 15

Regulatory speciﬁcations

The printer is a recognized component in conformance with the following regulatory standards:

■ The packaged product meets ASTM D4169-86 and ASTM D4728-87

Transportation Standards.

■ Listed UL 1950 Information Processing and Business Equipment.

■ Certiﬁed CSA C22.2 No. 950 Safety of Information Technology

Equipment, Including electrical Business Equipment.

■ GS licensed IEC 950 (1991) Second Edition; EN60950 Information

Processing and Business Equipment.

■ VDE 0871/6.78 (Class B) Regulation for the Radio Frequency Interface

Suppression of High Frequency Apparatus and Installations.

■ VDE 0875, Regulation for RFI Suppression of Electrical Equipment

and Installations

General Information

■ EN55022 (CISPR 22) Class B

VCCI (CISPR 22) Class B

■ FCC Class B (for 115 VAC equipment) pursuant to Sub-part J

of Part 15.

Service Manual

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Page 17

Service Manual

Phaser

540 and Phaser

Color Printers

540 Plus

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 operating instructions unless you are qualified to do so.

This printing June 1995 070-9013-01

Page 18

1995 by Tektronix, Inc., Wilsonville, Oregon. Printed in the United States of America. All rights

reserved. Contents of this publication may not be reproduced in any form without permission of Tektronix, Inc.

This instrument, in whole or in part, may be protected by one or more U.S. or foreign patents or patent applications. Information provided upon request from Tektronix, Inc., P.O. Box 1000, Wilsonville, Oregon 97070-1000.

If acquired subject to FAR or DFARS, the following shall apply:

Unpublished — rights reserved under the copyright laws of the United States.

■

Restricted Rights Legend — Use, duplication or disclosures by the government is subject to restrictions as set forth in subparagraph (c) (1)(ii) of the Rights in Technical Data and Computer Software at DFARS 252.227-7013, or in subparagraph (c) (2) of the Commercial Computer Software – Restricted Rights clause at FAR 52.227-19, as applicable. Tektronix, Inc., P.O. Box 1000, Wilsonville, Oregon 97070-1000.

Tektronix

is a registered trademark of Tektronix, Inc. TekColor™ and Photoﬁne™ are trademarks of Tektronix, Inc.

Phaser™ is a trademark of Tektronix, Inc. for color printers and related products.

Adobe™ and PostScript™ are trademarks of Adobe Systems, Incorporated which may be registered in certain jurisdictions.

EtherTalkg

is a registered trademark of Apple Computer, Incorporated.

Times™, Helvetica™, and Palatino™ are trademarks of Linotype-Hell AG and/or its subsidiaries.

Micronta

Microsoft

is a registered trademark of Radio Shack.

and Microsoft Windows® are registered trademarks of Microsoft Corporation.

Novell

OS/2

PANTONE

and NetWare

is a registered trademark of International Business Machine Corporation.

* Colors generated by the Phaser 540 and 540 Plus Color Printers are four-color process simulations and

are registered trademarks of Novell, Inc.

may not match PANTONE-identiﬁed solid color standards. Use current PANTONE Color Reference Manuals for accurate colors.

PANTONE Color simulations are only obtainable on these products when driven by qualiﬁed Pantone-licensed software packages. Contact Pantone, Inc. for a current list of qualiﬁed licensees. * Pantone, Inc.’s check-standard trademark for color reproduction and color reproduction materials. © Pantone. Inc., 1988.

TCP/IP is a trademark of FTP Software. Copyright (c) 1986, 1987, 1988, 1989 by FTP Software, Inc. All rights reserved. PC/TCP for DOS is based on a set of programs originally designed and developed by the Massachusetts Institute of Technology. FTP Software has made extensive modiﬁcations and enhancements to the M.I.T. programs.

TokenTalk® is a registered trademark of Apple Computer, Incorporated.

TORX™ is a trademark of TEKTRON.

The X Window System™ is a trademark of Massachusetts Institute of Technology.

Other marks are trademarks or registered trademarks of the companies with which they are associated.

TE/JG

Page 19

Users safety summary

Terms in manual:

Power source:

conductor and ground. Use only the speciﬁed power cord and connector. Refer to a qualiﬁed service technician for changes to the cord or connector.

Operation of product:

product. Do not operate without the covers and panels properly installed. Do not operate in an atmosphere of explosive gases.

Safety instructions: Terms on product:

cover the hazardous area. Also applies to a hazard to property including the product itself.

DANGER A personal injury hazard exists in the area where you see the sign.

Care of product:

power cord or plug is frayed or otherwise damaged, if you spill anything into the case, if product is exposed to any excess moisture, if product is dropped or damaged, if you suspect that the product needs servicing or repair, and whenever you clean the product.

Ground the product:

necessary, contact a licensed electrician to install a properly grounded outlet.

Symbols as marked on product:

CAUTION Conditions that can result in damage to the product. WARNING Conditions that can result in personal injury or loss of life.

Does not apply more than 250 volts RMS between the supply conductors or between either supply

Avoid electric shock by contacting a qualiﬁed service technician to replace fuses inside the

Read all installation instructions carefully before you plug the product into a power source.

CAUTION A personal injury hazard exists that may not be apparent. For example, a panel may

Disconnect the power plug by pulling the plug, not the cord. Disconnect the power plug if the

Plug the three-wire power cord (with grounding prong) into grounded AC outlets only. If

DANGER high voltage:

Protective ground (earth) terminal:

Use caution. Refer to the manual(s) for information:

Laser use caution. Refer to the manual(s) for information:

WARNING:

cause an electrical shock. Electrical product may be hazardous if misused.

If the product loses the ground connection, usage of knobs and controls (and other conductive parts) can

Page 20

Service safety summary

For qualiﬁed service personnel only: Do not service alone:

Do not perform internal service or adjustment of this product unless another person capable of

Refer also to the preceding Users Safety Summary.

rendering ﬁrst aid or resuscitation is present.

Use care when servicing with power on:

Dangerous voltages may exist at several points in this product. To avoid

personal injury, do not touch exposed connections and components while power is on.

Disconnect power before removing the power supply shield, soldering, or replacing components.

Do not wear jewelry:

Remove jewelry prior to servicing. Rings, necklaces, and other metallic objects could come into

contact with dangerous voltages and currents.

Power source:

This product is intended to operate from a power source that will not apply more than 250 volts rms between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.

This product is certiﬁed under IEC 825 as a Class 1 Laser Product.

DANGER:

Invisible laser radiation when open and interlock defeated. AVOID DIRECT EXPOSURE TO BEAM.

PELIGRO:

Cuando se abre y se invalida el bloqueo, se producen radiaciones invisibles de láser. EVITESE LA

EXPOSICION DIRECTA A TALES RAYOS.

CAUTION:

Invisible laser radiation when open and interlocks defeated. AVOID DIRECT EXPOSURE TO BEAM.

VARNING:

Osynlig laser- strálning när denna del är öppnad och spärrar är urkopplade. STRÅLEN ÄR FARLIG.

VORSICHT:

Unsichtbare Laserstrahlung, wenn Abdeckung geöffnet und Sicherheitsverriegelung überbrückt. NICH DEM STRAHL AUSSETZEN.

VAROI:

Näkymätön avattaessa ja suojalukitus ohitettaessa olet alttiina lasersäteilylle. ÄLÄ KATSO SÄTEESEN.

ATTENTION:

Rayonnement laser invisible dangereux en cas d'ouverture et lorsque la sécurité est neutralisée. EXPOSITION DANGEREUSE AU FAISCEAU.

VARNING:

Osynlig laserstrálning när denna del är öppnad och spärrar är urkopplade. BETRAKTA EJ STRÅLEN.

ADVARSEL:

Usynlig laserstràling ved abning når sikkerhedsafbrydere er ude af funktion. UNDGÅ UD ÆTTELSE FOR STRÅLING.

Class 3B

ADVARSEL:

Usynlig laserstraling nar deksel åpnes og sikkerhedslas brytes. UNNGÅ EKSPONERING FOR STRÅLEN.

PJQT4521ZA

9008-78

Page 21

Index

Adobe PostScript Level 2 antistatic mat authorization code, TCP/IP automatic color correction

8-1

1-2

5-16

8-27

BBS

4-10

block diagram of printer

5-2

cleaning the printer clearances, printer communication parameters

serial and parallel ports communication setup conﬁguration page

description conﬁguring a Novell server for the printer conﬁguring TCP/IP connecting the printer to a Token Ring

network connecting the printer to an Ethernet network connecting the printer to the Macintosh connecting the printer to the PC connectors

rear panel

Customer Support Hotline

2-14

1-8

2-9

2-3

7-1

2-20

2-31

2-10

2-8

4-10

2-9

2-8

2-30

driver and communication setup

2-20

electronic bulletin board service Engine diagnostics (interactive) engine failure codes EuroHAL, automated fax system

6-19

4-10

9-7

4-8

2-9

ﬁeld replaceable units list Font Downloader Utility front panel

description front panel menu front panel, messages FRUs

removal and replacement

1-6

9-2

6-19

A-1

2-11

8-1

Graphics Supplies Order Desk

2-3

HAL, automated fax system hard error health LED Highly Automated Library (HAL)

1-10

4-7

image processor

2-3

9-5

4-4

troubleshooting image processor board

theory imaging unit sensitivity to light interface cables

5-18

Jams

6-11

key operator

training

4-1

laser electrophotography laser printing, theory

7-2

5-9

laser scanner Laserwriter Utility Lubrication

2-11

5-4

2-4

4-7

Service Manual

Index-1

Page 22

Macintosh

connecting the printer printing

using the Error Handler Utility Measuring power supply voltages Media problems Microsoft Windows

standard PostScript printer driver

3-1

6-8

2-8

3-4

6-3

2-24

network card, installing normal power-up self-test, image processor Novell conﬁguration Novell Netware veriﬁcation null modem cable

2-29

2-30

8-26

3-7

OS/2 connection veriﬁcation OS/2 Version 2, Tektronix driver OS/2 Version 2.0, loading drivers

3-6

2-25

paper path

6-8

jams

3-5

1-2

5-6

5-4

5-17

6-1

2-9

2-1

7-1

5-15

6-24

3-8

5-6

Paper picking,theory PC

connecting the printer

using the Error Handler Utility PC veriﬁcation Phaser 540

description photoconductive belt PostScript Level 2 power supply

verifying power supply theory power-up sequence pre-exposure during laser printing pre-installation interview preventive maintenance print modes, description print quality problems

6-3

9-6

printcap ﬁle printer

troubleshooting printer page description ﬁle printing from a Machintosh printing test prints

2-29

6-1

9-4

3-4

3-1

RAM and printer capabilities RAM SIMMs, installing rear panel

connector

description registration, checking regulatory standards removal procedures required tools, disassembly resetting NVRAM, image processor

1-8

9-10

1-15

8-1

1-2

8-24

8-1

9-9

safety interlock 6-5

printer

1-10

2-11

9-6

6-3

1-10

2-1

4-10

6-9

2-25

2-13

4-7

SCSI address SCSI hard disk drive, installing on the

self-test modes

image processor self-test print sensing media Service Option S0 service support, calling skewed copy soft error Standard Windows PostScript driver

updating startup page

description supplies, ordering

Index-2

Phaser 540 Color Printer

Page 23

TCP/IP, conﬁguring 2-31 TCP/IP, enabling TCP/IP, veriﬁcation of printing TekColor terminator, SCSI Test Pattern Generator

test patterns

testing the print engine theory of laser printing Timeouts, Windows toner cartridges during printing Transmission Retry, Windows tray sensors troubleshooting

troubleshooting the printer

2-20

using

descriptions

image processor

8-27

2-11

B-1

6-2

5-4

2-23

1-10

9-5

6-1

using the Error Handler utility

for Macintosh

3-8

for PC for workstation

3-4

3-10

3-9

5-10

verifying a PC can print 3-5

verifying a workstation can print

verifying and printing using the TCP/IP

protocols

3-9

Windows 3.1 driver veriﬁcation 3-5

Windows 3.1, Tektronix driver

Windows printer driver

conﬁguring installing

workstation

connecting the printer

using the Error Handler Utility workstation veriﬁcation wrinkled print

2-22

2-21

6-28

2-21

2-9, 2-10

3-10

3-9

Service Manual

Index-3

Page 24

Page 25

Appendix

Test Pattern Generator

The Test Pattern Generator contains PostScript scripts to start test patterns for a number of Tektronix color printers. It allows you to test a printer as if it were receiving a ﬁle from a host computer. The test patterns are generated by the printer's image processor and then printed by the print engine.

Note

The Test Pattern Generator should contain ﬁrmware version 1.2 or higher.

Service Manual

D-3

Page 26

Test Pattern Generator

To use the Test Pattern Generator, do the following:

Select a test pattern to be printed using the Test Pattern Generator's ﬁve DIP switches. The following tables lists the available test patterns.

Plug the Test Pattern Generator onto the printer's parallel port. Use the parallel cable adapter (013-0299-00) to convert between the Test Pattern Generator’s Centronics-style connector and the printer’s new-style, high-density parallel port connector. You do not have to turn the printer off; you can plug in the Test Pattern Generator “hot.”

Press the Test Pattern Generator's START button. Its green LED ﬂashes as you press the button.

The printer will print the transmitted print ﬁle. The front panel displays the message “Waiting for data,” with the READY light ﬂashing, for ﬁve minutes after a test print has been sent to the printer. However, you do not have to wait ﬁve minutes before sending another test print from the Test Pattern Generator; the printer will accept another test print.

Besides print ﬁles, the test pattern generator also allows you to turn off and on the printer's startup page.

Additionally, the Test Pattern Generator lets you set up a printer for printing from a 4511A Network Interface. To do so, just select the appropriate DIP switch setting.

Table D-1 Test Pattern Generator DIP Switch settings for Phaser 540

Pattern or function 1 2 3

Print quality test pattern On On On On On Blank sheet Off On On On On Engine Pattern 1

(100%) Service print 1 Off Off On On On Blank sheet On On Off On On Engine pattern 2 (50%) Off On Off On On Service print 2 On Off Off On On Enable startup page Off Off Off On On Disable startup page On On On Off On

On Off On On On

D-4

Phaser 540 Color Printer

Page 27

Appendix

Wiring Diagram

Power  supply fan

Door- open switch

Power switch

Fuser- installed sensor

SCSI

Parallel

Serial

Network card

Front panel

J24

J11

Image

processor

J12

CN 853

CN 851

CN 802

CN 804

J22

CN 854

Power supply

J21

CN 855

CN 852

CN 805

Laser driver board

CN 501

CN 1

CN 5

CN 12

CN 503

CN 8CN 3

Engine control board

CN502

CN 11

CN 16

CN 4

CN 9

CN 7

CN 6

CN 13

CN 540

Laser scanner

CN 1

CN 570

CN 701

High voltage power supply board

CN 627

Image density sensor connector

CN 619

Toner cartridge level sensor (Receiver) and roller clutch board

CN 625

Charger unit sensor board

CN 624

Imaging unit

CN 632

Accumulator belt position sensor

Toner cartridge sub bias board

FTR Orange DEV Yellow STR Black CHG Red PTC White GRID Blue

CN 628

BK sensor

CN 620 CN 621

CN622 CN623

CN 626 CN 630

B Y M C

Pre-exposure lamp

CMY sensor

Fuser

Left door closed sensor

Fuser fan

Paper-feed motor

Developer cartridge drive motor

Main motor

Cleaning board

Paper tray switches

CN 618

CN 307

CN 312

CN 304

CN 306

CN 305

CN 313

CN 302 CN 311

CN 2

CN 301

Engine driver board

CN 310

Optional lower tray assembly

CN 14

CN 17

CN 303

CN 309

CN 308

Ozone fan

Toner cartridge level (transmitter) sensor

Pre-transfer lamp

CN 601

Paper feeder

Exit tray full 

CN 617

sensor

CN 611

Exit roller sensor board

Toner cartridge

CN 615

movement sensor

CN 616

Cam motor  board

CN 603

CN 604 CN 602 CN 606 CN 605

CN 614

CN 612

CN 613

Paper-pick sensor

Transp sensor

Registration sensor

Transfer roller solonoid

Registration clutch

Fuser exit

CN 610

sensor

Switchback solenoid

Face switching solenoid

9013-52

Figure C-1 Wiring diagram

Service Manual

C-1

Page 28

Page 29

Contents

1 General Information

The Phaser 540 Color Printers 1-2

RAM and printer capabilities 1-2 Print engine assemblies 1-3 Front panel 1-6 Rear panel 1-8

Network card LEDs 1-9

Test print button 1-9

Health LED 1-10

Media tray type sensing 1-10 Specifications 1-12

Regulatory specifications 1-15

2 Installing the Printer and Drivers

Pre-install questions for customers 2-2 Unpacking 2-5

Printer inventory 2-5

Accessory box 2-5 Setting up the printer 2-7

Installing SIMM memory 2-7

Installing a network card 2-7 Cabling the printer 2-8

Connecting the printer to a Macintosh 2-8

LocalTalk connection to a Macintosh 2-8 Ethernet connection to a Macintosh 2-8

Connecting the printer to a PC 2-9

Direct connection to a PC 2-9 Networked connection using the Ethernet port 2-9 Networked connection using the Token ring port 2-9

Connecting the printer to a workstation 2-10

Direct connection to the workstation 2-10 Networked connection to a workstation 2-10

Networked connection using the Token Ring port 2-10 Connecting an optional SCSI hard disk drive to the printer 2-11 Connecting the optional CopyStation to the printer 2-12

Turning on the printer 2-13

The startup page 2-13 The configuration page 2-14

Service Manual

Page 30

Driver and communication set up 2-20

Loading the Macintosh driver 2-20 Installing the Tektronix driver for Windows 3.1 2-21

If you have other Tektronix printer drivers already installed 2-21

Configuring the Tektronix Windows printer driver 2-22 Updating the standard Microsoft Windows PostScript driver 2-24 Installing the printer driver for OS/2 Version 2 2-25 Configuring the printer's serial port for a PC 2-27 Using printcap to configure a workstation for the printer's serial port 2-29 Configuring a Novell NetWare server for the printer 2-30 Configuring TCP/IP on a UNIX host 2-31

3 Verifying the Printer and Host Connections

Macintosh verification 3-1

Selecting the printer via the Chooser 3-1

Printing the directory from a Macintosh 3-3 Verifying that an application communicates to the printer 3-4 Using the Error Handler utility 3-4

PC verification 3-5

DOS connection verification 3-5 Windows 3.1 driver verification 3-5 OS/2 connection verification 3-6 Novell NetWare verification 3-7

Send a print file to the printer 3-7 Using the Error Handler utility 3-8

Workstation verification 3-9

Verifying connection and printing using TCP/IP protocols 3-9 Using the Error Handler utility 3-10

xvi

Phaser 540 Color Printer

Page 31

4 Key Operator Training

Overview 4-1 Printer controls and indicators 4-2 Loading media 4-3 Customer-replaceable consumables 4-4

Imaging unit 4-4 Toner cartridges 4-4 Transfer roller 4-4

Fuser 4-4 Clearing paper jams 4-5 Cleaning 4-5 Warranty information 4-6 Service support 4-6 Supplies ordering 4-7 If you need help 4-7

Using the automated fax systems 4-7

Tektronix Color Printer Information Server 4-9

Customer Support Hotline 4-10

Service support 4-10

Electronic bulletin board service 4-10

5 Theory of Operation

Overview 5-1 Functional block diagram 5-2 Laser imaging 5-4

Overview 5-4

Pre-exposure 5-6

Electrostatic charging 5-7

Laser exposure 5-8

The laser scanner 5-9

Toner pickup (development) 5-10

Toner transfer to the accumulator belt 5-11

Paper picking 5-12

Toner transfer to paper 5-13

Fusing and exiting 5-14

Print modes 5-15

Automatic color correction 5-16 Power supply 5-17 Image processor 5-18

Image rendering technology 5-18

Service Manual

xvii

Page 32

6 Troubleshooting

System power-up sequence 6-1 Print engine troubleshooting 6-2

Testing the print engine 6-2 Verifying printer operation by using its self-test print 6-3 Verifying power supply operation 6-3

Measuring power supply voltages 6-3 Inspecting the power supply fuses 6-5 Safety interlocks 6-5

Testing for a shorted motor 6-6 Testing motor resistances 6-7 Media jams and the paper path 6-8

Media-based problems 6-8 Media problems 6-8

Multiple-sheet pick 6-8

The printer is not distinguishing between paper and transparency film 6-9

The media skews passing through the paper path 6-9

Paper tray indicates empty when it is not 6-10

No paper feeder installed 6-10

No imaging unit installed 6-10 Jams 6-11

Paper mis-picks at the paper tray 6-11

Paper jams midway in the paper feeder 6-11

Paper jams at the second bias transfer roller 6-12

Fuser jams 6-13

Eject jams 6-13

Manual feed jams 6-14 Other problems 6-15

Waste tray for the photoconductive belt cleaner shows full when it is not 6-15

Transfer roller waste tray indicates not full when it is 6-15

No toner cartridge installed when it is 6-15

No pre-transfer charger installed when it is 6-16

No fuser installed when it is 6-16

Front door open when it is closed 6-16

Left-side door open when it is not 6-17

High temperature error 6-17

Low temperature error 6-17

High voltage error 6-18

Thermistor open error 6-18

Power supply fan does not run 6-18

xviii

Phaser 540 Color Printer

Page 33

Error messages 6-19 Print engine error codes 6-19 Printing and print quality problems 6-24

Blank print 6-24 All-black print 6-24 Missing primary color 6-24 Light print 6-25 Dark vertical line in print 6-25 Wavy light vertical lines in print 6-25 White horizontal line or band in all the colors of a print 6-25 White vertical lines in the print 6-26 Dirty background 6-26 Mis-transfer, missing portions of toner 6-26 Partial black dots 6-26 Dark, irregular steaks in all colors 6-26 Ghosting 6-27 Unfused or partially fused printing 6-27 Image is skewed on the paper 6-27 Stains on the back of the print 6-27 No printing on edge of print 6-28 Image is not centered on the print when it should be 6-28 The print is wrinkled 6-28

Macintosh printing problems 6-29

Image never prints 6-29 Image prints in black-and-white 6-29 Image is rotated 90 degrees 6-29 Printer isn’t in the Chooser 6-30

PC DOS printing problems 6-30

Image never prints 6-30

Windows printing problems 6-32

Image never prints 6-32 Blue color on the screen is printing too purple 6-32 Windows message “Problem writing device LPT1: Cancel or Retry” 6-32

Workstation printing problems 6-33

Image never prints 6-33

Service Manual

xix

Page 34

7 Cleaning and Maintenance

Service preventive maintenance procedure 7-1 Recommended tools 7-1 Cleaning 7-2 Lubrication 7-2

8 FRU Disassembly/Assembly

Required tools 8-1 The printer cabinet 8-2

Upper rear cover 8-2 Lower rear cover 8-2 Top cover 8-2 Left door (for paper feeder access) 8-2 Left side cover 8-2

Manual feed tray 8-2 Front door 8-4 Upper and lower front covers 8-4 Bottom front cover 8-4 Front panel board 8-4 Toner level sensor board 8-4 Right side covers (front, rear and lower) 8-5

Paper feeder 8-6 Paper tray sensor board 8-6 Cartridge selector/eject unit (right door) 8-8 Laser scanner 8-9 Laser modulation board 8-10 Power supply 8-11 Fuser installed switch 8-11

Power supply fuse 8-13

Printer rear assemblies 8-14

Engine control board 8-14 Engine driver board 8-14 Charger sensor board 8-15 Main motor 8-16 Paper feed motor 8-16 Cleaning board 8-16 Toner cartridge drive unit 8-18 Home position sensor assembly and the left door opened switch 8-18

High-voltage board 8-20 Pre-exposure lamp 8-21 Pre-transfer lamp 8-21

Phaser 540 Color Printer

Page 35

Toner auto-density sensor 8-21 Image processor board 8-23 Installing RAM SIMMs 8-24 Installing a network card 8-26

Enabling TCP/IP with the authorization code 8-27

Replacing the code ROM SIMM 8-28

9 Checks and Adjustments

Required tools 9-1 Front panel menu 9-2 Printing test prints 9-4

Print service test prints 9-4 Printing the configuration page 9-4 Printing the demonstration pages 9-4

Printing the print engine’s test print 9-4 Image processor normal indicators 9-5 Image processor hard and soft error indicators 9-5 Printer self-diagnostics 9-6 Resetting NVRAM 9-9 Print engine calibration 9-10 Checking print registration 9-10

A Field Replaceable Units List

B Test Patterns

C Wiring Diagram

D Test Pattern Generator

Index

Service Manual

xxi

Page 36

Figures

Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7

Figure 2-1 Figure 2-2 Figure 2-3

Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11 Figure 5-12 Figure 5-13 Figure 5-14

The Phaser 540 Color Printer 1-1 Print engine major components 1-3 Print engine components (continued) 1-4 Print engine sensor, switch and solenoid locations 1-5 The front panel and its functions 1-7 The Phaser 540 rear panel 1-8 Tray switch sensors and actuators 1-11

The Phaser 540 and its packaging 2-6 Connecting a SCSI hard disk drive to the Phaser 540 2-11 Connecting a CopyStation to the Phaser 540 2-12

Block diagram of the printer 5-2 Laser printing process overview 5-5 Pre-exposing the photoconductive belt 5-6 Electrostatic charging of the photoconductive belt 5-7 Laser exposure of the photoconductive belt 5-8 The laser scanner 5-9 Toner pickup 5-10 Toner transfer to the accumulator belt 5-11 Paper picking 5-12 Transferring toner to the paper 5-13 Fusing the toner to the paper 5-14 Print modes and printing dots 5-15 The power supply 5-17 The image processor graphics pipeline 5-19

Figure 6-1 Figure 6-2

xxii

Measuring the DC voltages (test points) 6-4 Door safety interlock switches 6-6

Phaser 540 Color Printer

Page 37

Figure 8-1 Figure 8-2 Figure 8-3 Figure 8-4 Figure 8-5 Figure 8-6 Figure 8-7 Figure 8-8 Figure 8-9 Figure 8-10 Figure 8-11

Figure 8-12 Figure 8-13 Figure 8-14 Figure 8-15 Figure 8-16 Figure 8-17

Removing cabinet covers 8-3

Removing cabinet covers 8-5

Removing the paper feeder and the paper tray sensor board 8-7

Removing the cartridge selector/eject unit 8-8

Removing the laser scanner 8-9

Removing the laser modulation board 8-10

Removing the power supply and the fuser installed switch 8-12

Replacing the power supply fuse 8-13

Removing the engine control, engine driver and charger sensor boards 8-15

Removing the main motor, paper-feed motor and cleaning board 8-17

Removing the toner cartridge drive unit, home position sensor and

the left door interlock switch 8-19

Removing the high-voltage board 8-20

Removing the pre-exposure lamp, pre-transfer lamp and toner auto-density sensor 8-22

Removing the image processor board 8-23

Installing RAM SIMMs 8-25

Installing a network card in the printer 8-26

Installing the code ROM SIMM 8-28

Figure 9-1 Figure 9-2 Figure 9-3

Figure A-1 Figure A-2 Figure A-3

Figure C-1

Menu map 9-2

Menu map 9-3

Checking the registration of the toner layers 9-10

Cabinet FRUs A-2

Cabinet FRUs A-3

The internal printer A-5

Wiring diagram C-1

Service Manual

xxiii

Page 38

Tables

Table 1-1 Table 1-2 Table 1-3 Table 1-4 Table 1-5 Table 1-6

Table 2-1 Table 2-2

Table 6-1 Table 6-2

Table A-1 Table A-2 Table A-3 Table A-4

Tray switch sensor combinations 1-10 Physical dimensions 1-12 Printer clearances 1-12 Functional specifications 1-13 Electrical specifications 1-13 Environmental specifications 1-14

Configuration page settings for the Phaser 540 2-14 Values for modifying the DEVPARAMS.PS file 2-28

Motor and solenoid resistances 6-7 Print engine service error codes 6-19

FRU parts list of the printer cabinet A-2 FRU part list of the printer cabinet A-3 FRU parts list of the exploded printer A-4 Supplies and accessories A-6

Table D-1

Test Pattern Generator DIP Switch settings for Phaser 540 D-4

xxiv

Phaser 540 Color Printer

Page 39

Appendix

Test Patterns

This appendix illustrates the test patterns produced by the print engine. It also illustrates a number of defective prints and the reason for the defects. Chapter 6

Troubleshooting discusses solutions to the problems shown in this appendix.

Phaser 540 test prints

Vertical streak of one color in the margin

This is usually caused by a leaking toner cartridge. Replace the toner cartridge.

Vertical line or scratch in print Single color If the scratch is of one missing primary color, then

the trouble can usually be traced to a scratch in the developer roller of the missing toner’s toner cartridge. No toner is transferred from the developer roller to the photoconductive belt at the defect point.

All colors The problem may be caused by contamination on the

laser window where the laser beam exits the laser scanner and enters the imaging unit. Since the blocked laser beam cannot discharge the portion of the photoconductive belt it cannot reach, toner will not transfer to those portions of the belt. Consequently a blank, vertical line will appear on the prints in all colors. Remove the imaging unit and, with a squeeze b ulb , b low an y dust or toner off of the window (located in the “ceiling” of the cavity left in the printer once the imaging unit is removed).

If it is in all colors then the problem may be in the imaging unit, which replacing will solve.

It could also be a scratched roller in the fuser which replacing will solve.

Lastly a protrusion of some kind in the paper path could be scratching the print.

Service Manual

B-1

Page 40

Test Patterns

Small, repeating light dot in one color

This can usually be traced to a dent-like defect in the developer roller of the toner cartridge in question. No toner is transferred from the developer roller to the photoconductiv e belt at the defect point.

Light, wavy, vertical streaks in all colors

This is caused by contamination on the pre-transfer charger corona wire. The contamination (usually toner) interf eres with the ﬂow of electrons from the wire to the toner on the accumulator belt. With the toner on the belt being unevenly charged, it transfers unev enly to the paper. Cleaning the corona wire usually ﬁxes this problem.

Service Manual

B-2

Page 41

Test Patterns

Contamination of one color by another color

This is most noticeable on solid primary ﬁlls. This is caused by a defective photoconductive belt cleaning belt. The blade is not scraping off all of the untransferred toner from the previous pass of the photoconductive belt to the accumulator belt prior to the next toner’s transfer to the photoconductive belt. Replacing the imaging unit corrects this problem.

Large smeared areas in the print

This is usually caused by the accumulator belt slipping on its rollers. Replacing the imaging unit solves this problem.

Service Manual

B-3

Page 42

Test Patterns

Single light, horizontal line in all the prints

This is probably caused by a defective photoconductive belt onto which toner will not transfer. Replace the imaging unit.

Large, random light smudges

Spots such as those illustrated are caused by ﬁngerprints on the photoconductive or accumulator belt. Often the smudges will gradually fade with additional printing. Alternately, the imaging unit will have to be replaced.

Service Manual

B-4

Page 43

Test Patterns

One or more dark vertical line in all colors

This can often be traced to a dirty scorotron charger corona wire. Contamination (dust or toner) interferes with the ﬂow of electrons from the wire to the photoconductive drum. Toner is then transferred to the area of low electron charge and consequently to the accumulator belt and ﬁnally the print. Remove the scorotron charger from the imaging unit and clean the charger’s corona wire. Alternately, replace the imaging unit.

Single, dark line near bottom of print

This is called a fuser stall. It is usually caused when the sheet of paper does not smoothly enter the fuser but momentarily stops, allowing the transfer roller (which is still transf erring toner from the accumulator belt to the paper) to transfer too much toner to the momentarily stalled paper. Fuser stalls are usually caused by excessively curled paper that does not properly enter the fuser rollers. Also ensure that there are no obstructions in the paper path.

Service Manual

B-5

Page 44

Test Patterns

Multiple, light, random horizontal lines. In all colors This is usually traced to a poor electro-mechanical

connection to the second bias transfer roller. The ﬂuctuating voltage to the transfer roller is causing irregular toner transfer to the paper. Clean the roller contacts or replace the transfer roller or the paper feeder.

In a single color This is usually traced to a poor

electro-mechanical connection to the particular toner cartridge. The ﬂuctuating voltage to the developing roller of the toner cartridge is causing irregular toner transfer to the paper. Clean the roller contacts or replace the toner cartridge or the toner cartridge bias assembly.

Blobs, spots, and streaks in all colors

The photoconductive belt cleaning blade is not properly cleaning the photoconductive belt. Replace the imaging unit

Service Manual

B-6

Page 45

Test Patterns

Faded, pale prints

The imaging unit is old or has been exposed to too much room light. Replace the imaging unit.

The image density sensors are not properly measuring the amount of toner transferred to the accumulator belt. Clean or replace the sensors.

The high-voltage board is not outputting sufﬁcient voltage to the second bias transfer roller, causing poor transfer of toner to paper. Likewise, low voltage to the toner cartridge will cause insufﬁcient transfer of toner to the photoconductive belt.

The beam from the laser scanner is weak and is not properly exposing the photoconductive belt. Poor laser exposure results in the negative charges remaining on the drum instead of being “erased” by the laser beam, thereby retarding toner transfer from the toner cartridges. Replace the laser scanner.

Dark, vertical streaks and smears on the entire page

This is usually due to the accumulator belt toner waste bin being ﬁlled and spilling out on the belt. The spilled toner is then being transferred to the print. A defective cleaning blade could also cause this. In either case, replacing the imaging unit should ﬁx the problem.

Service Manual

B-7

Page 46

Test Patterns

One primary color faded or pale

This indicates a problem with a single toner cartridge. Replacing the toner cartridge should ﬁx the problem.

If it does not, there may be a problem with the toner cartridge selector/eject unit. It may not be pushing the cartridge quite far enough to make proper contact with the photoconductive belt, resulting in poor toner transfer. Replace the toner cartridge selector/eject unit.

Lastly, poor electro-mechanical contact my be the problem, although this usually shows itself as light, horizontal streaks and lines. Replace the toner cartridge biasing assembly.

Interpreting Service Print 1

9013-60

Service Print 1, which is printed in 600 dpi, is useful for evaluating the condition of the imaging unit. With a properly functioning imaging unit and printer, you should see the following:

1. Diagonal lines. These two lines should be smooth and

unbroken.

2. Crosshairs. A thin white crosshair should be visible in each

block square.

3. 600 dpi parallel lines. Distinct parallel lines, both horizontal

and vertical, should be viewable. No mottling or blending should be seen. All vertical lines should be identical in appearance and thickness to their horizontal counterparts.

4. 2 pt. text. The 2point te xt, the smallest printed on the test print,

should be easily readable.

5. Registration. The top edges of each side-by-side solid ﬁll

should line up with each other.

6. Blended ﬁlls. The ﬁlls should be smooth and e v en in both the

primary and secondary color ﬁlls.

Service Manual

B-8

Page 47

Test Patterns

Phaser 540 Plus test prints.

The Test Print produced by the Phaser 540 Plus differ from those produced by the Phaser 540. Test Print consists of four 25% tint primary color bands. Service Print 1 prints out four 25% tint full page ﬁlls, each page one primary color. Service Print 2 shows 300 dpi printing.

From the Help Pages menu in the front panel, select Test Print

Test Print <--- ---> Print

Power

Error

From the Help Pages menu in the front panel, select Service Print 1

Service Print 1 <--- ---> Print

Power

Error

Black

Cyan

Magenta

Yellow

Imaging Unit XXXX Corona Wire XXXX

Test Print

Transfer Kit XXXX Fuser XXXX 

Black Cyan Magenta Yellow

Vertical line or scratch in print, single color

If the scratch is of one missing primary color, then the trouble can usually be traced to a scratch in the developer roller of the missing toner’s toner cartridge. No toner is transferred from the developer roller to the photoconductive belt at the defect point.

Vertical line or scratch in print, all colors

The problem may be caused by contamination on the laser window where the laser beam exits the laser scanner and enters the imaging unit. Since the b loc k ed laser beam cannot discharge the portion of the photoconductive belt it cannot reach, toner will not transfer to those portions of the belt. Consequently a blank, vertical line will appear on the prints in all colors. Remove the imaging unit and, with a squeeze bulb, blow any dust or toner off of the window (located in the “ceiling” of the cavity left in the printer once the imaging unit is removed).

If it is in all colors then the problem may be in the imaging unit, which replacing will solve.

It could also be a scratched roller in the fuser which replacing will solve.

Lastly a protrusion of some kind in the paper path could be scratching the print.

Service Manual

B-9

Page 48

Test Patterns

Small, repeating light dot in one color

Light, wavy, vertical streaks in all colors

Service Manual

B-10

Page 49

Test Patterns

Single light, horizontal line in all the prints

This is probably caused by a defective photoconductive belt onto which toner will not transfer. Replace the imaging unit.

Large, random light smudges

Service Manual

B-11

Page 50

Test Patterns

One or more dark vertical line in all colors

Faded, pale prints

The imaging unit is old or has been exposed to too much room light. Replace the imaging unit.

The image density sensors are not properly measuring the amount of toner transferred to the accumulator belt. Clean or replace the sensors.

Service Manual

B-12

Page 51

Test Patterns

Dark, vertical streaks and smears on the entire page

One primary color faded or pale OR a single color has a dark vertical streak

This indicates a problem with a single toner cartridge. Replacing the toner cartridge should ﬁx the problem.

Lastly, poor electro-mechanical contact my be the problem, although this usually shows itself as light, horizontal streaks and lines. Replace the toner cartridge biasing assembly.

Service Manual

B-13

Page 52

Test Patterns

Single white spot appear in the same place on the print

This indicates a bad spot has developed on one of the the imaging unit’s belt which will not trasfer toner. The imageing unit must be replaced.

Interpreting Service Print 2

9013-60

Service Print 2 is useful for evaluating the condition of the imaging unit. With a properly functioning imaging unit and printer , you should see the following:

1. Diagonal lines. These two lines should be smooth and

unbroken.

2. Crosshairs. A thin white crosshair should be visible in each

block square.

3. 300 dpi parallel lines. Distinct parallel lines, both horizontal

and vertical, should be viewable. No mottling or blending should be seen. All vertical lines should be identical in appearance and thickness to their horizontal counterparts.

4. 2 pt. text. The 2point te xt, the smallest printed on the test print,

should be easily readable.

5. Registration. The top edges of each side-by-side solid ﬁll

should line up with each other.

6. Blended ﬁlls. The ﬁlls should be smooth and e v en in both the

primary and secondary color ﬁlls.

Service Manual

B-14

Page 53

Figure A-3 The internal printer

9013-56

Service Manual

A-5

Page 54

Table A-4 Supplies and accessories

Part number Serial number

Effective Discontinued

Supply 016-1316-00 Imaging unit Supply 016-1323-00 Fuser (110 VAC) Supply 016-1354-00 Fuser (220 VAC) Supply 016-1317-00 Pre-transfer charger (corona wire kit) Supply 436-0282-00 Paper tray, Letter-size Supply 436-0283-00 Paper tray, A4-size Supply 436-0284-00 Transparency tray, Letter-size Supply 436-0285-00 Transparency tray, A4-size

436-0314-00 Paper tray, Legal-size 436-0297-00 Output tray 119-4799-00 Lower Tray Assembly (no trays supplied) 070-9008-01 Phaser 540 User Manual (English) 070-9008-11 Phaser 540 User Manual (French) 070-9008-21 Phaser 540 User Manual (Italian) 070-9008-31 Phaser 540 User Manual (German) 070-9008-41 Phaser 540 User Manual (Spanish) 070-9009-00 Phaser 540 Drivers and Utilities Printing

070-9109-00 Network Manual 070-9291-00 Phaser Share Administation Manual 070-9292-00 Phaser Share Status Monitor Manual 070-9013-01 Phaser 540 Service Manual 063-2179-00 Ethernet Network Software Kit

Quantity Name and description

Reference Manual

Table A-4 Supplies and accessories (cont'd.)

Part number Serial number

Effective Discontinued

016-1326-00 Transparency, Metric-size, 50 sheets 016-1368-00 Paper, A-size, 500 sheets 016-1369-00 Paper, A4-size, 500 sheets 013-0297-00 Adapter, Cable 103-0030-00 Adapter, Connector, BNC 011-0123-00 Coaxial Term. 50 ohms, BNC 016-1319-00 Black toner cartridge 016-1320-00 Cyan toner cartridge 016-1321-00 Magenta toner cartridge 016-1322-00 Yellow toner cartridge 161-0066-00 Power cord, domestic 161-0066-09 Power cord, 220V Euro 161-0066-10 Power cord, U.K. 161-0066-11 Power cord, Australian 161-0154-00 Power cord, Swiss 334-8366-22 Logo - Phaser 540 334-8366-32 Logo - Phaser 540 Plus 016-1318-00 Transfer Kit (Transfer roll and Waste box) 118-9070-00 Scorotron charger corona unit 006-7998-00 Conductive grease 118-9175-00 Pre-transfer corona cleaning tool 006-7971-00 Imaging unit light shield/drape

Quantity Name and description

A-6

063-2181-00 LocalTalk Network Software Kit 063-2089-00 Drivers and Utilities Software Kit 012-1379-00 Cable Serial, 9-pin to 9-pin 012-1299-00 Cable, interconnect., 2.5 m 50-pins. to

25-pins 012-1468-00 Cable, Parallel w/IEEE 1284C (mini) 012-1465-00 Cable, SCSI II to 50-pin SCSI 012-1380-00 Cable, Serial, 9-pin to 25-pin 013-0299-00 Parallel cable adapter (standard to mini) 003-1496-00 Toner Vacuum (115 VA C) 003-1497-00 Toner Vacuum (220 VA C) 003-1498-00 Filter for 3M Toner Vacuums 016-1325-00 Transparency, Letter-size, 50 sheets

Phaser 540 Color Printer

Page 55

Appendix

Field Replaceable Units List

This appendix provides a list of ﬁeld replaceable units for the printer.

Changes to Tektronix instruments are made to accommodate improved components as they become available. It is important when ordering parts to include the following information:

■

Component's part number.

Instrument type or number.

■

Instrument serial number.

■

Modiﬁcation number, if any.

Service Manual

A-1

Page 56

Field Replaceable Units List

Table A-1 FRU parts list of the printer cabinet

Figure A-1

1 118-9205-00 1 Front door 2 118-9204-00 1 Lower front cover 3 118-9203-00 1 Upper front cover w/display board 4 118-9206-00 1 Right side cover rear 5 118-9208-00 1 Right side cover front 6 118-9207-00 1 Right side cover lower 7 118-9182-00 1 Bottom front cover

Part number Serial number

Effective Discontinued

Quantity Name and description

Figure A-1 Cabinet FRUs

A-2

Phaser 540 Color Printer

9013-44

Page 57

Field Replaceable Units List

Table A-2 FRU part list of the printer cabinet

Figure A-2

1 118-9202-00 1 Lower rear cover 2 118-9201-00 1 Upper rear cover 3 118-9198-00 1 Top cover 4 118-9200-00 1 Left side cover 5 118-9199-00 1 SIMM access door 6 118-9184-00 1 Manual feed tray 7 118-9183-00 1 Left door

Part number Serial number

Effective Discontinued

Quantity Name and description

Figure A-2 Cabinet FRUs

9013-45

Service Manual

A-3

Page 58

Field Replaceable Units List

Table A-3 FRU parts list of the exploded printer

Figure A-3

1 118-9192-00 1 Ozone fan 2 118-9189-01 1 Engine control board 3 118-9191-00 1 Fuser/toner cartridge fan 4 118-9154-00 1 Power Supply (110 VAC) 4 118-9153-00 1 Power Supply (220 VAC) 5 118-9181-00 1 Toner cartridge drive motor 6 118-9186-00 1 Toner cartridge selector/paper-eject unit 7 118-9187-00 1 Laser scanner 8 118-9188-00 1 Laser modulation board 9 118-9166-00 1 Pre-transfer lamp 10 118-9169-00 1 Toner cartridge biasing assembly 11 118-9170-00 1 Toner level sensor board 12 118-9164-00 1 Pre-exposure erase lamp 13 118-9165-00 1 Image density sensor assembly 14 118-9167-00 1 Tray sensor board 15 118-9185-00 1 Paper feeder 16 118-9163-00 1 High-voltage board 17 671-3133-00 1 16-Mbyte RAM SIMM 18 671-3108-06 1 Image processing board w/rear panel 19 671-3468-00 1 Ethernet network card 19 671-3469-00 1 LocalTalk/serial network card 19 671-3470-00 1 Token Ring network card 20 118-9196-00 1 Engine driver board 21 118-9173-00 1 Left door-open switch 22 118-9193-00 1 Main motor 23 118-9172-00 1 Home-position sensor assembly 24 118-9171-00 1 Charger sensor board 25 118-9194-00 1 Paper feed motor 26 118-9190-00 1 Fuser installed switch 27 118-9195-00 1 Cleaning board 28 118-9168-00 1 Toner cartridge drive unit 29 671-3210-00 1 P540 PostScript Code ROM SIMM

29 671-3210-01 1 P540 Plus PostScipt Code ROM SIMM

29 671-3209-00 1 P540 PostScript Code ROM SIMM

29 671-3209-01 1 P540 Plus PostScript Code ROM SIMM

Part number Serial number

Effective Discontinued

118-9174-00 1 Hardware kit 118-9176-00 1 Gear kit

Quantity Name and description

(masked ROM - avail July ‘95)

(ﬂash ROM - avail until July ‘95)

A-4

Phaser 540 Color Printer

Page 59

Chapter

Checks and Adjustments

This chapter discusses using the front panel’s interactive mode to review and change the printer’s operation. It also contains the procedures to calibrate the printer after you replace key Field Replaceable Units and to evaluate the printer's functionality.

Required tools

■

Magnifying lens (preferably illuminating)

Phillips screwdriver

Service Manual

9-1

Page 60

Checks and Adjustments

Front panel menu

The print engine features an interactive front panel menu that allows you to review or change the printer’s stored parameters as well as initiate test prints and printer service routines. When the front panel displays to enter the printer’s interactive menu.

Idle

Ready , p ress Menu

Test Page

Demonstration Pages

Startup Page

Configuration Page

Service Print 1

Service Print 2

Menu Map

System counts menu

Page count

Imaging Unit

Corona Wire

Transfer Kit

Fuser

TekColor Correction menu

TekColor: None

TekColor: Vivid Color

TekColor:Display

TekColor: SWOP

TekColor: Euroscale

TekColor: Commercial

Monochrome

Print Quality menu

Standard

Enhanced

Fast

Printer defaults menu

Default tray

Upper

Middle

Lower

Media Tray

Manual Feed

Paper

Transparency

Auto Select

Startup Page

Startup Page: enabled

Startup Page: disabled

Startup Mode

Startup Mode: enabled

Startup Mode: disabled

Figure 9-1 Menu map

9-2

Phaser 540 Color Printer

Output order

Output order: face up

Output order: face down

Energy Star

Energy Star: enabled

Energy Star: disabled

Energy Star timeout

Energy Star timeout: xxx hrs

Timeout: xxx hrs

9013-54

Page 61

Serial settings

Baud Rate

Baud Rate: 300

Baude Rate: 600

Baud Rate: 1200

Baud Rate: 2400

Baud Rate: 4800

Baud Rate: 9600

Baud Rate: 19200

Baud Rate: 38400

Network settings

TCP/IP

TCP/IP: enabled

TCP/IP: disabled

Ether Talk

Ether Talk: enabled

Ether Talk: disabled

Novell

Novell: enabled

Language menu

Language: English

Language: Español

Language: Français

Language: Deutsch

Language: Italiano

Language: Japanese

Checks and Adjustments

Data Bits

Data Bits: 7

Data Bits: 8

Stop Bits

Stop Bits:1

Stop Bits: 2

Parity

Flow Control

Novell: disabled



Even

Odd

Mark

Space

None

Xon/Xoff

dtr

Figure 9-2 Menu map

9013-55

Service Manual

9-3

Page 62

Checks and Adjustments

Printing test prints

The prints printed via the front panel the are generated by the image processor. While the printer is idle you can use the front panel to print a conﬁguration page which is an image stored in the image processor.

Print service test prints

The service prints allow you to evaluate the printer’s print quality. Service Print 1 four pages of 25% tint primary color ﬁlls. Service Print 2 is printed in 300 dpi.

Press the Menu button.

With the Help pages menu displayed, scroll to the Service

Print 1

or Service Print 2 menu item. Press Print .

Printing the conﬁguration page

The conﬁguration page shows a great deal of information regarding the data and set-up values stored in NVRAM. Refer to the topic, “The conﬁguration page” on page 2-14 for an explanation of the conﬁguration page.

Press the Menu button.

With the Help pages menu displayed, scroll to the Configuration

menu item. Press Print .

Page

Printing the demonstration pages

Demo pages demonstrate the capabilities of the printer.

Press the Menu button.

With the Help pages menu displayed, scroll to the Demonstration

item. Press Print .

Page

Printing the print engine’s test print

The print engine can print a test print independent of the image processor. The print is a composite gray ﬁll composed of cyan, magenta and yellow toner. No black toner is used in the print.

9-4

Press and hold for 2 seconds the Test Print button in the center of the upper rear cover.

This veriﬁes the print engine’s ability to print independent of the image processor.

Phaser 540 Color Printer

Page 63

Image processor normal indicators

There are three indications that the print engine and its image processor are powered-up and operating normally: the front panel POWER LED is on (steady), processor health light is blinking (the ﬂashing health light is viewable through the grill behind the manual feed tray).

When the printer is receiving or processing data, the front panel displays the messages

for Data

Ready is displayed on the front panel LCD display and the image

Receiving Data and Processing Data . The message Waiting

may also be displayed periodically.

Image processor hard and soft error indicators

Image processor hard errors are self-test failures that would prevent the printer from printing a page. Hard errors cause the health light to stop blinking and remain

Soft errors are errors that occur during the normal power-up self-test that, while limiting the printer, would not stop the printer from printing. A message regarding the soft error would then be printed on the startup page (even if the startup page had been turned off). Soft errors include failures of the expansion SIMMs, as well as the SCSI, serial, LocalTalk, parallel, and Ethernet ports.

or off . Hard errors are also any error that occurs during service mode.

Checks and Adjustments

Service Manual

9-5

Page 64

Checks and Adjustments

Printer self-diagnostics

The printer’s image processor features four types of self-test modes. The type of self-tests run depend upon which front panel buttons are pressed while the printer is turned on. The button combinations are listed here.

■

Turning on the printer or restarting the printer remotely executes normal image processor power-up self-tests and then, if the tests pass, proceed to launch its PostScript interpreter.

Pressing and holding Button 1 (the left-most button, marked Exit), as

■

you turn on the printer, skips the image processor’s self tests and proceed directly to launching its PostScript interpreter.

■

Pressing and holding Button 2 (the second from the left button), as you turn on the printer, executes the image processor’s veriﬁcation self-tests. These series of test continue until the printer is turned off.

Pressing and holding Button 3, as you turn on the printer, executes

■

interactive service test with the image processor board and the print engine.

■

Pressing and holding Button 1 and 4, as you turn on the printer, allows you to reset the NVRAM to its factory-default values. Refer to the later topic, “Resetting NVRAM” on page 9-9.

Normal power-up self-tests.

a problem is encountered with the image processor's expansion memory or other options, then the information is printed on the printer's startup page. Normal power-up tests take slightly longer than one minute to complete.

The health LED, located on the image processor board, ﬂashing in a regular, one ﬂash-per-second rate means CPU is running.

Kernel tests.

then, if no error occurs, goes directly to PostScript initialization.

Veriﬁcation test.

all host cables from the printer before starting the test. A fully conﬁgured printer takes slightly longer that 3 minutes to execute the tests. The image processor continuously executes a series of tests of its CPU kernel, RAM and other image processor components. The series of tests run continuously until an error occurs. The printer continuously loops on that test indicating the number of times the test passed and failed. The printer must be turned off to exit the test series.

The printer’s image processor executes its core set of CPU tests and

This test requires no paper or customer interaction. Disconnect

This test requires no paper or customer interaction. If

no errors were detected and the image processor's

9-6

Phaser 540 Color Printer

Page 65

Checks and Adjustments

Service tests.

Service tests include all the available image processor self-tests. with the addition of some test prints and also being able to interact with the print engine motors, solenoids and sensors. You select and start tests using the front panel. The message

Service Tests is displayed on the top line of the

front panel when the service tests are activated and running. If no error is detected, the front panel displays

Ready and the image processor enters its

operational mode. If an error is detected, the front panel displays the failing test. Using the front panel buttons, scroll to an individual test and run it. In service mode, you can also scroll to a set of tests that allow you to start a single print or to print continuously. These are the service tests options:

All tests

■

Test groups

Kernel

■

DRAM

■

I/O

■

PWA (image processor board)

■

Test prints

■

Engine diagnostics (interactive)

Engine ﬁrmware version (this value is also printed on the startpage)

■

Engine status — loop on any engine status byte and see the byte

■

change in real-time.

Engine sensor states — indicates the real-time state of the displayed

■

sensor; this allows you to test the sensors in real time by manually interrupting them.

■

Fuser

Pre-transfer

■

charger Scorotron

■

charger

■

Paper pick sensor (registration sensor)

■

Fuser exit sensor

Paper exit sensor

Tray type sensors

Toner full sensors

■

Manual feed sensor

Paper empty

■

sensor Transparency

■

ﬁlm sensor

■ T oner cartridge

missing sensor

■

T oner cartridge

cam position sensors

Transfer roller

■

position sensor

Cleaning

■

blade position sensor

■ Paper low

sensor

■ Paper jam

(fuser entry sensor

■ Outputs tray

full sensor

■ Door open

interlock sensor

■ Belt home

position sensors

Service Manual

9-7

Page 66

Checks and Adjustments

■ Motor exercise — turns on the following motors for 2 seconds and then

off.

■ Main motor ■ Toner cartridge drive

■ Fans

motor

■ Paper feed motor ■ Laser scanner motor ■ Toner cartridge

selector cam motors 1 through 4

■ In addition, through this group of tests, you can exercise the following

parts:

■ Toner cartridge

developer rollers

■ Registration clutch ■ Transfer rollers

■ Fuser temperature — displayed in Celsius.

■ Print engine NVRAM contents — which can be viewed, changed or

■ Pick rollers ■ Cleaning blade

(accumulator belt)

reset.

■ Top margin values ■ Imaging unit page

count

■ Left margin value ■ Pre-transfer charger

page count

■ Fuser page count

■ Print engine page

count

■ Paper path exercise — pick and move a sheet of paper through the

paper path. Single-sheet pick or continuous-pick. Cycles through the installed trays.

9-8

Phaser 540 Color Printer

Page 67

Resetting NVRAM

Resetting NVRAM returns all the image processor's NVRAM-stored parameters to their factory defaults except the print counts and the Adobe ﬁrmware serial number.

To reset the image processor to its factory default values, follow this procedure:

Turn the printer off.

Press and hold the front panel Buttons 1 (Exit) and 4.

Turn the printer on.

When the front panel displays the message NVRAM Default, release Buttons 1 and 4.

At this point the message password? will be displayed. Within 10 seconds, press Buttons 1 (Exit) and 3 at the same time. The NVRAM parameters will be reset to their factory default values. If you do not press buttons 1 and 3 in the allotted time, the NVRAM will not be changed.

Checks and Adjustments

Service Manual

9-9

Page 68

Checks and Adjustments

Print engine calibration

Generally, no print engine calibration is required. Using its closed-loop, image density sensors, the printer can auto-calibrate its color output. Usually, if you note a print defect, replacing a toner cartridge, the imaging unit or the transfer roller (or perhaps the paper feeder) corrects the problem.

Checking print registration

A simple way to determine if the printer is properly registering the layers of toner is to print and examine the Startup Page.

Press the Menu button.

With the Help pages menu displayed, scroll to the Startup Page item. Press Print.

Examine the four six-color pies at the bottom of the print. You should see no white areas bordering the black lines separating the color slices. If you do, the printing is misregistered and the imaging unit should be replaced. Also clean the accumulator belt home position sensor.

TekColor Corrections

None Vivid Color Display Press Match

TekColor Corrections

None Vivid Color Display Press Match

Figure 9-3 Checking the registration of the toner layers

No white next to black printing  good resgistration

White seen next to blackprinting poor registration 

9013-57

9-10

Phaser 540 Color Printer

Page 69

Chapter

FRU Disassembly/Assembly

This chapter explains how to remove and replace many of the printer's Field Replaceable Units (FRUs). This chapter covers procedures for FRUs that are difﬁcult to remove or require special handling or precautions. Refer to Appendix A for a list of the printer's FRUs.

Required tools

■

Magnetic tip screwdrivers; 3-inch shaft and 6-inch shaft:

■

#1 POSIDRIV

Needle-nose pliers

Diagonal cutters



tip — extended shank

■

Replacement cable ties 343-0549-00

Flat-blade screwdriver

■

95% isopropyl alcohol

■

Antistatic mat 006-7056-00

Service Manual

8-1

Page 70

FRU Disassembly/Assembly

The printer cabinet

Upper rear cover

Remove the six screws securing the upper rear cover in place.

Lower rear cover

Remove the four screws securing the lower rear cover in place.

Top cover

Remove the upper rear cover ﬁrst.

Remove the three screws securing the rear of the top cover in place.

The front of the top cover is held by metal tabs. Tilt the cover up from the rear, slide it back slightly and remove.

Left door (for paper feeder access)

Open the left door.

Unhook the retaining strap from the door.

Unpin the two hinge spring arms (black plastic). Each is located at the ends of the door.

Unpin the door from the engine frame. Unpin the rear of the door ﬁrst.

Left side cover

Lower the manual feed tray.

Remove the four screws securing the left side cover to the print engine. Tilt forward and remove the cover.

8-2

Manual feed tray

Tilt the tray up slightly and squeeze the tray’s retaining pins inward to free it from the print engine frame.

Phaser 540 Color Printer

Page 71

Upper rear cover

FRU Disassembly/Assembly

Top cover

Lower rear cover

Figure 8-1 Removing cabinet covers

EMI shields

Initial printers feature many metal plates and shields. Later models may have fewer or no shields. Use a magnetic screwdriver when removing the many screws securing EMI shields in place to avoid losing the screws in the printer. Note the placement of the shields and the routing of all cables prior to removing them.

Left side cover

Manual feed tray

Left door

9013-27

EMI shielding on the printer may change as the printer is reﬁned.

Service Manual

8-3

Page 72

FRU Disassembly/Assembly

Front door

Open the front door.

Remove the two screws securing each door hinge to the front door.

Upper and lower front covers

Remove the top cover. Remove the imaging unit. Cover the imaging

unit to protect its photconductive belt from light.

Remove the four screws securing the front covers.

Disconnect the front panel board’s wiring harness.

To separate the lower front cover from the upper front cover, remove the two screws securing them together.

Bottom front cover

Open the front door.

Remove the three screws securing the bottom front cover in place.

Tilt the cover forward and remove it.

Front panel board

Remove the top cover. Remove the imaging unit. Cover the imaging unit to protect its photconductive belt from light.

Remove the four screws securing the front covers.

Disconnect the front panel board’s wiring harness.

Remove the four screws securing the front panel to the inside of the upper front cover.

Toner level sensor board

Remove the top cover. Remove the imaging unit. Cover the imaging unit to protect its photconductive belt from light.

8-4

Remove the three screws securing the toner level sensor board in place.

Disconnect the sensor board’s wiring harness. Remove the sensor.

Phaser 540 Color Printer

Page 73

Right side covers (front, rear and lower)

Remove the front and rear right side covers before removing the right side lower cover.

Remove the paper tray.

Remove the two screws securing each of the three right side cover in place. Remove the covers. Note that the lower side cover clips underneath the printer frame.

Toner level sensor board

FRU Disassembly/Assembly

Figure 8-2 Removing cabinet covers

Upper and lower front cover

Front door

Bottom front cover

Right side covers

Rear

Front

Lower

9013-28

Service Manual

8-5

Page 74

FRU Disassembly/Assembly

Paper feeder

Turn off the printer.

Open the left side door to access the paper feeder. Slide out the paper feeder.

With a screwdriver, back out the slide rail stop screws. There is one screw at the end of each slide rail.

Slide the paper feeder off the rails.

Paper tray sensor board

Remove the paper feeder as explained in the previous procedure.

Remove the paper tray.

Disconnect the wiring harness leading to the paper tray sensor board.

8-6

Phaser 540 Color Printer

Page 75

FRU Disassembly/Assembly

Remove the two screws securing the sensor board to the printer. (Lift the paper empty sensor ﬂag out of the way while you lift the paper tray sensor board out.)

Paper tray sensor board

Paper feeder

Back-out stop screws

Figure 8-3 Removing the paper feeder and the paper tray sensor board

9013-29

Service Manual

8-7

Page 76

FRU Disassembly/Assembly

Cartridge selector/eject unit (right door)

Remove the right-side covers as explained in the earlier topic, “Right side covers (front, rear and lower)” on page 8-5.

Disconnect the cartridge selector/eject unit’s wiring harness.

Remove the E-ring and bushing from each end of the cartridge selector/eject unit. Remove the third E-ring from the cartridge selector/eject unit’s shaft.

Unlatch the cartridge selector/eject unit and lower it half-way down to relieve spring pressure. Remove the shaft and then remove the cartridge selector/eject unit.

Remove E-ring

Remove E-ring and  bushing from each end of the cartridge selector/eject unit

Figure 8-4 Removing the cartridge selector/eject unit

Cartridge selector/ eject unit (right door)

Disconnect wiring harness

9013-30

8-8

Phaser 540 Color Printer

Page 77

Laser scanner

Note

FRU Disassembly/Assembly

Remove the top cover as explained in the earlier topic, “Top cover” on page 8-2.

Disconnect the three wiring harnesses connected to the laser scanner.

Remove the three screws securing the laser scanner in place. Lift and remove the laser scanner.

Cover the laser window slot leading to the imaging unit to protect the photoconductive belt from room light.

Remove three screws

Laser scanner

Figure 8-5 Removing the laser scanner

Disconnect wiring harnesses

9013-31

Service Manual

8-9

Page 78

FRU Disassembly/Assembly

Laser modulation board

Remove the top cover as explained in the earlier topic, “Top cover” on page 8-2.

Disconnect the ﬁve wiring harnesses connected to the laser modulation board.

Remove the four screws securing the laser modulation board in place. Lift and remove the laser modulation board.

Remove the four screws

Figure 8-6 Removing the laser modulation board

Disconnect the five wiring harnesses

9013-32

8-10

Phaser 540 Color Printer

Page 79

Power supply

FRU Disassembly/Assembly

Remove the upper and lower rear covers and the rear right side cover as explained in the earlier topic, “The printer cabinet” on page 8-2.

Disconnect the wiring harnesses connected to the power supply.

Remove the four screws securing the power supply in place. Lift and remove the power supply.

Caution

Reassembly Note: The bottom of the power supply features two slots that engage tabs in the printer frame for reassembly. At the rear base of the power supply, be sure to route the AC wiring harness through the top of the grommet and out the bottom before engaging the power supply’s assembly slots to the frame tabs. Failure to properly route the AC wiring harness can pinch the wiring and short AC power to the printer frame.

Fuser installed switch

Remove the upper and lower rear covers as explained in the earlier topic, “The printer cabinet” on page 8-2.

Remove the power supply as explained in the previous procedure.

Locate the fuser-installed switch located on the underside of the printer’s fuser fan housing. Disconnect the switch’s wiring harness.

Remove the screw securing the switch to the fan housing. Remove the switch.

Service Manual

8-11

Page 80

FRU Disassembly/Assembly

Remove the four screws

Power supply



Power supply frame tabs

For reassembly: Route AC wiring harness through top of grommet

AC wiring harness

Figure 8-7 Removing the power supply and the fuser installed switch

Disconnect the wiring harnesses

9013-33

8-12

Phaser 540 Color Printer

Page 81

Power supply fuse

FRU Disassembly/Assembly

Caution

To avoid damaging the printer, only replace the power supply fuse with a fuse of the same type and rating.

Remove the power supply as explained in the previous procedure, “Power supply” on page 8-11.

Remove the power supply’s cover. It is secured in place with 10 screws (one of the screws secures the power supply fan).

Locate the fuse near the bottom of the power supply by the power cord receptacle.

Fuse

Figure 8-8 Replacing the power supply fuse

9013-34

Service Manual

8-13

Page 82

FRU Disassembly/Assembly

Printer rear assemblies

Note

Engine control board

Engine driver board

If you are removing the engine control board or the engine driver board to access an assembly underneath, it is appropriate to disconnect the board’s wiring harnesses and then remove the board and its mounting bracket as an assembly.

Remove the upper rear cover as explained in the earlier procedure, “Upper rear cover” on page 8-2.

Disconnect the wiring harnesses leading to the engine control board.

Remove the four screws securing the board in place. Remove the engine control board by pulling it straight out, unplugging it from the engine driver board.

To remove the engine control board bracket, remove the four screws securing the bracket in place.

Remove the upper rear cover as explained in the earlier procedure, “Upper rear cover” on page 8-2.

Remove the engine control board and bracket as explained in the previous procedure.

Disconnect the wiring harnesses leading to the engine driver board.

Remove the ﬁve screws securing the board in place. Remove the engine driver board.

To remove the engine driver board bracket, remove the four screws securing the bracket in place.

8-14

Phaser 540 Color Printer

Page 83

Charger sensor board

FRU Disassembly/Assembly

Remove the upper rear cover as explained in the earlier procedure, “Upper rear cover” on page 8-2.

Remove the engine control board as explained in the previous procedure, “Engine control board” on page 8-14.

Disconnect the wiring harnesses leading to the charger sensor board.

Remove the two screws securing the board in place. Remove the charger sensor board.

Charger sensor board

Engine control board bracket

Engine control board

Engine driver board

Engine driver board bracket

Figure 8-9 Removing the engine control, engine driver and charger sensor boards

9013-35

Service Manual

8-15

Page 84

FRU Disassembly/Assembly

Main motor

Paper feed motor

Remove the upper and lower rear covers and the left side cover as explained in the earlier procedure, “The printer cabinet” on page 8-2.

Remove the engine control board and bracket as explained in the previous procedure, “Engine control board” on page 8-14.

Remove the engine driver board and bracket as explained in the earlier topic, “Engine driver board” on page 8-14.

Disconnect the motor’s wiring harness.

Remove the four screws holding the main motor in place. Remove the motor.

Remove the upper and lower rear covers and the left side cover as explained in the earlier procedure, “The printer cabinet” on page 8-2.

Cleaning board

Remove the power supply as explained in the earlier topic, “Power supply” on page 8-11.

Remove the engine control board and bracket as explained in the previous procedure, “Engine control board” on page 8-14.

Remove the engine driver board and bracket as explained in the earlier topic, “Engine driver board” on page 8-14.

Remove the four screws holding the paper feed motor in place. Remove the motor.

Remove the upper and lower rear covers and the left side cover as explained in the earlier procedure, “The printer cabinet” on page 8-2.

Remove the engine control board and bracket as explained in the previous procedure, “Engine control board” on page 8-14.

Remove the engine driver board as explained in the earlier topic, “Engine driver board” on page 8-14.

8-16

Disconnect the cleaning board’s wiring harness.

Remove the three screws securing the cleaning board in place. Remove the cleaning board.

If necessary, to remove the cleaning board bracket, remove the two screws securing the bracket in place.

Phaser 540 Color Printer

Page 85

Cleaning board

FRU Disassembly/Assembly

Engine driver board bracket

Paper feed motor

Main motor

Figure 8-10 Removing the main motor, paper-feed motor and cleaning board

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Service Manual

8-17

Page 86

FRU Disassembly/Assembly

Toner cartridge drive unit

Remove the upper and lower rear covers and the left side cover as explained in the earlier procedure, “The printer cabinet” on page 8-2.

Remove the power supply as explained in the earlier topic, “Power supply” on page 8-11.

Remove the engine control board and bracket as explained in the previous procedure, “Engine control board” on page 8-14.

Remove the engine driver board and bracket as explained in the earlier topic, “Engine driver board” on page 8-14.

Remove the front door/right side door interlock switch.

Remove the cleaning board and the cleaning board bracket as explained in the previous procedure, “Cleaning board” on page 8-16.

Remove the six screws securing the toner cartridge drive unit to the printer. Remove the drive unit.

Home position sensor assembly and the left door opened switch

Remove the upper and lower rear covers and left side cover as explained in the earlier procedure, “The printer cabinet” on page 8-2.

Remove the engine control board and bracket as explained in the previous procedure, “Engine control board” on page 8-14.

Remove the engine driver board and bracket as explained in the earlier topic, “Engine driver board” on page 8-14.

Accumulator belt home-position sensor assembly. Remove the two screws securing the home position sensor assembly in place.

Left door opened switch. Open the left door. Squeeze the interlock switch’s cover to release it. Move it out of the way.

Disconnect the wiring harness leading to the interlock switch.

Remove the two screws securing the interlock switch in place. Remove the switch.

8-18

Phaser 540 Color Printer

Page 87

FRU Disassembly/Assembly

Toner cartridge drive unit

Home position sensor

Left door-opened interlock switch

Interlock switch cover

Figure 8-11 Removing the toner cartridge drive unit, home position sensor and the left door interlock switch

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Page 88

FRU Disassembly/Assembly

High-voltage board

Remove the upper rear cover and the left side cover as explained in the earlier topic, “The printer cabinet” on page 8-2.

Remove the image processor board as explained in the later topic, “Image processor board” on page 8-23.

Remove the eight screws securing the card cage in place.

Slide the card cage out of the printer far enough to access the wiring harness at the end of the card cage. Remove the two screws securing the wiring harness to the card cage. Remove the card cage.

Disconnect the wiring harness leading to the high-voltage board. Disconnect the high-voltage wires leading from the high-voltage board to the print engine assemblies.

Remove the four screws and the ground wire securing the high-voltage board to the printer. Remove the board.

Card cage

Wiring harness

High-voltage board

9013-38

8-20

Figure 8-12 Removing the high-voltage board

Phaser 540 Color Printer

Page 89

Pre-exposure lamp

Turn off the printer. Remove the imaging unit.

Remove the screw securing the pre-exposure lamp in place.

Disconnect the pre-exposure lamp’s wiring harness. Remove the lamp.

Pre-transfer lamp

Turn off the printer. Remove the imaging unit.

Remove the E-ring securing the front end of the cleaning cam roller. Move the front end of the roller out of the way.

Remove the screw securing the pre-transfer lamp in place.

Disconnect the pre-transfer lamp’s wiring harness. Remove the lamp.

FRU Disassembly/Assembly

Toner auto-density sensor

Turn off the printer. Remove the imaging unit.

Remove the two screws securing the auto-density sensor in place.

Disconnect the sensors’s wiring harness. Remove the auto-density sensor.

Service Manual

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Page 90

9013-39

Toner auto-density sensor

Pre-transfer lamp

Pre-exposure lamp

Cleaning cam roller

FRU Disassembly/Assembly

Figure 8-13 Removing the pre-exposure lamp, pre-transfer lamp and toner auto-density sensor

8-22

Phaser 540 Color Printer

Page 91

Image processor board

Power down the printer. Disconnect all host interface cables.

Remove the upper rear cover as explained in the earlier topic, “Upper rear cover” on page 8-2.

Disconnect the image processor’s data wiring harness from the engine control board. Disconnect the power wiring harness from the underside of the image processor board.

Remove the two screws securing the board's rear panel to the printer.

Grasp the rear panel and slide the board out of the printer card cage.

Reverse these steps to reinstall the board.

If you are replacing the image processor board, exchange the NVRAM IC and the Ethernet address ROMs between the two boards. The 8-pin NVRAM chip contains important customer-created parameters. The printer may not operate correctly without the NVRAM IC being swapped. The socketed NVRAM IC is located near the RAM SIMMs. The 16-pin Ethernet address ROM is located above the network card connector.

FRU Disassembly/Assembly

Disconnect data wiring harness

Remove screws

Disconnect power wiring harness

Figure 8-14 Removing the image processor board

Service Manual

Image processor board

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Page 92

FRU Disassembly/Assembly

Installing RAM SIMMs

Turn off the printer. Do not unplug the printer; this preserves a ground path to dissipate static charges.

Open the manual feed tray on the left side of the printer.

Loosen the two thumbscrews securing the RAM access cover.

Remove the EMI shield.

Insert a memory module in connector P81 SIMM ONE (or in P82 SIMM TWO if P81 SIMM ONE is already ﬁlled) (a) and tilt the module down until it locks in place (b).

Repeat Step 4 to install additional memory modules. Install memory modules in the order P81 SIMM ONE and then P82 SIMM TWO.

When properly inserted, a tab on each end of the connector slips into a hole on each end of the RAM SIMM. Also, a pawl on each end of the connector latches around each end of the RAM SIMM to lock it in place.

Reinstall the EMI shield and the SIMM access cover. Close the manual feed tray.

Print a startup page to check its listing of the printer's memory and options.

8-24

Phaser 540 Color Printer

Page 93

FRU Disassembly/Assembly

Note

Ensure that the SIMM's RAM ICs are 70 nsec (-70) components. Slower RAM ICs won't work with the image processor board.

Image processor board

RAM SIMM access cover

Manual feed tray

RAM SIMM

Figure 8-15 Installing RAM SIMMs

SIMM 1

SIMM 2

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Page 94

FRU Disassembly/Assembly

Installing a network card

Note

EtherTalk and LocalTalk protocols require you to attach the Ethernet cable to the printer with the printer powered off. After connection, turn on the printer. During the printer's boot-up process, the printer's network node address is resolved with the network.

Power down the printer. Do not unplug the printer; this preserves a ground path to dissipate static charges.

Remove the network card cover plate from the rear panel of the printer.

Slide the network card into the card slot and ﬁrmly push it in place. Secure it in place with two screws.

Token Ring network card.

printer’s Token Ring network card is set for the speed of the token ring network. Not installed set the card for 16 Mbps (the most common conﬁguration); installed set the card for 4 Mbps.

Connect the appropriate host interface cable to the network card.

Turn on the printer and print the startup page. It lists the installed memory and options.

Ensure the transmission speed jumper on the

8-26

Network card

9013-43

Figure 8-16 Installing a network card in the printer

Phaser 540 Color Printer

Page 95

Enabling TCP/IP with the authorization code

Newer printers with PhaserShare Version 2.0 or higher ﬁrmware installed on the network card already have TCP/IP authorized; older printers do not. Print and refer to the printer’s conﬁguration page to determine the version of PhaserShare operating on the network card. Phaser Share network card upgrades, 4676UP1 (for an Ethernet card) or 4676UP4 (for a Token Ring card), are available to upgrade network cards to Version 2.0 PhaserShare.

When the Ethernet card is installed, the EtherTalk and Novell protocols are immediately active. The Ethernet card’s TCP/IP protocol must be activated (for older printers) by a downloadable authorization code, sometimes referred to as its software key. The authorization code is printed on a certiﬁcate included with the printer (if the option was factory-installed) or with the ﬁeld upgrade kit. The Phaser Share User Manual explains how to activate the authorization code and download it to the printer. Downloading the code depends on the available computers and cables as explained in the network user manual.

Each Ethernet card requires a unique authorization code to activate its TCP/IP protocol. The authorization code is based on the printer’s Ethernet address and is generated by a special computer program. The computer program is held by the staff of the Customer Support Hotline. A staff member of the Customer Support Hotline can generate an authorization code for an Ethernet-capable printer anytime once purchase of the TCP/IP option has been conﬁrmed, even long after the Ethernet card was installed.

FRU Disassembly/Assembly

Service Manual

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Page 96

FRU Disassembly/Assembly

Replacing the code ROM SIMM

Turn off the printer. Do not unplug the printer; this preserves a ground path to dissipate static charges.

Open the manual feed tray on the left side of the printer. Loosen the two thumbscrews securing the RAM access cover.

Remove the EMI shield.

Remove the PostScript ROM SIMM by spreading the pawls securing it in its connector.

Install the new PostScript ROM SIMM. When properly inserted, a tab on each end of the connector slips into a hole on each end of the ROM SIMM. Also, a pawl on each end of the connector latches around each end of the ROM SIMM to lock it in place.

Reinstall the EMI shield and the SIMM access cover. Close the manual feed tray.

Image processor board

RAM SIMM access cover

Manual feed tray

Code ROM SIMM

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8-28

Figure 8-17 Installing the code ROM SIMM

Turn on the printer and print a startup page to check the printer’s performance.

Phaser 540 Color Printer

Page 97

Chapter

Cleaning and Maintenance

Service preventive maintenance procedure

Whenever you check, service, or repair a printer, you should perform the following procedures. Cleaning the printer, as outlined in the following steps, assures proper operation of the printer and reduces the probability of having to service the printer in the future.

The frequency of use and the type of paper a customer prints on will, in large part, determine how critical cleaning the machine is. Users of ordinary Bond paper (copier paper) should have very few problems since this paper is smooth and relatively dust-free. You should thoroughly inspect and clean these printers.

Ask each printer customer about the type of paper he or she uses so that you can be sure to clean the parts of the printer that particular paper may affect. If a customer is printing on the more unusual or dustier papers, then you should pay particular attention to these printer parts:

■

The pick roller

The feed rollers

■

The cabinet interior

■

The exit rollers

Recommended tools

vacuum cleaner

■

suction bulb (air blower)

cleaning alcohol

■

lint-free wipes

cotton swabs

■

imaging unit cover

Service Manual

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Cleaning and Maintenance

Cleaning

Turn off the printer.

Remove the imaging unit and cover it to protect it from the light.

Remove the toner cartridges.

Remove the fuser.

Remove the paper tray.

Slide out the paper feeder.

Clean the pre-transfer corona with its cleaning tool.

Clean the image density sensor with the cotton swab.

Lubrication

Clean the accumulator belt home position sensor with a cotton swab.

10.

Clean all printer rollers with alcohol wipes.

11.

Clean the laser window with puffs of air from the suction bulb. Alternately, you can vacuum the window clean.

12.

Wipe off the pre-exposure lamp bezel and the pre-transfer lamp bezel with a lint-free wipe.

13.

Vacuum out the interior of the printer.

■

Molybdenum-based grease

For all metal-to-metal, metal-to-plastic, and plastic-to-plastic gears.

High-temperature, electrically-conductive grease,

■

FLOIL GE-676 by Kanto Kasei, Ltd.

For the plastic gears of the fuser and the end of the transfer roller shaft.

7-2

Phaser 540 Color Printer

Page 99

Chapter

Troubleshooting

This chapter discusses troubleshooting the printer. Troubleshooting is discussed with two approaches:

■

A step-by-step veriﬁcation procedure that systematically conﬁrms that particular components of the printer are properly functioning until a problem is found.

■

A symptom/cause scheme that lists particular printer failures and error codes and their possible causes.

System power-up sequence

The following lists the chain of events that occur when you turn on the printer. You can follow this list as one means of determining if the printer is operating correctly.

When the power switch is turned on, these events occur:

■

The engine control board checks its RAM.

■

All the engine fans are turned on to ensure they work properly.

■

The fuser heater (a halogen lamp) is activated to heat up the heated roller.

The position of each toner cartridge is checked to ensure they are in

■

their parked positions.

■

A print engine checks to see that the imaging unit, the paper feeder and the pre-transfer charger are installed.

■

The engine motors are rotated to ensure that their rotation sensors are detected.

The transparency ﬁlm sensor and the image density sensors are

■

“tuned” for the amount of infrared light they each emit.

A check is made to determine if any paper is jammed in the printer.

■

The print engine checks the level of toner in each toner cartridge.

Service Manual

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Page 100

Troubleshooting

After the fuser reaches its idle temperature, a color correction cycle is

■

performed.

The printer is placed on line in its READY state.

■

The print engine is initialized. If the startup page feature has not been disabled and no error occurred with the printer, the printer prints a startup page.

Print engine troubleshooting

This topic is a step-by-step procedure for systematically verifying particular aspects of the printer's operation. Following this procedure should lead to the cause of a printer's failure.

Testing the print engine

If the printer does not power up, or does not initialize, or the printer initializes but the motors do not run properly, go to the later topic, “Verifying power supply operation” on page 6-3.

Note

If the printer prints a gray ﬁll, then the printer's print engine is working correctly. Proceed with the next topic, “Verifying printer operation by using its self-test print” on page 6-3.

If the image processor does not power up or is disconnected from its power source, then the print engine will not power up.

Observe that the Ready message is displayed on the front panel. If it is not, go to the later topic “Verifying power supply operation” on page 6-3.

Verify that the image processor’s health LED is ﬂashing. If it is not, go to the topic, “Printer self-diagnostics” on page 9-6. The health LED is viewable through the grill behind the manual feed tray (when the tray is lowered).

Press the test button on the rear of the printer (in the center of the rear cabinet panel). The print engine responds by making a gray ﬁll test print.

6-2

If the printer does not make the gray ﬁll print, then a problem exists with the printer. If the printer does not print a test pattern, then a problem exists with the print engine. Proceed with the topic, “Verifying power supply operation” on page 6-3.

Phaser 540 Color Printer