Xerox Phaser 3500 Service Manual

Service

Phaser® 3500

laser printer

Manual

Service Terms

Cautions, Notes, and Warnings

Note: A note indicates an operating or maintenance procedure, practice or condition that

is neccessary to efficiently accomplish a task. A note can provide additional information
related to a specific subject or add a comment on the results achieved through a previous
action.

Caution: A caution statement indicates an operating or maintenance procedure, practice

or condition that, if not strictly observed, could result in damage to, or destruction of,
equipment.

Warning: A warning statement indicates an operating or maintenance procedure, practice

or condition that, if not strictly observed, could result in injury or loss of life.

Product Terms

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

may cover the hazardous area.

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

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Symbols Marked on the Product

DANGER high voltage.

Protective ground (earth) symbol.

Hot surface on or in the printer. Use caution to avoid personal
injury.

0

30 min.

The surface is hot while the printer is running. After turning off
the power, wait 30 minutes.

Avoid pinching fingers in the printer. Use caution to avoid
personal injury.

Use caution (or draws attention to a particular component). Refer
to the manual(s) for information.

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Power Safety Precautions

Power Source

For 110 VAC printers, do not apply more than 140 volts RMS between the supply conductors
or between either supply conductor and ground. Use only the specified power cord and
connector. For 220 VAC printers, do not apply more than 264 volts RMS between the supply
conductors or between either supply conductor and ground. Use only the specified power
cord. This manual assumes that the reader is a qualified service technician.

Plug the three-wire power cord (with grounding prong) into a grounded AC outlet only. If
necessary, contact a licensed electrician to install a properly grounded outlet. If the product
loses its ground connection, contact with conductive parts may cause an electrical shock.

Disconnecting Power

Turning the power off using the On/Off switch does not completely de-engergize the printer.
You must also disconnect the printer power cord from the AC outlet. Position the power cord
so that it is easily accessible during servicing so that you may power down the printer during
an emergency.

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

Disconnect the power cord in the following cases:

■ if the power cord or plug is frayed or otherwise damaged,

■ if any liquid or foreign material is spilled into the case,

■ if the printer is exposed to any excess moisture,

■ if the printer is dropped or damaged,

■ if you suspect that the product needs servicing or repair,

■ whenever you clean the product.

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Electrostatic Discharge (ESD) Precautions

Some semiconductor components, and the respective sub-assemblies that contain them, are
vulnerable to damage by Electrostatic Discharge (ESD). These components include Integrated
Circuits (ICs), Large-Scale Integrated Circuits (LSIs), field-effect transistors and other
semiconductor chip components. The following techniques will reduce the occurrence of
component damage caused by static electricity.

Be sure the power to the chassis or circuit board is off, and observe all other safety
precautions.

■ Before handling any semiconductor components assemblies, drain the electrostatic

charge from your body. This can be accomplished by touching an earth ground source
or by wearing a wrist strap device connected to an earth ground source. Wearing a
wrist strap will also prevent accumulation of additional bodily static charges. Be sure
to remove the wrist strap before applying power to the unit to avoid potential shock.

■ After removing a static sensitive assembly from its anti-static bag, place it on a

grounded conductive surface. If the anti-static bag is conductive, you may ground the
bag and use it as a conductive surface.

■ Do not use freon-propelled chemicals, as they can generate electrical charges that may

damage some devices.

■ Do not remove a static sensitive replacement component or electrical sub-assembly

from its protective package until you are ready to install it.

■ Before removing the protective material from the leads of a replacement device, touch

the protective material to the chassis or circuit assembly into which the device will be
installed.

■ Minimize body motions when handling unpackaged replacement devices. Simple

motions such as your clothes brushing together or lifting a foot from a carpeted floor
can generate enough static electricity to damage a static sensitive device

■ Handle IC’s and EPROM’s carefully to avoid bending pins.

■ Pay attention to the direction of parts when mounting or inserting them on Printed

Circuit Boards (PCB’s).

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Service Safety Summary

General Guidelines

Note: The material presented here is intended as a safety reminder for qualified service

personnel. Refer also to the preceding Power Safety Precautions.

Avoid servicing alone

Do not perform internal service or adjustment of this product unless another person capable of
rendering first aid or resuscitation is present.

Use care when servicing with power

Dangerous voltages may exist at several points in this product. To avoid personal injury, do not
touch exposed connections and components while power is on. Disconnect power before
removing the power supply shield or replacing components.

Do not wear jewelry

Remove jewelry prior to servicing. Rings, necklaces and other metallic objects could come
into contact with dangerous voltages and currents.

Power Source

This product is intended to operate from a power source that will not apply more then 264
volts rms for a 220 volt AC outlet or 140 volts rms for a 110 volt AC outlet between the supply
conductors or between either supply conductor and ground. A protective ground connection by
way of the grounding conductor in the power cord is essential for safe operation.

Warning Labels

Read and obey all posted warning labels. Warning labels are displayed on potentially dangerous printer
components. As you service the printer, check to make certain that all warning labels remain in place.

Safety Interlocks

Make sure all covers and the printer’s control panel are in place and all interlock switches are
functioning correctly after you have completed a printer service call. If you bypass an interlock
switch during a service call, use extreme caution when working on or around the printer.

CLASS 1 LASER PRODUCT

The Phaser 3500 Laser Printer is certified to comply with Laser Product Performance
Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser
Product. This means that this is a class of laser product that does not emit hazardous laser
radiation; this is possible only because the laser beam is totally enclosed during all modes of
customer operation. The laser is not hazardous during servicing if you follow the procedures
specified in the manual.

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Servicing Electrical Components

Before starting any service procedure, switch off the printer power and unplug the power cord
from the wall outlet. If you must service the printer with power applied, be aware of the
potential for electrical shock.

Warning: Turning the power off by using the On/Off switch does not completely de-energize

the printer. You must also disconnect the printer power cord from the AC outlet. Position the
power cord so that it is easily accessible during servicing.

Warning: Do not touch any electrical component unless you are instructed to do so by a

service procedure.Servicing Mechanical Components

Caution: When servicing mechanical components within the printer, manually rotate drive

assemblies, rollers, and gears.

Warning: Do not try to manually rotate or manually stop the drive assemblies while any

printer motor is running.

Warning: This printer uses heat to fuse the toner image to media. The Fuser Assembly is

VERY HOT. Turn the printer power off and wait at least 5 minutes for the Fuser to cool before
you attempt to service the Fuser Assembly or adjacent components.

Regulatory Specifications

Regulatory Specifications for this printer can be found in the User Guide and on the Xerox
Website.

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Contents

Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Cautions, Notes, and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Product Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Disconnecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

CLASS 1 LASER PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Servicing Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

1 Service Call Procedures

Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Service Preventive Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Recommended Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2 Repair Analysis Procedures

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Accessing Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Using the Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Entering Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Service Diagnostics Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Service Diagnostic Control Panel Button Descriptions . . . . . . . . . . . . . . . . . 2-5

Troubleshooting Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Jam At Tray [1] [2] [3] (Jam 0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Jam At Top (Jam 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Jam At Exit (Jam 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Jam At Rear (Duplex Jam 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Jam At Duplex (Duplex Jam 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge,

Replace Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Close Fuser Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Close Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Fuser Failure, Engine Fuser Low Heat Error, or Engine Fuser Over Heat Error . . . 2-15

Laser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Output Tray Is Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

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Contents

General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Control Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

No Control Panel Display after Power Is Turned ON . . . . . . . . . . . . . . . . . 2-17

Control Panel LED is On, Control Panel Display Is Blank . . . . . . . . . . . . . 2-17

Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Taking Voltage Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

3 Image-Quality Troubleshooting

Image-Quality Problems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Repeating Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Repeating Defects Measurement Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Control Panel (Internal) Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Deletions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Registration and Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Skips or Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Image-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

No Image/Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Light Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Dark Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Ghosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Non-Uniform Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Black Spots/Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Spot or Vertical Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Horizontal Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Character Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Unfused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Skips/Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

OHP Print Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4 Repairs and Adjustments

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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Contents

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Control Panel and LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Open Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Tray 1 (MPT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Tray 1 Knock-Up Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Tray 1 Pick-Up Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Transfer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Tray 1 Separator (Holder) Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Feed2 Idle Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Registration Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

PTL Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Main Drive Assembly and Registration (Feed) Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Feed Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Tray 1 Pick-Up Assembly and Pick Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Tray 1 Pick Roller Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Pick Roller and Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Tray 2 Pick-Up Assembly and Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Feed 2 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Developer Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Connector Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Tray 1 (MPT) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Main Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Exit Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Exit and Duplex Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Exit Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Tray Full Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Duplex Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Laser (LSU) Assembly and Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

LSU Lower Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Left Side Cooling Supply Fan and Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Toner Sensor Board and CRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Cover Open Board and Harness Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Main Board and Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Power Supply and Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Fuser Gear Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Paper Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

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Contents

5Parts List

Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

PL 8.1 Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

PL 8.1 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

PL 8.2 Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

PL 8.2 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

PL 8.3 Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

PL 8.3 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

PL 8.4 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

PL 8.4 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

PL 8.9 Tray 2 Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

PL 8.9 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

PL 8.10 Tray 3 Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

PL 8.10 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

PL 8.11 Duplex Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

PL 8.11 Parts List Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

6 General Information and Specifications

Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Printer Options and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Consumable and Service Part Life Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Error and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Printer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Printer Location and Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Printer Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

7 Wiring Data

Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

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Contents

8 Theory of Operation

Overview of the Phaser 3500 Laser Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Summary of the Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Printer Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Duplex Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Paper Feed Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Paper Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Paper Feed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Major Assemblies and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Laser Scan Unit (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Sensor Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Paper Empty Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Tray 1 Paper Empty Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Registration Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Fuser Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Cover Open Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Duplex Unit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Printer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Image Processor Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Print Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Paper Size Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Paper Pick Auto-Select. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Toner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Laser Light Intensity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Fuser Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Phaser® 3500 Laser Printer Service Manual

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Service Call Procedures

This section includes the following:

■ Servicing Instructions on page 1-2

■ Service Preventive Maintenance Procedure on page 1-3

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2-1

Service Call Procedures

Servicing Instructions

The service flowchart is an overview of the path a service technician should take, using this
manual, to service the print engine and options.

Step 1: Identify the Problem

1. Verify the problem reported and check for any error codes and write them down.

2. Print normal customer prints and service test prints and look for any of the following:

■ any image quality problems in the test prints.

■ any mechanical or electrical abnormalities present.

■ any unusual noise or smell coming from the printer.

3. View the fault and jam histories and look at the total print count for the printer.

4. Verify the AC input power supply is within proper specifications by measuring the

voltage at the electric outlet while the printer is running.

Step 2: Inspect and Clean the Printer

5. Switch OFF printer power and disconnect the AC power cord from the wall outlet.

6. Verify the power cord is free from damage or short circuit and is connected properly.

7. Remove the Print Cartridge and protect it from light, then inspect the printer interior

and remove any foreign matter, obstructions, or loose toner.

8. Inspect the interior of the printer for damaged wires, loose connections, toner leakage,

and damaged or obviously worn parts.

■ Do not use solvents or chemical cleaners to clean the printer interior.

■ Do not use any type of oil or lubricant on printer parts.

■ Use only an approved toner vacuum.

9. Clean all rubber rollers with a lint-free cloth, dampened slightly with cold water.

10. Replace any service items that have reached their 150,000 end-of-life.

Step 3: Find the Cause of the Problem

11. Use the Repair Analysis Procedures to find the cause of the problem.

12. Use Diagnostics to check printer and optional components.

13. Use the Wiring Diagrams to locate test points.

14. Take voltage readings at various test points as instructed in the appropriate

troubleshooting procedure.

Step 4: Correct the Problem

15. Use the Parts List to locate a part number.

16. Use the Repair and Adjustments Procedures to replace the part.

Step 5: Final Checkout

17. Test the printer to be sure you have corrected the initial problem and there are no

additional problems present.

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1-2

Service Call Procedures

Service Preventive Maintenance Procedure

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

The frequency of use and the type of paper a customer prints on determines how critical and
how often cleaning the machine is necessary. Record the number of sheets printed.

Recommended Tools

■ Toner vacuum cleaner

■ Clean water

■ Clean, dry, lint-free cloth

■ Black light protective bag

Cleaning

■ Never apply alcohol to any parts in the printer.

■ Never use a damp cloth to clean up toner.

■ If you remove the Print Cartridge, place it in a light protective bag. Exposure to light

can degrade its performance and result in early failure.

1. Record number of sheets printed.

2. Print several sheets of paper to check for problems or defects.

3. Print several cleaning sheets to clear up image-quality problems.

4. Turn off the printer.

5. Remove any debris or foreign objects.

6. Remove any loose toner from the interior of the printer using a Type II toner vacuum only.

7. Remove and clean the paper trays.

8. Clean pick rollers with a slightly damp, lint-free cloth.

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1-3

Repair Analysis Procedures

This section includes the following:

■ Introduction on page 2-2

■ Service Diagnostics on page 2-4

■ Troubleshooting Error Messages on page 2-10

■ General Troubleshooting on page 2-17

■ Power Supply Troubleshooting on page 2-18

Phaser® 3500 Laser Printer Service Manual

2-1

Repair Analysis Procedures

Introduction

This section covers troubleshooting procedures for the Phaser 3500 Laser Printer. When an
error first occurs, record the error message and code and then cycle power to the printer to see
if the error recurs. Be sure to follow the Service Call Procedures on page 1-1 before servicing
the printer.

To troubleshoot image-quality problems, see image-quality Troubleshooting on page 3-1.

Accessing Fault History

Any code associated with an error message or jam can be viewed by displaying the Fault

History or Jam History on the Control Panel.

1. View the printer’s fault history on the Control Panel.
a. Go to Troubleshooting --> Service Tools --> Fault History or Jam History.

If the printer is connected to a network and has a TCP/IP address, you can view the
printer’s web page using a web browser.

b. Open a web browser.
c. Enter the printer’s IP address as the URL.
d. Select the Troubleshoot link and the fault history will be displayed.

Fault History Code Printer Error Message

41 Insufficient Memory

44 Output Tray Is Full

5A Laser Failure

53 Replace Print Cartridge

55 Invalid Print Cartridge

56 Fuser Failure/Open Fuser Error

57 Fuser Failure/Low Heat Error

58 Fuser Failure/Over Heat Error

Jam History Code Jam Error Message

01 Jam At Tray 1, 2, or 3 (Jam 0)

02 Jam At Top (Jam 1)

03 Jam At Exit (Jam 2)

04 Jam At Rear (Duplex Jam 1)

05 Jam At Duplex (Duplex Jam 2)

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Repair Analysis Procedures

Using the Troubleshooting Procedures

1. Each Step in a Troubleshooting Procedure instructs you to perform a certain action or

procedure. The steps are to be followed sequentially until the problem is fixed or resolved.

2. The Actions and Questions box contains additional information and/or additional

procedures you must follow to isolate the problem.

3. When a procedure instructs you to test a component using service diagnostics, see the

Service Diagnostics Menu Map on page 2-5 for the detailed steps and functions for testing

parts of the printer.

4. The action is followed by a question. If your response to the question is “Ye s”, then follow

the instructions for a “Ye s ” reply. If your response to the question is “No”, then follow the
instructions for a “No” reply.

5. Troubleshooting Procedures may ask you to take voltage readings or test for continuity at

certain test points within the printer. For detailed diagrams, see Section 7, Wiring Data on
page 7-1 for complete information on test point locations and signal names.

6. Troubleshooting Procedures often ask you to replace a printer component, see Repairs and

Adjustments on page 4-1 for detailed steps in removing and replacing all major

components of the printer. Section 5, Parts List on page 5-1, details the location, quantity,
and part number for all spared printer components.

Phaser® 3500 Laser Printer Service Manual

2-3

Repair Analysis Procedures

Service Diagnostics

The printer has built-in diagnostics to aid in troubleshooting problems. The Service
Diagnostics Menu provides a means to test sensors, motors, switches, clutches, fans and
solenoids. Diagnostics also contain built-in test prints, cleaning procedures, printer status and
some NVRAM access.

Service diagnostics are to be executed through the control panel by a certified service
technician only. The printer must be rebooted to enter Service Diagnostics.

Entering Service Diagnostics

1. Turn the printer power OFF.

2. Hold down the OK button and turn the printer back ON.

3. Continue to hold the button until the following mesage is displayed on the Control Panel:
“Diagnostic Mode” / “Press Menu Key”, and then release the OK button.

4. Press the Menu button and use the Arrow buttons to scroll through the available functions

(see the following Service Diagnostic Menu Map Table).

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2-4

Repair Analysis Procedures

Service Diagnostics Menu Map

Service Diagnostic Control Panel Button Descriptions

Button Function

BACK Returns to the prior higher level menu structure, if available.

Stops the actively running test.

CANCEL Terminates the current test.

MENU Cycles through all of the top level menu items.

UP Scrolls up one menu item within a menu list. This control does not ‘wrap’.

Used to increment values in tests requiring user input.

DOWN Scrolls up one menu item within a menu list. This control does not ‘wrap’.

Used to increment values in tests requiring user input.

OK Enters the highlighted menu. Executes the current test item.

Used to select the value entered by the user.

Main Menu Sub Menu Description/Function Control Panel Display

Optins
Interface

Tes t
Pattern

Motor/Fan Main Motor Main drive motor runs when

Tr ay 3
Interface

Duplex
Interface

Simplex Prints the test print page in

Duplex Prints the test print page in

Tests the interface between
the main controller and the
Tray 3 interface board.

Tests the interface between
the main controller and the
duplex interface board.

simplex mode. The Control
Panel will display the papers
location during the print
process.

This process will print
continuosly until stopped by
the user.

2-sided or duplex mode.

This process will print
continuosly until stopped by
the user.

the OK button is pressed
and stops when the Cancel
button is pressed.

Tray 3 Interface:

Pass /Fail :x.x.x

Duplex Interface

Pass/Fail :x.x.x

Simplex Print

Start -> Feed On -> Exit On

Duplex Print

Start -> Feed On -> Exit On -> Duplex
On

Main Motor

Running Test

ON/OFF

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2-5

Repair Analysis Procedures

Main Menu Sub Menu Description/Function Control Panel Display

DEV Motor Developer motor runs when

the OK button is pressed
and stops when the Cancel
button is pressed.

Laser
Motor

Duplex
Motor

Tra y 3
Motor

(If installed)

Main Fan Main fan runs when the OK

Laser motor runs when the
OK button is pressed and
stops when the Cancel
button is pressed.

Duplex motor runs when the
OK button is pressed and
stops when the Cancel
button is pressed.

Tray 3 motor runs when the
OK button is pressed and
stops when the Cancel
button is pressed.

If Tray 3 is not installed, test
does not run.

button is pressed and stops
when the Cancel button is
pressed.

DEV Motor

Running Test

ON/OFF

Laser Motor

Running Test

ON/OFF

Duplex Motor

Running Test

ON/OFF

Tray 3 Motor

Running Test

ON/OFF

Tray 3 Not Installed

Main Fan

Running Test

ON/OFF

Solenoid/
Clutch

SMPS Fan SMPS fan runs when the

OK button is pressed and
stops when the Cancel
button is pressed.

Duplex Fan Duplex fan runs when the

OK button is pressed and
stops when the Cancel
button is pressed

Tra y 1
Solenoid

Tra y 2
Solenoid

Tra y 3
Solenoid

When the OK button is
pressed the Tray 1 solenoid
is turned on for 200ms, and
then it automatically stops.

When the OK button is
pressed the Tray 2 solenoid
is turned on for 200ms, and
then it automatically stops.

When the OK button is
pressed the Tray 3 solenoid
is turned on for 200ms, and
then it automatically stops.

When Tray 3 is not installed,
this function does not work.

SMPS Main

Running Test

ON/OFF

Duplex Fan

Running Test

ON/OFF

Tray 1 Solenoid

ON/OFF

Tray 2 Solenoid

ON/OFF

Tray 3 Solenoid

ON/OFF

Tray 3 Not Installed

Phaser® 3500 Laser Printer Service Manual

2-6

Repair Analysis Procedures

Main Menu Sub Menu Description/Function Control Panel Display

Reg Clutch When the OK button is

Duplex
Solenoid

Tr ay 3
Clutch

Sensors Paper Size

Sensor

T1 NP
Sensor

pressed, the registration
clutch and main motor turn
on for 200ms, and then they
automatically stop.

You can visually observe
this test by removing the Top
Cover and Print Cartridge.

When the OK button is
pressed, the duplex
solenoid is turned on for
200ms, and then it
automatically stops.

When the OK button is
pressed, the Tray 3 clutch
and motor turn on for
200ms, and then they
automatically stop.

Place paper in the tray and
compare the size with the
control panel display.

Pull out Tray 1 and manually
toggle the actuator.

Reg Clutch

ON/OFF

Duplex Solenoid

ON/OFF

Tray 3 Clutch

ON/OFF

Example:

Tray2: Legal

Tray3: Letter

Tr ay 1

W/Out Paper or With Paper

T2 NP
Sensor

T3 NP
Sensor

Duplex
Sensor

Cover
Open
Sensor

Feed
Sensor

Exit Sensor Open the rear cover, and

Out Bin
Sensor

Pull out Tray 2 and manually
toggle the actuator.

Pull out Tray 3 and manually
toggle the actuator.

When Tray 3 is not installed,
this function does not work.

With the rear cover open,
push a piece of paper into
the duplex path and watch
the control panel display.

Open the top cover and
toggle the actuator.

Open the top cover, remove
the print cartridge, and then
actuate the sensor

insert paper into the exit
path.

Actuate the output sensor. Out Bin Sensor

Tr ay 2

W/Out Paper or With Paper

Tr ay 3

W/Out Paper or With Paper

Tray 3 Not Installed

Duplex Sensor

W/Out Paper or With Paper

Cover

Open/Closed

Feed Sensor

W/Out Paper or With Paper

Exit Sensor

W/Out Paper or With Paper

Not Full/Full

Phaser® 3500 Laser Printer Service Manual

2-7

Repair Analysis Procedures

Main Menu Sub Menu Description/Function Control Panel Display

Tray 2 Out
Sensor

Tray 3 Out
Sensor

Fuser Door
Sensor

HVPS Dev Bias

DC

Dev Bias
AC

Charge
Roll
Voltage

Transfer
Roll (+)

Remove Tray 2 from the
printer.

Remove Tray 3 from the
printer.

Open the rear cover and
actuate the fuser door
sensor.

Developer Bias DC is
applied when the OK button
is pressed, and then goes
off when the Cancel button
is pressed.

Developer Bias AC is
applied when OK is pressed
and goes off when Cancel is
pressed.

Charge Roller Voltage

(+1200V) is supplied when

OK is pressed and goes off
when Cancel is pressed.

Positive Transfer Voltage

(+1200V) is supplied when

OK is pressed and goes off
when Cancel is pressed.
[%d] is the value of the ADC.

Tray 2

IN/OUT

Tray 3

IN/OUT

Fuser Door Sensor

Closed/Opened

Dev Bias DC

ON/OFF

Dev Bias AC

ON/OFF

Charge Roll

ON/OFF

Transfer Roll (+)

[%d]

ON/OFF

Laser Scan
Unit

Transfer
Roll (-)

Pre­transfer
Lamp
(PTL)

Laser
Diode_0

Laser
Diode_1

Negative Transfer Voltage
(-800V) is supplied when
OK is pressed and goes off
when Cancel is pressed.
Measure voltage with a
DMM, if required.

PTL turns on when OK is
pressed and goes off when
Cancel is pressed. Visual
confirmation is possible with
the cover open and the Print
Cartridge removed.

Laser Diode0 On is
displayed when the laser
diode is on. In the other
case Laser Diode0 Off is
displayed.

Laser Diode1 On is
displayed when the laser
diode is on. In the other
case Laser Diode0 Off is
displayed.

Transfer Roll (-)

ON/OFF

Pre-transfer Lamp

ON/OFF

Laser Diode0

ON/OFF

Laser Diode1

ON/OFF

Phaser® 3500 Laser Printer Service Manual

2-8

Repair Analysis Procedures

Main Menu Sub Menu Description/Function Control Panel Display

L Motor
Ready

Fuser Fuser

Te m p.

Read OPC
Cycle

This tests if the laser unit is
ready and capable of
printing, or at a stable
polygon motor speed.

When the Target Temp is
displayed, INput the
temperature you would like
to set with the arrow buttons.
Press the OK button.

The target temperature and
the real temperature will be
displayed on the bottom line.

Default is T:190

Note: You can adjust the

temperature value while in
diagnostics, however, once
you exit the temperature will
return to the default.

The total rotating number of
the OPC drum is displayed
on the bottom line of the
control panel display when
the process is on.

Laser Ready Test

Pass/Fail

Target/Current

T: 190, C: XX

Total OPC-Cycle

XXXX

Phaser® 3500 Laser Printer Service Manual

2-9

Repair Analysis Procedures

Troubleshooting Error Messages

Error Description Page

Jam At Tray [1|2|3] (JAM 0)

The leading edge of the paper doesn’t pass the registration sensor or the sensor does
not turn ON.

■ After paper pick, paper is not fed.

■ After paper pick, paper enters the printer but does not reach the registration sensor

in the specified time.

■ After paper pick, the registration sensor turns ON and tries to pick again but the

paper does not reach the registration senor in the specified time.

Jam At Top (JAM 1)

The paper is between the registration sensor and the exit sensor.

■ The leading edge of the paper passes the registration sensor but the trailing edge

does not pass through the registration sensor in the specified time. (The registration
sensor cannot be OFF).

■ The leading edge of the paper passes the registration sensor, but the paper cannot

reach the exit sensor in the specified time. (The exit sensor cannot be ON).

Jam At Exit (JAM 2)

■ The trailing edge of the paper passes the registration sensor, but the paper does not

pass the exit sensor in the specified time.

Jam at Rear (Duplex JAM 1)

■ The trailing edge of the paper passes the exit sensor, but does not reach the duplex

sensor in the specified amount of time.

page 2-11

page 2-11

page 2-12

page 2-12

Jam at Duplex (Duplex JAM 2)

■ The leading edge of the paper passes the duplex sensor, but the leading edge of the

paper does not reach the registration sensor in the specified time.

Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge

■ A print cartridge is not detected.

■ A non-Xerox print cartridge is installed.

■ The toner sensor board is malfunctioning.

Close Fuser Door

■ The fuser door sensor or actuator is malfunctioning or damaged.

Close Top Cover.

■ Top cover is damaged

■ Sensor or actuator is damaged.

Fuser Failure, Engine Fuser Low Heat Error, Engine Overheat Error

■ Fuser is damaged or malfunctioning.

Laser Failure

■ The laser unit is malfunctioning or damaged.

Output Tray is Full

■ The outbin full sensor or actuator is malfunctioning or damaged.

page 2-14

page 2-14

page 2-14

page 2-15

page 2-15

page 2-15

page 2-16

Phaser® 3500 Laser Printer Service Manual

2-10

Repair Analysis Procedures

Jam At Tray [1] [2] [3] (Jam 0)

Step Actions and Questions Yes No

1.

2.

3.

4.

5.

6.

1. Check the side guides for the

inoperative tray for damage or
improper seating.

2. Are guides damaged or loose?

1. Check the surface of the pick-up rollers

for dirt or damage.

2. Are the rollers dirty or damaged?

1. Do the Registration Rollers turn freely? Go to Step 4. Replace Registration

1. Is the Registration/Feed Sensor

Actuator damaged or binding?

1. Use service diagnostics to checkthe

operation of the tray solenoids.

2. Do the tray solenoids operate

correctly?

1. Use service diagnostics to check the

operation of the Regi Clutch and Feed
Clutch.

2. Do the clutches operate correctly?

Replace the Tray. Go to Step 2.

Clean rollers with a
soft cloth very
slightly dampened
with water or replace
if damaged.

Repair or replace the
actuator and/or
sensor.

Go to Step 6. Replace the

Go to Step 7. Replace the

Go to Step 3.

Assembly.

Go to Step 5.

inoperative solenoid.

defective clutch.

7.

1. If paper feeds into the printer and the

Jam error message appears, use
service diagnostics to check the feed
sensor operation.

2. Does the feed sensor operate

correctly?

Replace the Main
Board

Jam At Top (Jam 1)

Step Actions and Questions Yes No

1.

2.

1. Clean the paper path of any

obstructions, dirt or debris.

2. Did this correct the problem

1. Use service diagnostics to test the

operation of the Registration roller and
clutch.

2. Does the registration roller and clutch

operate correctly?

Complete. Go to Step 2.

Go to Step 3. Replace the

Replace the
defective sensor or
actuator.

Registration
Assembly.

Phaser® 3500 Laser Printer Service Manual

2-11

Repair Analysis Procedures

Step Actions and Questions Yes No

3.

4.

1. Use service diagnostics to test the exit

sensor.

2. Does the sensor operate correctly?

1. Replace the Fuser Assembly and

retest.

2. Did this correct the problem?

Go to Step 4. Replace the exit

Complete. Replace the SMPS.

Jam At Exit (Jam 2)

Step Action and Questions Yes No

1.

2.

3.

4.

5.

1. Is the Exit Sensor Actuator damaged or

binding?

1. Inspect the Exit Roller Assembly.

2. Use service diagnostics to test the main

drive to exit.

3. Is the exit roller damaged or binding?

1. Visually inspect the Fuser.

2. Is there paper wrapped around the

Fuser rollers?

1. Is the Fuser Assembly operational.

2. Do the Fuser gears rotates when the

Main motor is on?

1. Use the embedded diagnostics to check

the Exit Sensor.

2. Is the sensor operational?

Repair or replace the
actuator and/or
sensor.

Replace the Exit
Roller Assembly.

Remove obstruction
and clean Fuser
rollers.

Go to Step 5. Replace the Fuser

Replace Main Board. Replace SMPS.

sensor.

Go to Step 2.

Go to Step 3.

Go to Step 4.

Assembly.

Jam At Rear (Duplex Jam 1)

Step Actions and Questions Yes No

1.

2.

3.

1. Does paper jam after reversal but

before reaching duplex sensor?

1. Replace Transport Roller Shaft

Assembly.

2. Does problem recur?

1. Use service diagnostics to check the

operation of the Duplex Sensor.

2. Does the sensor operate correctly?

Phaser® 3500 Laser Printer Service Manual

Go to Step 2. Go to Step 3.

Replace Duplex
Assembly.

Go to Step 4. Replace the Duplex

2-12

Complete

Sensor and/or
Actuator.

Repair Analysis Procedures

Step Actions and Questions Yes No

4.

5.

6.

7.

8.

1. Inspect the Duplex Assembly. Is any

paper wrapped around the Duplex
rollers?

1. Use service diagnostics to check the

exit sensor.

2. Does the sensor operate correctly?

1. Inspect the exit and duplex roller

assemblies.

2. Are the rollers damaged or binding?

1. Inspect the duplex assembly for

damage.

1. Does the Feed Roller Assembly

operate properly without binding?

Remove obstruction
and clean rollers.

Go to Step 6. Replace the exit

Replace the exit or
duplex roller as
necessary.

Replace the duplex
assembly.

Replace Main Board. Replace the Feed

Go to Step 5.

sensor and/or
actuator.

Go to Step 7.

Go to Step 8.

Roller Assembly.

Phaser® 3500 Laser Printer Service Manual

2-13

Repair Analysis Procedures

Jam At Duplex (Duplex Jam 2)

Step Actions and Questions Yes No

1.

2.

3.

4.

1. Does the paper jam after reversal but

before reaching the duplex sensor?

1. Use service diagnostics to test the

duplex sensor.

2. Does the sensor operate correctly?

1. Inspect the exit and duplex rollers for

any signs of damage or binding.

1. Replace the Duplex Assembly.

2. Does the problem still occur?

Replace the transport
roller shaft.

Go to Step 3. Replace the duplex

Replace the problem
roller.

Replace the Main
Board.

Go to Step 2.

sensor.

Go to Step 4.

Replace the Power
Supply Board.

Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge, Replace Print Cartridge

Step Action and Questions Yes No

1.

1. Open the top cover and ensure that the

Print Cartridge is properly seated.

2. Does the error clear after reseating the

cartridge?

Complete Go to Step 2.

2.

3.

4.

1. Check the Print Cartridge for damage.

2. Does the cartridge contain toner and

appear to be operating properly?

1. Reseat all harness connections to the

Toner Sensor (CRUM) Board.

2. Does the error clear?

1. Check continuity between the Toner

Sensor (CRUM) Board and CN6 on the
Main Board.

2. Does the harness show continuity?

Go to Step 3. Replace Print

Complete Go to Step 4.

Replace the Toner
Sensor Board.

Close Fuser Door

Step Action and Questions Yes No

1.

1. Visually inspect the fuser door close tab

for damage.

2. Is the tab broken?

Replace the Fuser. Go to Step 2.

Cartridge.

Replace Harness.

Phaser® 3500 Laser Printer Service Manual

2-14

Repair Analysis Procedures

Step Action and Questions Yes No

2.

1. Verify the sensor and actuator on the

Fuser is operating correctly.

Replace the Main
Board.

Replace the Fuser.

Replace the SMPS.

Close Top Cover

Step Action and Questions Yes No

1.

2.

1. Visually inspec the top cover and the

top cover actuator.

2. Is the top cover or actuator damaged?

1. Use diagnostics to test the cover open

sensor.

2. Does the sensor function properly?

Replace the Top
Cover.

Replace the Main
Board.

Go to Step 2.

Replace the Sensor.

Fuser Failure, Engine Fuser Low Heat Error, or Engine Fuser Over Heat Error

Step Action and Questions Yes No

1.

2.

3.

4.

1. Does the error report Fuser Failure? Go to Step 2. Go to Step 3.

1. Check the thermistor.

2. Is the circuit open?

1. Check the line voltages across the

thermostats.

2. Are they open?

1. Is the Fuser getting power? Replace the Fuser. Replace the SMPS.

Replace the Fuser. Replace the Main

Replace the Fuser. Go to Step 4.

Laser Failure

Step Actions and Questions Yes No

1.

1. Reseat the connections to the laser

and visually inspect the laser unit for
damage.

2. Did this correct the problem?

Complete Go to Step 2.

Board.

Replace the Main
Board.

Phaser® 3500 Laser Printer Service Manual

2-15

Repair Analysis Procedures

Step Actions and Questions Yes No

2.

1. Use diagnostics to check the laser

motor function.

2. Did the laser motor fail?

Replace the Laser
Unit.

Output Tray Is Full

Step Actions and Questions Yes No

1.

2.

1. Check the Output Tray sensor and

actuator for obvious damage.

2. Is the actuator damaged?

1. Use diagnostics to test the output tray

sensor.

2. Does the sensor operate correctly?

Replace the actuator. Go to Step 2.

Replace the Main
Board.

Replace the Main
Board.

Replace the Output
Tray S e n s o r .

Phaser® 3500 Laser Printer Service Manual

2-16

Repair Analysis Procedures

General Troubleshooting

The following procedures cover Control Panel and Start-up problems with the printer when no
specific error code or Control Panel message is displayed.

Control Panel Troubleshooting

No Control Panel Display after Power Is Turned ON

1. Verify that power cord is securely plugged into both the printer and the grounded, three

prong AC outlet with the appropriate power available.

2. Ensure that all covers are securely closed.

3. Verify the Top Cover, Print Cartridge, and Fuser interlocks are functional.

4. Verify voltages at the Main Board, see Power Supply Troubleshooting on page 2-18.

5. Replace the Power Supply Board.

6. Replace the Main Board.

7. Replace the Control Panel.

Control Panel LED is On, Control Panel Display Is Blank

1. Remove and reseat the Control Panel wiring to the Main Board.

2. Replace the Control Panel.

3. Replace the Main Board.

Phaser® 3500 Laser Printer Service Manual

2-17

Repair Analysis Procedures

Power Supply Troubleshooting

1. Check the voltage at the AC wall outlet, there should be approximately 110 VAC (or 220

VAC if the printer is a 220 V model) at the AC wall outlet?

2. Check the power cord for defects, damage, or a loose connection.

3. Check the AC switch harness for continuity.

4. Verify the Power Supply is operating correctly.

Taking Voltage Measurements

To locate connectors or test points, refer to Wiring Data on page 7-1 for more information.

Unless otherwise specified, the following voltage tolerances are used within this section

Stated Measured

+3.3 VDC +3.135 to +3.465 VDC

+5.0 VDC +4.75 to +5.25 VDC

+24.0 VDC +21.6 to +26.4 VDC

0.0 VDC Less than +0.5 VDC

Phaser® 3500 Laser Printer Service Manual

2-18

Image-Quality

Troubleshooting

This section covers the following:

■ Image-Quality Problems Overview on page 3-2

■ Control Panel (Internal) Test Print on page 3-4

■ Image-Quality Troubleshooting on page 3-7

Phaser® 3500 Laser Printer Service Manual

3-1

image-quality Troubleshooting

Image-Quality Problems Overview

Image-quality defects can be attributed to printer components, consumables, media, internal
software, external software applications, and environmental conditions. To successfully
troubleshoot image-quality problems, as many variables as possible must be eliminated.

The following guidelines should be used before troubleshooting an image-quality problem:

■ Use an unopened ream of approved media for evaluating image-quality problems

Note: See the approved media list, Media and Tray Specifications on page 6-9, for media

that has been tested and approved for use with the Phaser 3500 Laser Printer.

■ Generate the Control Panel (Internal) Test Print on page 3-4, and see if the image-

quality problem still exists

■ When analyzing a image-quality defect, first determine if the defect is repeating or

random. Repeating defects can often be associated with a particular component.

■ Inspect the surfaces of all rollers in the paper path for obvious defects.

Phaser® 3500 Laser Printer Service Manual

3-2

image-quality Troubleshooting

Repeating Defects

Some image-quality problems can be associated with specific assemblies, the most common
problems and the associated assemblies are listed below. Also, see the specific image-quality
troubleshooting procedure for more information.

Print Cartridge

■ Streaks

■ Fine Lines

■ Banding in Process Direction

■ Uneven Density

■ Vo i d s

■ Repeating Defects

Transfer Roller

■ Toner on the back side of the printed page (simplex mode)

■ Light Prints

■ Repeating Defects

■ Spots on Image

Fuser

■ Hot or Cold Offsetting

■ Repeating Defects

■ Vo i d s

Repeating Defects Measurement Table

Distance between

Assembly Component

Print Cartridge Developer Roller 50 mm (1.97 in.) Horizontal image band

Drum 94 mm (3.70 in.) White spots on black image

Drum Charge Rollers 38 mm (1.50 in.) Black spots

Supply Roller 42 mm (1.65 in.) Light or dark horizontal

Transfer Roller Transfer Roller 56 mm (2.20 in.) Image ghost

Fuser Assembly Heat Roller 126 mm (4.96 in.) Black spots and image

Pressure Roller 126 mm (4.96 in.) Black spots on back

Defects Typical Defect

or black spots on white

image bands

ghost

Phaser® 3500 Laser Printer Service Manual

3-3

image-quality Troubleshooting

Control Panel (Internal) Test Print

A test print is available to aid in determining the quality of output from the printer and to assist
in troubleshooting image-quality problems. Each area of the test print is used for a image­quality parameter. The following pages explain each of the areas and the image-quality
parameters. Follow these guidelines when generating the test print:

■ Use supported paper from a fresh, unopened ream

■ Print five copies of the test print.

■ Discard the first two prints and retain the remaining prints for image-quality analysis.

Deletions

Inspect the test print for the presence of deletions or unprinted spots. If these are found, see

Spot or Vertical Deletions on page 3-10.

Fusing

Rub the image three times at the indicated points with a soft cloth or tissue. The toner should
not lift off of the surface of the print. If the image smears or toner lifts off the image onto the
cloth, see Unfused Image on page 3-11.

s3500-039

Phaser® 3500 Laser Printer Service Manual

3-4

image-quality Troubleshooting

Resolution

Observe the three resolution check points on several test prints.

■ Ensure that the 2 pixel horizontal, vertical, and diagonal lines are clear and

continuous. The diagonal lines might appear to be narrower than the others.

■ Characters in the text paragraphs should be uniform and equal in density.

■ The halftone patches should be uniform in appearance.

If the image does not meet the criteria, see Non-Uniform Image on page 3-9 or Character

Defects on page 3-10.

Registration and Skew

Fold the paper from two consecutive test prints in half (first side edge to side edge and then top
edge to bottom edge). Observe the fold lines with reference to the crosshairs of the printed
target. The fold line should be aligned perpendicular to the target crosshairs and should be
within ±2.0 mm of the target crosshairs (each line on the target is 1.0 mm). If the image does
not meet the criteria, see Skewed Image on page 3-11.

Phaser® 3500 Laser Printer Service Manual

3-5

image-quality Troubleshooting

Skips or Smears

Check the test print in the indicated areas for loss, stretching, or distortion of the image in
bands across the process direction that make the image seem distorted, blurred, or compressed.
If these faults are observed, see Skips/Smears on page 3-11.

Phaser® 3500 Laser Printer Service Manual

3-6

image-quality Troubleshooting

Image-Quality Troubleshooting

The following table provides examples and descriptions, possible causes, and the solutions for
troubleshooting various image or printing defects that may be observed in the Phaser 3500
Laser Printer.

Image Defect Possible Causes Solutions

No Image/Blank Prints

Prints have no visible image.

s3500-043

Light Prints

All areas of the print are light with
no ghosting.

■ Sealing tape or shipping

restraint was not removed
from the cartridge.

■ Low or no toner

■ Defective ground to the

Print Cartridge or OPC
Drum

■ Malfunctioning solenoid or

drive.

■ Main Board

■ Incorrect high-voltage

output from the Power
Supply Board.

■ Multiple sheet feeding

■ Unsupported Media (paper)

■ Seal tape or shipping

restraint was not removed
from the cartridge.

■ Incorrect Control Panel

settings

■ Low toner

■ Transfer Roller

■ Laser contamination or

obstruction

■ Incorrect high-voltage

output

■ Low ambient temperature

(<10º C)

1. Ensure that sealing tape and

shipping restraint have been
removed.

2. Verify Print Cartridge ground.

3. Verify continuity between the

cartridge ground and frame.

4. Ensure the feed solenoid is

functioning properly.

5. Replace in the following

order:

■ Print Cartridge

■ Main Board

■ Power Supply Board

■ Laser Assembly

1. Verify paper meets printer

specifications. Print 20 to
30 pages using the
recommended paper.

2. Verify image-quality menu is

not set to “draft.”

3. Ensure that the sealing tape

and the shipping restraint
have been removed.

4. Verify low toner warning is not

displayed on control panel.
Remove the Print Cartridge
and shake, reinstall or
replace.

5. Inspect the Transfer Roller for

contamination and verify high­voltage contacts. Replace as
required.

6. Inspect the Laser assembly

for any obstructions; clean the
laser exit window.

7. Replace the Power Supply

Board.

Phaser® 3500 Laser Printer Service Manual

3-7

image-quality Troubleshooting

Image Defect Possible Causes Solutions

Black Prints

The prints are completely black,
has no visible image.

s3500-045

Dark Image

All areas of the print are too
dark.

Background Contamination

Uniform toner contamination in
non-image area.

s3500-046

■ No charge voltage

■ Power Supply Board

■ Print Cartridge

■ Main board

■ Laser is always ON

■ Incorrect Control Panel

settings

■ Print Cartridge

■ Incorrect high-voltage

outputs (Developer Bias
voltage)

■ Laser assembly

■ Media (paper)

■ Operating environment

■ Print Cartridge

■ Transfer Roller

■ Incorrect High Voltage

outputs

1. Verify the high-voltage

contacts are operational and
make good contact with the
print cartridge.

2. Replace in the following

order:

■ Print Cartridge

■ Power Supply Board

■ Main Board

■ Laser Assembly

1. Verify Remote Control Panel

setting for the Print Density
menu is not set to "dark.”

2. Verify that the high-voltage

contacts are operational and
make good contact with the
print cartridge.

3. Replace the following in

order:

■ Print Cartridge

■ Power Supply Board

■ Laser assembly

1. Verify that paper meets

printer specifications. Print 20
to 30 pages using
recommended paper. If using
recycled paper, try non­recycled paper.

2. Printer is installed in specified

environment.

3. Replace Print Cartridge.

4. Inspect Transfer Roller for

contamination and good
electrical contact, replace if
required.

5. Clean the Pre-transfer Lamp.

6. Replace Power Supply Board.

Phaser® 3500 Laser Printer Service Manual

3-8

image-quality Troubleshooting

8

Image Defect Possible Causes Solutions

Ghosting

Image from the previous page
prints on consecutive pages.

.

s3500-047

Non-Uniform Image

The Line darkness and solid­area density image vary across
the print.

.

s3500-04

■ Operating environment

■ Media (paper)

■ Print Cartridge

■ Transfer Roller

■ Fuser assembly

■ Incorrect high-voltage

outputs.

■ Print Cartridge

■ Print Cartridge grounding

■ Unstable high voltage

output

■ Transfer Roller

contamination

■ Laser Window or optic

contamination

1. Printer is installed in specified

environment?

2. Verify that paper meets

printer specifications. Print 20
to 30 pages using
recommended paper.

3. Determine ghosting pitch and

replace the corresponding
assembly.

NOTE: See Repeating

Defects on page 3-3 for defect

pitch.

4. Replace Power Supply Board.

1. Ensure that Cartridge is not

out of toner. Inspect Drum for
deterioration or
contamination.

2. If defective, replace the Print

Cartridge.

3. Verify Print Cartridge ground.

Check continuity between
cartridge ground contact and
frame ground. Ensure that
drum contact is clean and
undamaged.

4. Inspect the Transfer Roller

spring tension and bearing
contacts.

5. Remove Laser assembly,

clean window, or replace
assembly as necessary.

6. Replace Power Supply Board.

Phaser® 3500 Laser Printer Service Manual

3-9

image-quality Troubleshooting

2

Image Defect Possible Causes Solutions

Black Spots/Marks

There are spots and/or marks of
toner on the printed side of the
page.

s3500-051

Spot or Vertical Deletions

Solid areas are marked with
irregular white spots.

.

■ Print Cartridge

■ Fuser Assembly

■ Paper transports

■ Transfer Roller

■ Damp paper

■ Foreign matter

contamination of printer
components

■ Print Cartridge

■ Transfer Roller

1. Replace the Print Cartridge.

NOTE: See Repeating

Defects on page 3-3 for defect

pitch.

2. Inspect /clean/replace Fuser

Assembly as necessary.

3. Clean contamination from

paper transports and exit
rollers.

4. Clean or replace the Transfer

Roller.

1. Replace paper.

2. Check printer components for

surface contamination or
paper scraps. Clean as
required.

3. If deletions repeat every 94

mm, replace Print Cartridge.

s3500-05

Horizontal Bands

Dark bands appearing in the
horizontal direction.

Character Defects

Garbled print, missing, repeating
or scrambled characters are
problems relating to font data or
character generation.

■ Print Cartridge

■ Fuser Assembly

■ Transfer Roller

■ Incorrect high-voltage

outputs

■ Laser Assembly

■ Loose/defective interface

cables; cable not within
specification.

■ Optional DIMM memory

■ Main Board

NOTE: See Repeating

Defects on page 3-3 for defect

pitch.

4. Remove the Transfer Roller

and clean (dust off). If
deletions repeat every 56
mm, replace Transfer Roller.

1. Replace the Print Cartridge.

2. Inspect /clean/replace Fuser

Assembly as necessary.

3. Inspect the Transfer Roller

spring tension and bearing
contacts.

4. Replace Power Supply Board.

5. Replace Laser Assembly.

1. Inspect cable connections;

verify that cables meet
specified requirements.

2. Replace optional DIMM

memory.

3. Replace Main Board.

Phaser® 3500 Laser Printer Service Manual

3-10

image-quality Troubleshooting

Image Defect Possible Causes Solutions

Unfused Image

Part or all of the image is
unfused.

Skewed Image

The printed image is not parallel
with the sides of the page.

Skips/Smears

Skips, loss or stretching of the
image in bands across the
process direction.

Smears, the distortion of the
image in bands across the
process direction. Causes image
to appear blurred or
compressed.

OHP Print Distortion

Trembling appearance when
printing on transparencies.

■ Paper quality (damp paper)

■ Operating environment

■ Remote Control Panel

settings

■ Fuser Assembly

■ Main Board

■ Paper

■ Paper tray

■ Pick-up roller assembly/

Paper transportation

■ Fuser Assembly

■ Paper transportation

■ Main drive motor assembly

■ Fuser Assembly

■ Print Cartridge

■ Remote Control Panel

settings

■ Recommended Media

■ Transfer roller voltage

1. Paper is too thick, damp or

contains a high percentage of
cotton.

2. Printer is not installed in

specified environment.

3. Verify Remote Control Panel

settings, such as envelope.

4. Inspect /clean/replace Fuser

assembly as necessary.

5. Replace Main Board.

1. Inspect paper for damage.

Replace as necessary.

2. Check paper tray for damage.

Properly install fresh paper in
the paper tray.

3. Inspect Pick-up roller

assembly. Replace as
necessary.

4. Inspect paper transportation

areas for proper operation.

5. Inspect /clean/replace Fuser

assembly as necessary.

1. Inspect paper transportation

areas for proper operation.

2. Inspect main drive motor

assembly for damage or worn
gears. Replace as necessary.

3. Inspect /clean/replace Fuser

assembly as necessary.

4. Replace Print Cartridge.

1. Verify Remote Control Panel

is configured to Transparency
mode.

2. Verify transparency meets

printer specifications.

3. Inspect the Transfer Roller

spring tension and bearing
contacts.

4. Replace Power Supply Board.

Phaser® 3500 Laser Printer Service Manual

3-11

Repairs and Adjustments

This section covers the following:

■ Overview on page 4-2

■ General Notes on Disassembly on page 4-3

■ Covers on page 4-4

■ Control Panel and LCD Display on page 4-10

■ Open Cover on page 4-11

■ Tray 1 (MPT) Assembly on page 4-12

■ Inner Cover on page 4-16

■ Transfer Roller on page 4-17

■ Retard Assembly on page 4-18

■ Tray 1 Separator (Holder) Pad Assembly on page 4-19

■ Feed2 Idle Unit on page 4-20

■ Registration Assembly on page 4-21

■ Main Drive Assembly and Registration (Feed) Clutch on page 4-24

■ Tray 1 Pick-Up Assembly and Pick Rollers on page 4-26

■ Tray 2 Pick-Up Assembly and Rollers on page 4-29

■ Developer Drive Assembly on page 4-33

■ Connector Board on page 4-34

■ Tray 1 (MPT) Solenoid on page 4-35

■ Main Solenoid on page 4-36

■ Fuser Assembly on page 4-37

■ Exit Solenoid Assembly on page 4-38

■ Exit and Duplex Rollers on page 4-39

■ Laser (LSU) Assembly and Lower Cover on page 4-42

■ Left Side Cooling Supply Fan and Duct on page 4-44

■ Toner Sensor Board and CRUM on page 4-45

■ Main Board and Shield on page 4-47

■ Power Supply and Shield on page 4-48

■ Fuser Gear Assembly on page 4-50

■ Paper Size Sensor on page 4-51

Phaser® 3500 Laser Printer Service Manual

4-1

Repairs and Adjustments

Overview

This section contains the removal and replacement procedures for selected parts of the printer
according to the Service Parts List. Not all Replacement Procedures are included in this
Service Manual. In most cases, to reinstall a part, simply reverse the Removal Procedure
shown. In some instances, the Replacement Procedure is included, because it may contain
special steps. For specific assemblies and parts, see Parts List on page 5-1.

Standard Orientation of the Printer

When needed, the orientation of the printer is called out in the procedure for locating printer parts. Refer
to the printer orientation graphic for locating the right, left, front and back sides of the printer.

FRONT

REARLEFT

RIGHT

s3500-056

Phaser® 3500 Laser Printer Service Manual

4-2

Repairs and Adjustments

General Notes on Disassembly

Preparation

Before you begin any Removal and Replacement Procedure:

1. Switch OFF the printer power and disconnect the power cord from the wall outlet.

2. Remove the Print Cartridge and protect it from exposure to light by covering it with a light

proof bag or by placing it in a light-tight container.

3. Disconnect all computer interface cables from the printer.

4. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive

electronics of the printer circuit boards.

5. Remove the Fuser Assembly or wait at least 5 minutes after you have switched OFF

printer power for the Fuser to cool before you work on or around the Fuser.

6. Tray 2 can interfere with the removal of many printer parts. Remove Tray 2 before further

disassembly.

Wherever this video icon appears throughout the manual, detailed
instructions for that procedure are available with videos on the
Phaser 3500 Product Training CD-ROM.

Note: Part names that appear in the disassembly procedures may not exactly match the names

that appear in the Parts List. For example, a part called the Registration Transport Assembly
may appear on the Parts List as Assembly, Transport Regi.

Caution: Many parts are secured by plastic tabs. DO NOT over flex or force these parts. Do

not over torque the screws threaded into plastic parts.
Always use the correct type and size screw. Using the wrong screw can damage tapped holes.
Do not use excessive force to either remove or install either a screw or a printer part.
A spring hook is required for removal and replacement of the various springs in the printer.
Springs can be damaged using pliers or other tools for this task.

Warning: Unplug the AC power cord from the wall outlet before removing any printer part.

Notations in the Disassembly Text

■ The notation “(item X)” points to a numbered callout in the illustration corresponding to the

disassembly procedure being performed.

■ The notation “PLX.X.X” indicates that this component is listed in the Parts List.

■ Bold arrows in an illustration show direction of movement when removing or

replacing a component.

Phaser® 3500 Laser Printer Service Manual

4-3

Repairs and Adjustments

Covers

Right Cover

1. Disconnect the power cord.

2. Remove the Duplex Unit.

3. Remove the 2 rear screws securing the Right Cover to the rear of the

printer.

Note: In the next step, ensure the power switch is in the OFF position in order to free the

Right Cover.

4. Slide the Right Cover towards the rear of the printer to release the 3 tabs, and remove it

from the printer.

Phaser® 3500 Laser Printer Service Manual

4-4

Cover Right

s3500-068

Repairs and Adjustments

Left Cover

1. Disconnect the power cord.

2. Remove the Duplex Unit.

3. Open the Rear Cover for access to the rear top screw.

4. Remove 2 screws, from the rear of the printer, securing the Left Cover.

5. Close the Rear Cover.

6. Slide the left cover towards the rear of the printer to release the 3 tabs securing it to the

printer.

Cover-Left

Phaser® 3500 Laser Printer Service Manual

4-5

s3500-080

Rear Cover

1. Open the Rear Cover.

2. Release the Restraining Strap (tie stopper).

1

Repairs and Adjustments

Tie Stopper

2

s3500-081

Phaser® 3500 Laser Printer Service Manual

4-6

Repairs and Adjustments

3. To release the 2 posts securing the Rear Cover; Lift up on the left (printer left) hinge pin,

then slide the Rear Cover to the left to free the right hinge pin and remove the Rear Cover
from the printer.

Rear Cover

1

2

s3500-082

Phaser® 3500 Laser Printer Service Manual

4-7

Repairs and Adjustments

Top Cover

1. Remove the Print Cartridge and protect it from light exposure.

2. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

Note: Open the Rear and Top Covers for access.

3. Remove the 2 screws located on the front of the Top Cover.

4. On the rear, left side of the printer, remove 1 screw securing the Top Cover.

Phaser® 3500 Laser Printer Service Manual

4-8

s3500-083

Repairs and Adjustments

5. Release 3 tabs, one on the left, one on the right, and one on the rear of the Top Cover.

s3500-085

6. Disconnect the Control Panel wiring harnesses from the Main Board, note the connector

location and routing for reassembly.

Phaser® 3500 Laser Printer Service Manual

4-9

Repairs and Adjustments

Control Panel and LCD Display

1. Remove:

■ Top Cover on page 4-8

2. Remove the 6 screws securing the LCD and control panel and remove from the top cover.

■ 2 screws to the LCD Board.

■ 4 screws on the key panel board.

Note: DO NOT remove the 3 screws securing the plastic portion of the LCD display.

LCD Panel

Key Panel

s3500-086

Phaser® 3500 Laser Printer Service Manual

4-10

Repairs and Adjustments

Open Cover

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

2. Remove the 2 screws and stoppers from the Open Cover.

3. Remove the Open Cover from the Top Cover by flexing the 2 tabs as shown below.

Open Cover

Stopper

s3500-087

s3500-088

Phaser® 3500 Laser Printer Service Manual

4-11

Repairs and Adjustments

Tray 1 (MPT) Assembly

1. Open Tray 1.

2. Unhook the 2 springs connecting the Knock-up Plate to the Pick-Up

Rack.

Note: DO NOT unhook the springs from the Pick-Up Rack.

s3500-058

Note: In the next step, if you exert too much pressure you can break the tracks.

Phaser® 3500 Laser Printer Service Manual

4-12

Repairs and Adjustments

3. Flex the left and right side tracks to disengage the Knock-Up Plate from the Tray 1

Assembly.

Caution: Tray 1 and the Knock-Up Plate contain unsecured plastic parts that fall off and

are easy to lose.

Tray Link

s3500-059

4. Slide Tray 1 to the right side of the printer to release the 4 pivot points securing the Tray,

then remove the Tray 1 Assembly from the printer.

Phaser® 3500 Laser Printer Service Manual

4-13

Repairs and Adjustments

Tray 1 Knock-Up Plate

1. Follow all the steps for removing the Tray 1 (MPT) Assembly on page 4-12.

2. Rotate the tray links down slightly until they come free from the printer.

Note: The tray links are marked “L” for the left and “R” for the right.

3. To free the Knock-Up Plate, carefully spread the slotted hinge piece to release the post,

then remove the Knock-Up Plate.

Note: Tray 1 and the Knock-up Plate contain unsecured plastic parts that fall off and are

easy to lose.

Knock Up Plate Ass'y

Phaser® 3500 Laser Printer Service Manual

Tray Link

4-14

s3500-060

Repairs and Adjustments

Tray 1 Pick-Up Rack

1. Remove 2 screws securing the Pick-Up Rack and remove the rack.

2. Separate the clips from the Pick Roller shaft and remove the Pick-Up Rack.

Caution: Do not remove or loose the springs.

MP Pick Up Rack

s3500-118

Phaser® 3500 Laser Printer Service Manual

4-15

Inner Cover

1. Remove:

■ Tray 1 (MPT) Assembly on page 4-12

■ Top Cover on page 4-8

2. Open or remove Tray 2 for better access.

3. Remove 2 screws securing the Inner Cover to the printer frame.

4. Remove the Inner Cover.

Repairs and Adjustments

Inner Cover

s3500-089

Phaser® 3500 Laser Printer Service Manual

4-16

Repairs and Adjustments

Transfer Roller

Caution: Do not touch the surface of the Transfer Roller.

1. Open the Top Cover.

2. Remove the Print Cartridge and protect it from exposure to light.

3. Remove the cap from the left side of the Transfer Roller.

4. Pinch the bearing clips on both ends of the Transfer Roller.

Note: The gear on the left end of the Transfer Roller shaft is not secured in place. Hold

the gear when removing the roller to prevent it from falling into the printer.

Note: The 2 bearing clips are not interchangeable, and the levers face the rear of the

printer. The clip with the ground contact goes on the gear side of the Transfer Roller.

5. Slide the roller slightly to the right so the end of the shaft clears the lip on the printer case

and lift the Transfer Roller, together with the Bearing Clips and the Transfer Roller Gear,
out of the printer.

Holder

Transfer Roller

s3500-057

Phaser® 3500 Laser Printer Service Manual

4-17

Retard Assembly

1. Remove:

■ Tray 1 (MPT) Assembly on page 4-12

2. Squeeze the lock as shown below and take out the retard assembly.

Retard Ass'y

Repairs and Adjustments

s3500-065

Reassembly Notes

Note: When reassembling the retard roller, insert the left end of the retard shaft through

the retard roller first.

s3500-066

Phaser® 3500 Laser Printer Service Manual

4-18

Repairs and Adjustments

Tray 1 Separator (Holder) Pad Assembly

1. Remove:

■ Tray 1 (MPT) Assembly on page 4-12

■ Tray 1 Knock-Up Plate on page 4-14

■ Retard Assembly on page 4-18

2. Disconnect the connector from the Separator Pad Assembly.

Caution: Be careful not to break the actuator flag.

There is a spring located behind the separator pad, do not loose the spring.

3. Remove the 3 screws shown below and then remove the Separator Pad Assembly from the

printer.

s3500-062

Friction Pad

MP Actuator

Holder Pad Ass'y

Phaser® 3500 Laser Printer Service Manual

4-19

s3500-063

Feed2 Idle Unit

1. Remove:

■ Tray 1 (MPT) Assembly on page 4-12

■ Retard Assembly on page 4-18

■ Tray 1 Separator (Holder) Pad Assembly on page 4-19

2. Remove 4 screws, 2 for each of the feed idle units.

3. Remove each idle unit.

Repairs and Adjustments

Feed2 Idle Unit

Phaser® 3500 Laser Printer Service Manual

4-20

s3500-067

Repairs and Adjustments

Registration Assembly

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

2. Remove the Gear Cap located on the right side of the Registration Assembly, the release is

on the front of the cap.

Gear Cap

s3500-115

Phaser® 3500 Laser Printer Service Manual

4-21

Repairs and Adjustments

3. Remove the 4 screws securing the Registration Assembly to the printer.

4. Remove the Registration Assembly from the printer.

REGI Ass'y

s3500-114

s3500-116

Phaser® 3500 Laser Printer Service Manual

4-22

PTL Board

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

■ Registration Assembly on page 4-21

2. Disconnect the wiring harness.

3. Remove 1 screw and take out the PTL board.

Repairs and Adjustments

PTL Upper

Terminal

PTL PBA

Phaser® 3500 Laser Printer Service Manual

4-23

s3500-117

Repairs and Adjustments

Main Drive Assembly and Registration (Feed) Clutch

1. Remove:

■ Covers on page 4-4

Feed Clutch

1. Loosen the grounding bracket screw attached to the plate on the Main Drive Assembly,

and rotate the grounding bracket to gain access to the e-ring.

2. Remove the e-ring securing the clutch to the feed roller shaft.

3. Disconnect the connector to the connector board, and remove the clutch from the printer.

Clutch

E-Ring

s3500-073

Phaser® 3500 Laser Printer Service Manual

4-24

Main Drive Assembly

1. Disconnect 1 connector from the main motor assembly.

2. Remove the 6 screws securing the Main Drive to the printer.

3. Remove the Main Drive from the printer.

Repairs and Adjustments

Main Drive
Ass'y

s3500-074

Replacement Notes

Note: There are numbers for replacing each of the 6 screws in the appropriate order when

reassembling the Main Drive Assembly. There is a veristor that is secured underneath the
number 3 screw.

Phaser® 3500 Laser Printer Service Manual

4-25

Repairs and Adjustments

Tray 1 Pick-Up Assembly and Pick Rollers

Tray 1 Pick Roller Only

Note: If you are only removing the Pick Roller, and not the shaft, it may be necessary to

rotate the shaft, release the solenoid, and then rotate the shaft gear clockwise to position
the roller properly.

Caution: Do not break the pick shaft by trying to force the pick roller off.

1. Slide the idle gears outward. Release the locking tab on the pick roll assembly and slide

the roller to the right.

1

1

Pick Roller

Idle

2

s3500-123

Phaser® 3500 Laser Printer Service Manual

4-26

Repairs and Adjustments

Pick Roller and Shaft Removal

1. Remove:

■ Covers on page 4-4.

■ Left Cover on page 4-5.

■ Top Cover on page 4-8.

■ Tray 1 (MPT) Assembly on page 4-12.

■ Inner Cover on page 4-16.

■ Main Drive Assembly and Registration (Feed) Clutch on page 4-24.

2. On the left side of the printer, remove the locking bearing on the front of the shaft by

rotating it in the direction of the arrows shown below.

Bearing

Phaser® 3500 Laser Printer Service Manual

4-27

s3500-119

Repairs and Adjustments

3. Remove 1 screw, on the right end of the shaft, securing the bracket, remove the bracket

with the bearing.

Bracket

Gear ass'y

Bearing

s3500-120

4. Remove the right side gear from the shaft.

5. Lift the latch on the idle cam and slide the shaft to the right, throught the cam, to free it

from the printer.

1

2

Idle-Cam

Phaser® 3500 Laser Printer Service Manual

4-28

s3500-121

Repairs and Adjustments

Tray 2 Pick-Up Assembly and Rollers

Note: It is not necessary to remove the entire assembly in order to

remove the Pick Rollers.

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

■ Tray 1 (MPT) Assembly on page 4-12

■ Inner Cover on page 4-16

■ Main Drive Assembly and Registration (Feed) Clutch on page 4-24

■ Tray 2 and Tray 3 (if installed)

2. Release the latch on the pick-up cam and slide off the right side of the shaft.

2

1

Gear-Pick Up Cam

Phaser® 3500 Laser Printer Service Manual

4-29

s3500-124

Repairs and Adjustments

3. Remove the e-clip from the feed shaft.

4. Remove the locking bearing, rotating in the direction of the arrow as shown below.

Bearing

Feed2
Gear

5. Remove the gear by sliding off the shaft.

6. Turn the printer onto its left side.

7. Remove the front crossbar secured by 2 screws.

s3500-125

Bottom Cross Bar

Phaser® 3500 Laser Printer Service Manual

4-30

s3500-127

8. Slide the actuator down and remove it from the printer.

Actuator

2

1

Repairs and Adjustments

s3500-128

9. Remove the 4 screws securing the pick assembly and manuever the pick assembly out of

the printer.

1

Pick Up Unit

3

2

Phaser® 3500 Laser Printer Service Manual

4-31

s3500-129

Repairs and Adjustments

Feed 2 Unit

1. Perform all steps for Tray 2 Pick-Up Assembly and Rollers on page 4-29.

2. Remove the pick up gear.

3. Remove remove the locking bearing.

4. Remove the 4 screws securing the Feed 2 Unit to the printer and remove the assembly.

2

Bearing

1

Pick Up Gear

s3500-126

Phaser® 3500 Laser Printer Service Manual

4-32

Developer Drive Assembly

1. Remove:

■ Covers on page 4-4

2. Disconnect the connector from the developer drive assembly.

3. Remove 4 screws securing the developer drive to the printer.

Repairs and Adjustments

DEVE Drive
Ass'y

s3500-075

Replacement Notes

Note: There are numbers for replacing each of the 4 screws in the appropriate order when

reassembling the Developer Drive Assembly.

Phaser® 3500 Laser Printer Service Manual

4-33

Connector Board

1. Remove:

■ Covers on page 4-4

2. Disconnect all connectors to the connector board.

3. Remove 1 screw securing the board to the chassis.

4. Remove the connector board.

Repairs and Adjustments

Connector
PBA

s3500-076

Phaser® 3500 Laser Printer Service Manual

4-34

Tray 1 (MPT) Solenoid

1. Remove:

■ Covers on page 4-4

2. Disconnect the connector to the Tray 1 Solenoid.

3. Remove 1 screw securing the Tray 1 Solenoid.

Repairs and Adjustments

MP Solenoid

s3500-078

Phaser® 3500 Laser Printer Service Manual

4-35

Main Solenoid

1. Remove:

■ Covers on page 4-4

■ Feed Clutch on page 4-24

2. Disconnect the connector to the Main Solenoid.

3. Remove 1 screw securing the Main Solenoid.

Repairs and Adjustments

Main Solenoid

s3500-079

Phaser® 3500 Laser Printer Service Manual

4-36

Fuser Assembly

1. Remove:

■ Rear Cover on page 4-6

2. Pull the locking lever and take out the Fuser Assembly.

Repairs and Adjustments

Fuser Ass'y

Thermistor
Connector

s3500-090

Phaser® 3500 Laser Printer Service Manual

4-37

Repairs and Adjustments

Exit Solenoid Assembly

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

2. Disconnect the connector running to the main board.

3. Remove 3 screws securing the solenoid to the printer.

4. Remove the solenoid assembly.

Note: There is a resistor attached by the upper right hand screw. When reassembling the

printer, ensure the resistor is in place.

Exit Solenoid
Ass'y

Phaser® 3500 Laser Printer Service Manual

4-38

s3500-099

Repairs and Adjustments

Exit and Duplex Rollers

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

Note: When you remove the exit rollers, the rollers underneath are spring loaded and can

become lost if not careful.

2. Remove the locking bearings from both ends of the shaft.

Exit Roller

Rack-Exit Roller

Bearing

Phaser® 3500 Laser Printer Service Manual

4-39

s3500-101

Exit Gear

1. Remove the bearing in order to remove the gear.

Bearing

2

Tray Full Actuator

1. Remove the actuator from the exit roller.

Repairs and Adjustments

1

Exit Gear

s3500-102

Actuator

s3500-100

Phaser® 3500 Laser Printer Service Manual

4-40

Repairs and Adjustments

Duplex Roller

1. Using a small flatblade screwdriver, spread apart the bearings on both side of the duplex

roller and remove from the printer.

Duplex
Exit Roller

Holder

s3500-103

Phaser® 3500 Laser Printer Service Manual

4-41

Repairs and Adjustments

Laser (LSU) Assembly and Lower Cover

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

2. Remove the cover-frame exit cover.

3. Disconnect the connector from the LSU to the Main Board.

4. Remove the 3 screws securing the LSU to the chassis.

5. Remove the LSU from the printer.

Note: The screws are numbered and need to be replaced and tightened in the correct order.

LSU

s3500-106

Phaser® 3500 Laser Printer Service Manual

4-42

LSU Lower Cover

1. Remove 1 screw securing the fan duct.

2. Remove the fan and duct to access the screw in the next step.

3. Remove 3 screws securing the LSU Cover and remove the cover.

4. Disconnect all the connectors running to the LSU Cover.

Repairs and Adjustments

LSU Lower
Cover

Phaser® 3500 Laser Printer Service Manual

4-43

s3500-113

Left Side Cooling Supply Fan and Duct

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

■ Laser (LSU) Assembly and Lower Cover on page 4-42

2. Disconnect the connector to the Toner Sensor Board.

3. Remove 1 screw to remove the fan from the printer.

DC Fan

Stopper

Repairs and Adjustments

Phaser® 3500 Laser Printer Service Manual

4-44

s3500-108

Repairs and Adjustments

Toner Sensor Board and CRUM

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

■ Laser (LSU) Assembly and Lower Cover on page 4-42

2. Disconnect all connectors running to the toner sensor board.

3. Remove 2 screws securing the toner sensor board to the LSU cover.

4. Release the 2 locking tabs to remove the board.

Toner Sensor PBA

HV Small
Spring

Phaser® 3500 Laser Printer Service Manual

4-45

s3500-111

Repairs and Adjustments

Cover Open Board and Harness Cover

1. Remove:

■ Covers on page 4-4

■ Left Cover on page 4-5

■ Top Cover on page 4-8

■ Laser (LSU) Assembly and Lower Cover on page 4-42

2. Remove 1 screw securing the cover open housing harness cover.

3. Release the latching tab and remove the cover open housing harness cover.

4. Disconnect the connector from the main board.

5. Using a small flatbladed screwdriver, release the 4 tabs to remove the cover open board.

Cover Open PBA

Harness Cover

Cover Open

Phaser® 3500 Laser Printer Service Manual

4-46

s3500-112

Repairs and Adjustments

A

Main Board and Shield

Note: If the NIC Board is installed, it must be removed to access screws to the main

board.
NVRAM parameters are not transferable to the replacement board. These parameters
include serial number and copy count. Serial Number can be reinstalled via CentreWare IS
if the NIC Board is installed or via a downloadable PJL command. Observe proper ESD
procedures when removing or replacing any circuit boards in the printer.

1. Remove:

■ Covers on page 4-4

2. Disconnect all connectors from the Main Board.

3. Remove the NIC card or the dummy bracket from the main board.

4. Remove the 6 screws (4 on the Main Board and 2 to the parallel connector) securing the

Main Board to the printer, and then remove the Main Board.

5. Position the retainers on the parallel port connector straight out from the connector for

removal.

6. Move the board toward the front of the printer so the connectors clear the bracket and

remove the Main Board to the right.

7. Remove 1 screw in the center of the shield.

8. Turn the printer onto its left side and remove the rear crossbar and the right duplex guide.

9. Remove the right rear corner screw from the power supply shield to remove.

Phaser® 3500 Laser Printer Service Manual

4-47

Main PB

s3500-071

Power Supply and Shield

1. Remove:

■ Print Cartridge

■ Tray 2 and Tray 3 (if installed)

■ Covers on page 4-4

■ Rear Cover on page 4-6

■ Fuser Assembly on page 4-37

2. Turn the printer onto it’s left side.

3. Remove the rear crossbar secured by 2 screws.

4. Remove the Tray 2 no paper actuator for better access.

5. Remove the left and right duplex unit guides.

Repairs and Adjustments

Guide-Duplex L

Guide-Duplex R

Phaser® 3500 Laser Printer Service Manual

4-48

s3500-136

Repairs and Adjustments

6. Remove 5 screws from the power supply shield.

7. Remove 1 grounding screw from the rear of the power supply shield.

Engine Shield
Ass'y

s3500-135

8. Pull out the shield slightly and disconnect all connectors to the power supply board.

9. Remove the power supply from the printer.

Engine Shield Ass'y

Phaser® 3500 Laser Printer Service Manual

4-49

s3500-137

Repairs and Adjustments

Fuser Gear Assembly

1. Remove:

■ Print Cartridge

■ Tray 2 and Tray 3 (if installed)

■ Covers on page 4-4

■ Rear Cover on page 4-6.

■ Fuser Assembly on page 4-37

■ Exit Solenoid Assembly on page 4-38

■ Main Board and Shield on page 4-47

2. Remove the 3 screws securing the fuser gear train and remove it from the printer.

Phaser® 3500 Laser Printer Service Manual

4-50

Repairs and Adjustments

Paper Size Sensor

Note: If the optional Tray 3 Feeder is installed, it must be removed before perfoming this

procedure.

1. Remove:

■ Print Cartridge

■ Tray 2 and Tray 3 (if installed)

■ Left Cover on page 4-5

2. Disconnect CN 1 from the Paper Size Sensor.

3. Gently turn the printer upside down.

Note: The Paper Size Sensor can be removed and replaced without removing the rear

crossbar. However, to provide improved access, remove the crossbar screw above the
Paper Size Sensor and loosen the screw on the other side so you can swing the crossbar out
of the way.

4. On the left side of the printer, remove 2 screws, one on either side of the rear crossbar, that

secure the Paper Size Sensor to the printer chassis.

5. Pull up on the sensor assembly until it is clear of the mounting pins and then remove it

from the printer.

Phaser® 3500 Laser Printer Service Manual

4-51

Parts List

This section covers the following:

■ Using the Parts List on page 5-2

■ PL 8.1 Main Assembly on page 5-3

■ PL 8.2 Cover Assembly on page 5-7

■ PL 8.3 Frame Assembly on page 5-9

■ PL 8.4 Fuser Assembly on page 5-17

■ PL 8.9 Tray 2 Cassette on page 5-20

■ PL 8.10 Tray 3 Cassette on page 5-22

■ PL 8.11 Duplex Assembly on page 5-25

Phaser® 3500 Laser Printer Service Manual

5-1

Parts List

Using the Parts List

1. No.: The callout number from the exploded part diagram.

2. Part Number: The material part number used to order specific parts.

3. Qty: This number represents the parts per printer, not the number of parts supplied in the

actual part order.

4. Name/Description: Details the name of the part to be ordered and the number of parts

supplied per order.

5. Parts identified throughout this manual are referenced PL #.#.#; For example, PL 3.1.10

means the part is item 10 of Parts List 3.1.

6. A black triangle preceding a number followed by a parenthetical statement in an illustrated

parts list means the item is a parent assembly, made up of the individual parts called out in
parentheses.

7. The notation “with X~Y” following a part name indicates an assembly that is made up of

components X through Y. For example, “1 (with 2~4)” means part 1 consists of part 2, part
3, and part 4.

8. An asterisk (*) following a part name indicates the page contains a note about this part.

9. The notation (NS) next to a part indicates that pariticular part is not spared, but contained

in a kit or major assembly.

10. The notation “J1<>J2 and P2” is attached to a wire harness. It indicates that connector

Jack 1 is attached to one end of the wire harness and connector J2 is attached to the other
end that is plugged into P2.

Only parts showing part numbers are available for support. Parts not showing part
numbers are available on the parent assembly.

Legend:

Identifier Meaning

CC-ring

EE-ring

KL K-clip

SScrew

Phaser® 3500 Laser Printer Service Manual

5-2

PL 8.1 Main Assembly

10

8

8-1

8-2
8-3

8-4

7

15

34

32

12

31

14

11

13

Parts List

0

2

37

3

9-1
9-2

9-3

9

38

16

3-4

3-3

3-6

3-5

3-2

3-1

39(Network only)

39-2

35

19

17

1

24

18

20-1

20-3

20-2

22

20

4

23

30

29

30

28

36

25
26

21

27

21-2

21-3

21-1

5

4-1

39-1

40

6

4-2

Phaser® 3500 Laser Printer Service Manual

5-3

PL 8.1 Parts List Table

Main Assembly

Item No. Description Qty Part Number

1 ELA UNIT FRAME BASE

2 ELA HOU BASE HOUSING

3 MEA UNIT KNOCK UP MP 050N00475

3.1 PLATE M KNOCK UP MP

3.2 MPR PAD KNOCK UP MP

3.3 PMO SIDE GUIDE MP R

3.4 PMO SIDE GUIDE MP L

3.5 GEAR PINION

3.6 SHAFT REINFORCEMENT

4 MEA UNIT COVER MP XRX 002N02410

Parts List

4.1 COVER M MP XRX

4.2 TRAY M EXTND MP

5 TRAY M LINK MP L 012N00521

6 TRAY M LINK MP R 012N00522

7 ROLLER TRANSFER 022E29520

8 ELA UNIT HOLDER TR R 019E63470

8.1 PMO BUSHING TR

8.2 SPRING ETC TR R HAWK

8.3 PMO TRANSFER HOLDER

8.4 IPR PLATE TR

9 ELA UNIT HOLDER TR L 019E63480

9.1 PMO BUSHING TR

9.2 SPRING ETC TR R HAWK

9.3 PMO TRANSFER HOLDER

10 PMO CAP TR 021N02248

11 GEAR TR29 (Transfer) 007N01013

12 ELA UNIT REGI (Registration Assembly) 022N02171

13 GEAR REGI Z25 007N01360

14 CAP M GEAR 807E06450

15 UNIT LSU (Laser Unit) 122N00242

Phaser® 3500 Laser Printer Service Manual

5-4

Main Assembly (Continued)

Item No. Description Qty Part Number

16 ELA UNIT EXIT SOLENOID 121N01100

17 ELA UNIT DEVE MOTOR 127N07389

18 ELA UNIT MAIN MOTOR 127N07390

19 PBA MAIN (Main Board) 140N63016

20 MEA UNIT GEAR PICK UP 007N01361

20.1 GEAR M PICK UP CAM

20.2 GEAR M PICK UP

20.3 SPRINT ETC CAM MP

21 MEA UNIT GEAR P/UP MP CARDINAL 007K13470

21.1 GEAR MP HOLDER CAM

21.2 GEAR MP PICK UP

21.3 SPRING ETC CAM MP

Parts List

22 BEARING PICK UP

23 BRACKET P SHAFT MP

24 MEP CLUTCH FEED 121N01101

25 SOLENOID MAIN 121E19250

26 SOLENOID MP 121N01102

27 RING E

28 SHIELD P SMPS

29 SMPS V1 HVPS - 110V

SMPS V2 HVPS - 220V

30 BAR P CROSS BOTTOM

31 FAN DC 127E14630

32 STOPPER M FAN80

34 ELA UNIT DEVE (Print Cartridge)

6K Toner Cartridge

12K Toner Cartridge

35 ELA UNIT CASSETTE (Tray 2) 109R00756

36 ELA UNIT SCF (Optional Tray 3) 050N00476

105N02059

105N02060

106R01148

106R01149

37 ELA UNIT DUPLEX 084N00718

38 BRACKET P DUMMY CTRL 015N00555

39 ELA HOU NPCE High (Network Interface Card) 140N63021

Phaser® 3500 Laser Printer Service Manual

5-5