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
Phaser® 3500 Laser Printer Service Manual
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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
xii
Service Call Procedures
This section includes the following:
■ Servicing Instructions on page 1-2
■ Service Preventive Maintenance Procedure on page 1-3
Phaser® 3500 Laser Printer Service Manual
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.
Phaser® 3500 Laser Printer Service Manual
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.
Phaser® 3500 Laser Printer Service Manual
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)
Phaser® 3500 Laser Printer Service Manual
2-2
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).
Phaser® 3500 Laser Printer Service Manual
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
Phaser® 3500 Laser Printer Service Manual
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
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