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Service Manual
Phaser® 3600
Laser Printer
Service Manual
Phaser® 3600 Printer
Warning
The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so.
First Printing: September 2008
Prepared By:
Xerox Corporation
XOG Worldwide Product Training and Information
26600 SW Parkway
Wilsonville, OR 97070
Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation.
Copyright protection claimed includes all forms and matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc.
Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale. These materials may not be distributed, copied, or otherwise reproduced without prior written consent from Xerox Corporation.
XEROX®, CentreWare®, Phaser®, PrintingScout®, and Walk-Up® are trademarks of Xerox Corporation in the United States and/or other countries.
Adobe® and PostScript® are trademarks of Adobe Systems Incorporated in the United States and/or other countries.
Apple®, Bonjour®, ColorSync®, EtherTalk®, Macintosh®, and Mac OS® are trademarks of Apple Computer, Inc. in the United States and/or other countries.
PCL® is a trademark of Hewlett-Packard Corporation in the United States and/or other countries.
Microsoft®, Windows®, Windows Server®, and Windows Vista® are trademarks of Microsoft Corporation in the United States and/or other countries.
Novell®, NetWare®, and IPX/SPX™ are trademarks of Novell, Incorporated in the United States and/or other countries.
SunSM, Sun Microsystems™, and Solaris™ are trademarks of Sun Microsystems, Incorporated in the United States and/or other countries.
UNIX® is a registered trademark in the US and other countries, licensed exclusively through X/Open Company Limited.
As an ENERGY STAR® partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.
Service Terms
Manual Terms
Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when they are used, and always read Note, Caution, and Warning statements.
Note
A note indicates an operating or maintenance procedure, practice or condition that is necessary 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 indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in damage to, or destruction of, equipment.
Warning
A warning indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results 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.
Danger: A personal injury hazard exists in the area where you see the sign.
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Symbols Marked on the Product
0°C 
35°C 32°F 95°F
Warning. Danger invisible laser radiation when open. Avoid direct exposure to beam.
Hot surface on or in the printer. Use caution to avoid personal injury.
Warning. Use caution to avoid personal injury.
Use caution (or draws attention to a particular component). Refer to the manual(s) for information.
Do not touch the OPC Drum.
Do not expose the item to sunlight.
Do not tilt the Print Cartridge.
Do not expose item to extreme temperature.
Recycle the item.
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Phaser 3600 Printer Service Manual |
Power Safety Precautions
Power Source
For 115 VAC printers, do not apply more than 127 volts RMS between the supply conductors or between either supply conductor and ground. For 230 VAC printers, do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. 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. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.
Disconnecting Power
Warning
Turning the power Off using the power switch does not completely deenergize the printer. You must also disconnect the power cord from the printer’s Alternating Current (AC) inlet. Disconnect the power cord 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 product,
■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 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 is Off to the chassis or circuit board, and observe all other safety precautions.
■Immediately before handling any semiconductor components assemblies, drain the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock.
■After removing a static sensitive assembly from its anti-static bag, place it on a grounded conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface.
■Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage some devices.
■Do not remove a replacement component or electrical sub-assembly from its protective package until you are ready to install it.
■Immediately before removing the protective material from the leads of a replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed.
■Minimize body motions when handling unpacked replacement devices. Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device.
■Handle IC’s and Erasable Programmable Read-Only Memories (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 and Safety precautions:
For qualified service personnel only: Refer also to the preceding “Power Safety Precautions” on page v.
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.
Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers 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 3600 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 product does not emit hazardous laser radiation; which is possible only because the laser beam is totally enclosed during all modes of customer operation. When servicing the printer or laser unit, follow the procedures specified in this manual and there will be no hazards from the laser.
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Servicing Electrical Components
Before starting any service procedure, switch the printer power Off 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
Do not touch any electrical component unless you are instructed to do so by a service procedure.
Servicing Mechanical Components
When servicing mechanical components within the printer, manually rotate the Drive Assemblies, Rollers, and Gears.
Warning
Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.
Servicing Fuser Components
Warning
This printer uses heat to fuse the toner image to paper. The Fuser is VERY HOT. Turn the printer power Off and wait at least 5 minutes for the Fuser to cool before attempting to service the Fuser or adjacent components.
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Regulatory Information
Xerox has tested this product to electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a typical office environment.
United States (FCC Regulations)
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the Federal Communications Commission (FCC) Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy. If it is not installed and used in accordance with these instructions, it may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment Off and On, the user is encouraged to try to correct the interference by one or more of the following measures:
■Reorient or relocate the receiver (device being interfered with).
■Increase the separation between the printer and the receiver.
■Connect the equipment into an outlet on a circuit different from that which the receiver is connected.
■Consult the dealer or an experienced radio/television technician for help.
Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interface cables.
Canada (Regulations)
This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.
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European Union
The CE mark applied to this product symbolizes Xerox’s declaration of conformity with the following applicable Directives of the European Union as of the dates indicated:
December 12, 2006: Council Directive 2006/95/EC as amended. Approximation of the laws of the member states related to low voltage equipment.
December 15, 2004: Council Directive 2004/108/EC as amended. Approximation of the laws of the member states related to electromagnetic compability.
This product, if used properly in accordance with the user's instructions, is neither dangerous for the consumer nor for the environment.
To ensure compliance with European Union regulations, use shielded interface cables.
A full declaration of conformity, defining the relevant directives and referenced standards, can be obtained from your Xerox Limited representative.
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Manual Organization
The Phaser 3600 Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. Use this manual as your primary resource for understanding the operational characteristics of the printer and all available options. This manual describes specifications, theory, and the diagnosis and repair of problems occurring in the print engine and attached options. Also included are detailed replacement procedures, parts lists, and wiring diagrams.
The Phaser 3600 Printer Service Manual contains these chapters:
Introductory, Safety, and Regulatory Information: This section contains important safety information and regulatory requirements.
Chapter 1 - General Information: This chapter contains an overview of the printer’s operation, configuration, specifications, and consumables.
Chapter 2 - Theory of Operation: This chapter contains detailed functional information on the printer components.
Chapter 3 - Error Messages: This chapter provides detailed troubleshooting procedures for error messages generated by resident diagnostics.
Chapter 4 - General Troubleshooting: This chapter contains general information on troubleshooting the printer. In addition, this chapter includes troubleshooting methods for situations where error indicators are not available.
Chapter 5 - Print-Quality Troubleshooting: This chapter focuses on techniques to correct image quality problems associated with the printer output.
Chapter 6- Cleaning and Maintenance: This chapter provides periodic cleaning procedures for the printer.
Chapter 7- Service Parts Disassembly: This chapter contains removal procedures for spare parts listed in the Parts List. A replacement procedure is included when necessary.
Chapter 8- Parts List: This chapter contains exploded views of the print engine and optional Field Replaceable Units (FRUs), as well as part numbers for orderable parts.
Chapter 9- Plug/Jack and Wiring Diagrams: This chapter contains the plug/jack locations and the wiring diagrams for the printer.
Reference: This section provides a list of acronyms and abbreviations
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Table Of Contents
Table Of Contents
Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Electrostatic Discharge Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Regulatory Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1 General Information
Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printer Options and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Consumable and Service Part Life Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Parts of the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Error and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Printer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Printer Location and Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Printer Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Functional Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Environmental Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
2 Theory of Operation
Phaser 3600 Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Summary of the Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Print Cartridge and Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Printer Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Duplex Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Print Engine Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Image Processing Assembly and Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Laser Scan Unit (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Motor Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Feed Assembly Process and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Transfer Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Duplex and Tray Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Duplex Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Tray 2 and Optional Tray 3 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Printer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Paper Size Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Automatic Paper Pick Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Laser Scan Unit (LSU) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Laser Light Intensity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Toner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Fuser Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
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Sensor Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Sensor Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Sensors in the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
High Voltage Power Supply (HVPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Switching Mode Power Supply (SMPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
3 Error Messages
Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Entering Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Service Diagnostic Control Panel Button Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Diagnostic Test Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Troubleshooting Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Jam At Tray [1] [2] [3] (Jam 0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Jam At Top (Jam 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Jam At Exit (Jam 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Jam At Rear (Duplex Jam 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Jam At Duplex (Duplex Jam 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge, Replace Print Cartridge . . . . . . . . . . . . . . . 3-18 Close Fuser Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Close Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Fuser Failure, Engine Fuser Low Heat Error, or Engine Fuser Over Heat Error. . . . . . . . . . . . . . . . . . . . . . . 3-20 Laser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Output Tray is Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
4 General Troubleshooting
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Preventive Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Recommended Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
No Control Panel Display after Power Is Turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Control Panel LED is On, Control Panel Display Is Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Taking Voltage Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
5 Print-Quality Troubleshooting
Print-Quality Problems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Repeating Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Repeating Defects Measurement Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Control Panel (Internal) Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
2 |
Phaser 3600 Printer Service Manual |
Table Of Contents
Image-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Blank Print (No Print) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Light or Undertone Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Black Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Residual Image or Ghosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Faded or Missing Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Random Spots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Repeating Bands, Lines, Marks, or Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Unfused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Horizontal Band, Voids, or Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
6 Cleaning and Maintenance
Service Maintenance Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Recommended Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Cleaning the Laser Scan Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Cleaning the Print Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Control Panel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Cleaning the Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Cleaning the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
7 Service Parts Disassembly
Service Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Fastener Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Notations in the Disassembly Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Covers and Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Right Cover (PL 1.2.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Left Cover (PL 1.2.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Rear Cover (PL 1.2.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Rear Cover Fan (PL1.2.6.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Top Cover (PL 1.2.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Access Door (PL 1.2.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Control Panel (PL 1.2.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Tray 1 (MPT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Inner Cover (PL 1.2.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Tray 1 (MPT) Knock-Up Plate Only (PL 1.1.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Tray 1 (MPT) Pick-Up Rack (PL 1.3.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Retard Assembly (PL 1.3.49) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Tray 1 (MPT) Separator Pad Assembly (PL 1.3.4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Tray 1 (MPT) Feed Sensor (PL1.3.97). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Paper Tray Empty Sensor (PL1.3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Paper Tray Empty Actuator (PL1.3.58) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Sub Toner Low Sensor Board (PL1.3.47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Pick Roller and Shaft (PL 1.3.2.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Tray 1 (MPT) Pick Roller Only (PL 1.3.2.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Tray 1 (MPT) Solenoid (PL 1.1.26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
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Tray 2 Pick-Up Assembly and Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Pick-Up Gear and Bearing (PL 1.1.21). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Tray 2 Feed Roller (PL1.3.59.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Tray 2 Pick Roller (PL1.3.59.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Tray 2 (PL2.1.0) and Optional Tray 3 (PL2.2.0) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Duplex Unit (PL2.3.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Main Drive and Registration Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Main Drive Assembly (PL 1.1.18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Main Board (PL 1.1.19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Main Solenoid (PL 1.1.25). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Registration Assembly (PL 1.1.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Transfer Roller (PL 1.1.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Exit Roller (PL 1.3.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Exit Gear (PL 1.3.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Outbin Full Actuator (PL 1.3.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Outbin Full Sensor (PL1.3.21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
Duplex Roller (PL 1.3.11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
Exit Solenoid (PL 1.1.16). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Feed Idle Unit (PL 1.3.50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Pre-transfer Lamp (PTL) Board (PL 1.3.71) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Developer Drive Assembly (PL 1.1.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Joint Board (PL 1.3.61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Paper Size Sensor (PL 1.3.14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
Fuser Assembly (1.3.80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
Fuser Interlock Switch (PL 1.3.77) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Fuser Exit Sensor (PL 1.3.76) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Fuser Thermostat (PL 1.4.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Fuser Thermistor (PL 1.4.40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Heat Roller (PL 1.4.53) and Bushing (PL 1.4.44) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Dual-lamp (PL 1.4.56) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Pressure Roller (PL 1.4.66) and Bushing (PL 1.4.50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Laser Scan Unit (PL 1.1.15). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
LSU Lower Cover (PL 1.3.48) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Left Side Cooling Supply Fan and Duct (PL 1.1.31). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Cover Open Board and Sensor (PL 1.3.47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
High Voltage Power Supply (HVPS) (PL 1.1.29.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Switched Mode Power Supply (PL 1.1.29.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
8 Parts List
Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Serial Number Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
PL 1.1 Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
PL 1.2 Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
PL 1.3 Frame Assembly (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
PL 1.3 Frame Assembly (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
PL 1.4 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
PL 2.1 Tray 2 Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
PL 2.2 Tray 3 Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
PL 2.3 Duplex Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
4 |
Phaser 3600 Printer Service Manual |
Table Of Contents
9 Plug/Jack and Wiring Diagrams
Plug/Jack Diagrams and Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Plug/Jack and Connector Locators and Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Printer Plug/Jack/Connector Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Map 1- LSU and Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Map 2- Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Map 3- SMPS Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Map 4 - HVPS Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Notations Used in the Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 General Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 HVPS/SMPS to Main Board Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 Sensor to Main Board Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Main Drive/Joint Board and Optional Tray Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 LSU and Main Motor to Main Board Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 Controller Unit and Duplex Board to Main Board Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
A Reference
Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Index
Phaser 3600 Color Laser Printer Service Manual |
5 |
General Information
In this chapter...
■Printer Configurations
■Consumable and Service Part Life Expectancy
■Parts of the Printer
■Control Panel
■Printer Specifications
■Media and Tray Specifications
Chapter 1
General Information
Printer Configurations
Print Features and Configurations
|
Printer Configurations |
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Features |
3600_B |
3600V_B |
3600_N |
3600V_N |
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Maximum Print Speed |
40 ppm |
40 ppm |
40 ppm |
40 ppm |
Letter |
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|
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|
|
|
|
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Memory (Optional) |
64 MB |
64 MB |
128 MB |
128 MB |
Up to 512 MB Optional if |
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|
|
|
the original DIMM is |
|
|
|
|
replaced with 256MB RAM |
|
|
|
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DIMM and the second slot |
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|
|
|
has a 256MB RAM DIMM |
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PostScript and PCL Fonts |
Yes |
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Yes |
Yes |
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Default Resolution |
600 x 600 dpi |
600 x 600 dpi |
|
|
Maximum Resolution |
1200 x 1200 |
1200 x 1200 |
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|
dpi |
dpi |
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500-Sheet Feeder (Tray 3) |
Optional |
Optional |
Optional |
Optional |
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Network Interface |
Not Optional |
Not Optional |
Standard |
Standard |
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|
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Automatic 2-Sided Printing |
Optional |
Optional |
Optional |
Standard |
(Separate Duplex Unit) |
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USB, Parallel Interface |
Yes |
Yes |
Yes |
Yes |
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Printer Options and Supplies
Options and Supplies |
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Printer Option |
|
Item |
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Part Number |
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Memory |
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64 MB additional RAM memory |
|
097S03759 |
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128 MB additional RAM memory |
|
097S03760 |
|
|
256 MB additional RAM memory |
|
097S03761 |
|
|
|
|
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Optional Units |
|
Duplex Unit |
|
097S03387 |
|
|
500-Sheet Feeder |
|
097S03385 |
|
|
|
|
|
Cartridges |
|
Standard-Capacity Print Cartridge |
|
106R01370 |
|
|
(7,000 pages) |
|
106R01371 |
|
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High-Capacity Print Cartridge (14,000 |
|
|
|
|
pages) |
|
106R01372 |
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Extra High-Capacity Print Cartridge |
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|
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(20,000 pages) |
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Metered/Pagepack Print cartridge |
|
106R01369 |
|
|
(20,000 pages) |
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Gear Lubricant |
|
Xerox lubricant Plastislip grease |
|
043E00550 |
|
|
|
|
|
1-2 |
Phaser 3600 Printer Service Manual |
General Information
Consumable and Service Part Life Expectancy
Consumable (toner/print cartridge) usage is tracked by the CRUM and monitored by the Main Board in order to display the near end-of-life and end- of-life messages. Life ratings are based on 5% coverage and an average 4 page job length.
Consumables |
Print Life |
|
|
Print Cartridge |
Standard Capacity 7,000 pages |
|
High Capacity 14,000 pages |
|
Extra High Capacity 20,000 pages |
|
Metered/Pagepack 20,000 pages |
|
|
Service Parts |
|
|
|
Fuser Assembly |
150,000 pages |
|
|
Transfer Roller |
150,000 pages |
|
|
Feed Roller Kit |
150,000 pages |
|
|
Retard Roller |
150,000 pages |
|
|
Separator Pad |
150,000 pages |
|
|
Note
The service parts are not tracked with an NVRAM counter and there is no replace or low warnings associated with these service parts.
Phaser 3600 Printer Service Manual |
1-3 |
General Information
Parts of the Printer
Front View
Print Cartridge |
Output Tray |
Control Panel |
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||
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Paper Output Support |
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Control Board |
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Cover |
Tray 1 (MPT)
Tray 1 (MPT) Release
Tray 2
On/Off Switch
Paper Gauge s3600-001
Rear View
Rear Door
Network Port |
|
(optional for 3500B) |
Duplex Unit |
|
|
USB Port |
(optional) |
|
IEEE 1284 Parallel Port |
|
Tray 3 Optional |
|
Cable Connector |
Power Cord Receptacle |
|
s3600-112 |
1-4 |
Phaser 3600 Printer Service Manual |
General Information
Control Panel
The Control Panel has three components:
■Multi-colored Light Emitting Diode (LED) light
■Alphanumeric display
■Six-button cluster
Control Panel Buttons
Button Function
Return |
Returns to the prior higher level menu structure, if |
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available. |
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CANCEL |
Terminates the current action. |
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MENU |
Cycles through all of the top level menu items. |
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UP |
Scrolls up one menu item within a menu list. If you |
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continually press this control, the menu items will ‘wrap’. |
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DOWN |
Scrolls up one menu item within a menu list. If you |
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continually press this control, the menu items will ‘wrap’. |
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OK |
Executes the highlighted menu item. |
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Menu Map
The Menu Map is a visual representation of the Control Panel settings and information pages. All Menu Map settings are documented in the User Guide.
Error and Warning Messages
When there is a problem with the printer, the Control Panel LED (3) blinks red for an error and a warning. An error or warning message is displayed in the Alphanumeric Display (5).
Phaser 3600 Printer Service Manual |
1-5 |
General Information
Printer Specifications
Printer Location and Clearance
Place the printer in a dust-free area where the temperature range is 50 degrees F to 89 degrees F (10 degrees C to 32 degrees C) and the relative humidity range is between 20% to 80%.
■Place the printer in an area where there is adequate space for ventilation, operation, and servicing. See the clearance graphic below.
■Do not block or cover the slots and openings on the printer. The printer can overheat without adequate ventilation.
■For altitudes under 2,050 meters (6,726 feet), use the Low Altitude setting. For altitudes over 2,050 meters (6,726 feet), use the High Altitude setting.
■Do not place the printer near a heat source.
■Do not place the printer in direct sunlight.
■Do not place the printer in line with the cold air flow from an air conditioning system.
■Place the printer on a level, solid surface with adequate strength for the weight of the printer.
1255.6 mm |
596 mm |
(24.6 in.) |
|
(49.2 in.) |
|
100 mm
(4 in.)
320 mm
(12.6 in.)
100 mm (4 in.)
482.6 mm (18.8 in.)
s3600-003
1-6 |
Phaser 3600 Printer Service Manual |
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|
|
General Information |
Printer Physical Specifications |
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Physical Dimensions and Weight |
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Item |
Specification |
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Packaging |
Packing Dimension w/o |
518*566*568mm |
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Dimension |
option tray |
(20.4"*22.3"*22.4") |
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(W*D*H) |
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Net Dimension w/o Option |
396*453*353mm |
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Net Dimension |
Tray |
(15.6"*17.8"*13.9") |
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(W*D*H) |
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Net Dimension with Option |
396*453*501mm |
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||
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Tray |
(15.6"*17.8"*19.7") |
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Toner Dimension |
Toner |
314 x 225 x 116 mm |
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(W*D*H) |
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Toner Packing |
368 x 286 x 169 mm |
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Weight |
SET with 10K toner |
17.30kg (38.14lb) |
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cartridge |
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SET w/o toner cartridge |
15.46kg (34.06lb) |
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Consumable toner |
10K : 1.85kg (4.08lbs) 20K : |
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|
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cartridge |
2.06kg (4.54 lbs) |
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Set + Consumables |
19.15 kg (42.2lb) with 10K toner |
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cart. |
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Packing Weight |
22.46kg (49.50lb) |
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Functional Specifications
Print Operability
Characteristic |
Specification |
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|
Printing process |
Non-Impact Electrophotography |
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|
Color medium |
Monochrome |
|
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Resolution / Addressability |
True 600 x 600 dpi |
|
Addressable 1200 x 1200 dpi |
|
|
Operating Modes |
Standby Mode: Print engine capable of making |
|
prints in less than 9 seconds. |
|
Sleep/ Low Power/ Power Saver Mode: 31 |
|
seconds from completion of a print. |
|
|
Continuous Operating Printing |
Letter: |
Speed (ppm = pages per |
Up to 40 ppm |
minute) |
A4: |
|
Up to 38 ppm |
|
|
First Print-Out |
10 seconds or less |
(in seconds) |
|
|
|
Warm-Up Time |
Power-on Boot: 40 seconds or less |
|
|
Phaser 3600 Printer Service Manual |
1-7 |
General Information
Print Quality
Property |
Characteristic |
Specification |
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|
|
Resolution |
Normal |
Up to 1200 x 1200 dpi effective output |
|
|
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Line Width @ 600dpi |
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Line Width @ 1200dpi |
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Dot Diameter @ 600dpi |
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Dot Diameter @ 1200dpi |
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RET |
Yes |
|
|
|
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Halftone (Gray Scale) |
256 levels |
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Blackness |
>1.20 |
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Homogeneity of Halftone |
at five points on page must be 0.1 |
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Halftone |
20 % = 0.17 50 % = 0.49 80 % = 0.91 |
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Printable Area |
Letter |
208 x 271 mm |
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A4 |
200 x 289 mm |
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Non-Printable Area |
Envelope |
10mm(0.4") from edge(Top/Bottom/Left/Right) |
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Other Media |
4mm(0.16") from edge(Top/Bottom/Left/Right) |
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Toner Fixing |
Black (100% Solid) |
80% |
|
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Halftone |
70% |
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Magnification |
Horizontal (applied to |
< 1.0 mm (0.04 ) ( 0.5 % ) |
|
177.8mm length) |
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|
|
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Vertical (applied to |
< 3.0 mm (0.12 ) ( 1.2 % ) |
|
241.3mm length) |
|
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Printing Skew |
Tray 1 (MPT) |
< 1.5 mm (0.06 ) Simplex & Horizontal |
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< 2.0 mm (0.08 ) Duplex & Horizontal |
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< 2.0 mm (0.08 ) Simplex & Vertical |
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< 2.5 mm (0.10 ) Duplex & Vertical |
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Tray 2 |
< 1.5 mm (0.06 ) Simplex & Horizontal |
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< 2.0 mm (0.08 ) Duplex & Horizontal |
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< 2.0 mm (0.08 ) Simplex & Vertical |
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< 2.5 mm (0.10 ) Duplex & Vertical |
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Optional Tray 3 |
< 2.0 mm (0.08 ) Simplex & Horizontal |
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< 2.5 mm (0.1 ) Duplex & Horizontal |
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< 2.5 mm (0.10 ) Simplex & Vertical |
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< 3.0 mm (0.12 ) Duplex & Vertical |
|
|
|
1-8 |
Phaser 3600 Printer Service Manual |
|
|
|
General Information |
||
Electrical Specifications |
|
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||
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Power Rating and Line Voltages |
||||
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Characteristic |
Specification |
||
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Primary line voltages |
110 - 127 V Printer - (100 - 135 V) 13 amp circuit |
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220 - 240 V Printer - (180 - 264 V) 7-8 amp circuit |
||
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Primary line voltage |
100 - 135 V Printer - 50/60 Hz + 3 Hz |
||
|
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frequency range |
220 - 240 V Printer - 50/60 Hz + 3 Hz |
||
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Power consumption |
Printing: 550 Watts (average) |
||
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Sleep: under 10 Watts |
||
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Environmental Specification |
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Operating Environment |
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Characteristic |
Specification |
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Optimal Temperature |
10 - 30 degrees C (50-60 degrees F) |
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Optimal Humidity |
20% - 80% Relative Humidity |
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Altitude |
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Operating |
0 - 2,500 meters (8,200 ft.) |
||
|
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Low Altitude Setting |
0 - 2,050 meters (6,726 ft.) |
||
|
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High Altitude Setting |
2,050 - 2,500 meters (6,726 - 8,200 ft.) |
||
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Transportation |
0 - 6,092 meters (20,000 ft.) |
||
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Acoustic Noise |
|
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Idle |
35.0db or less |
||
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Printing |
49.0db or less |
||
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Acoustic Characteristic |
Mode |
Specification |
|
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Printing |
Simplex from Tray1 |
Less than 56.0 dBA |
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|
Simplex from MP |
Less than 56.0 dBA |
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Simplex from SCF |
Less than 59.0 dBA |
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Duplex from Tray1 |
Less than 59.0 dBA |
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Measurement |
Standby |
Less than 35.0 dBA |
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Warm up |
Less than 50.0 dBA |
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Maximum |
Less than 60.0 dBA |
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Phaser 3600 Printer Service Manual |
1-9 |
General Information
Media and Tray Specifications
Media Tray Capacity
Property |
Media |
Specification |
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Input Size Max |
Custom Paper (W*H) |
216 x 356 mm (8.5" x 14") |
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Min Custom Paper |
76 x 127 mm (3.0" x 5.0") (>105g) |
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(W*H) |
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Input Capacity |
Standard |
500-sheet Cassette Tray/100-sheet Multi |
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Purpose Tray @75g |
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Maximum |
1 to 100 sheets |
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Output Capacity |
Face-Down Capacity |
250 sheets |
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Face-Up Capacity |
100 sheets |
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Output Full sensing |
Yes (Paper Outbin Full Sensor) |
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Output path change |
Face Up/Down controlled manually by |
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opening rear cover |
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Multi-Purpose |
Plain Paper Capacity |
100 sheets |
Tray |
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Envelope Capacity |
10 sheets |
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Card Stork Capacity |
10 sheets |
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Labels Capacity |
25 sheets |
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Transparencies |
50 sheets |
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Capacity |
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Media sizes |
A4/A5/A6/Letter/Legal/Oficio/Folio/ |
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Executive/ISO B5/JIS B5/3"x5"/Monarch/ |
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No.10/DL/C5/C6 |
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Media type |
Transparencies/Envelopes/Labels/Card |
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stock |
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Media weight |
16~43lb (60 to 163g |
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Sensing |
Paper Empty Sensor |
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Standard |
Capacity |
500 sheets |
Cassette Tray |
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Media sizes |
A4/A5/Letter/Legal/Executive/Folio/ |
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Oficio/ISO B5/JIS B5 |
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Media types |
Plain paper |
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Media weight |
16~28lb (60 to 105g) |
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Sensing |
Paper Empty Sensor and Paper Size |
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Sensor |
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1-10 |
Phaser 3600 Printer Service Manual |
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General Information |
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Media Tray Capacity |
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Optional Cassette Capacity |
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500 sheets@75g |
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Tray |
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Media sizes |
A4/A5/Letter/Legal/Executive/Folio/ |
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Oficio/ISO B5/JIS B5 |
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Media types |
Plain paper |
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Media weight |
16~28lb (60 to 105g/) |
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Sensing |
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Paper Empty Sensor |
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Duplex |
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Supporting |
Optional |
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Media sizes |
A4/Letter/Legal/Folio/Oficio |
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Media types |
Plain paper |
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Media weight |
20~24lb (75 to 90g ) |
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Media Input Size/Weight |
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Source |
Media Types |
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Media Sizes |
Media Weights |
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Tray 1 |
Paper, Envelope, |
A4, Letter, Legal, Folio, |
16 lb. ~ 28 lb. |
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Paper Labels, |
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Executive, ISO and JISB5, A5 |
(60 ~ 176 gsm) |
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Transparency. |
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Tray 2 |
Paper, Cardstock |
A4, Letter, Legal, Folio, |
16 lb. ~ 43 lb. |
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Min: 76 mm x 127 |
Executive, ISO and JISB5, A5, |
(60 ~ 105 gsm) |
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mm |
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A6, Statement Monarch, COM |
65# Cover |
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(3 in. x 5 in.) |
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10, C5, DL, 3” x 5” |
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Max: Legal |
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Tray 3 |
Paper |
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A4, Letter, Legal, Folio, |
16 lb. ~ 28 lb. |
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Executive, ISO and JISB5, A5 |
(60 ~ 105 gsm) |
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Duplex |
Paper |
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A4, Letter, Legal, Folio |
20 lb. ~ 24 lb. |
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(75 ~ 90 gsm) |
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Media Print Speed |
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Property |
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Mode |
Specification |
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Speed |
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Simplex |
Up to 38 ppm in A4 |
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(40 ppm in Letter) |
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Duplex |
26 ipm in A4 (27 |
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ipm in Letter) |
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(Letter A4 Folio |
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Oficio Legal) |
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First-Page Output Time |
from standby |
Less than 9 sec |
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(FPOT) |
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from sleep/power save mode |
Less than 40 sec |
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from cold status |
Less than 49 sec |
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Warm Up Time |
from sleep/power save mode |
Less than 31 sec |
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from cold status |
Less than 40 sec |
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|
Phaser 3600 Printer Service Manual |
1-11 |
General Information
Media Print Speed
Toner save setting unit |
SWS |
Support |
|
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|
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PSU |
Support (30%) |
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LUI(Local UI) |
Support(UI2.0) |
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Duplex Print |
Simplex |
Support |
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Manual Duplex |
N/A |
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Duplex |
Optional |
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1-12 |
Phaser 3600 Printer Service Manual |
Theory of Operation
In this chapter...
■Phaser 3600 Operational Overview
■Printer Paper Path
■Printer Controls
■Sensor Functions
■Printer Controls
Chapter 2
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