Xerox WorkCentre PE16 Service Manual

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SERVICE

WorkCentre PE16

Manual

WorkCentre PE16 CONTENTS

1. Precautions

2. Reference Information

3. Specifications

4. Summary of product

5. Disassembly and Reassembly

6. Alignment and Adjustments

7. Troubleshooting

8. Exploded Views and Parts List

9. Block Diagram

10. Connection Diagram

XXX-XXXX-XX

1-1

Precautions

Service Manual

WorkCentre PE16 July 2003

1. Precautions

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.

Symbols Marked on the Product

Hot surface on or 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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Precautions

Service Manual

July 2003 WorkCentre PE16

Laser Safety Statement

The Printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, chapter 1 Subchapter J for Class 1(1) laser products, and elsewhere, it is certified as a Class I laser product conforming to the requirements of IEC 60825. Class I laser products are not considered to be hazardous. The laser system and printer are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.

Warning >> Never operate or service the printer with the protective cover removed from Laser/Scanner assembly. The reflected

beam, although invisible, can damage your eyes. When using this product, these basic safety precautions should always be followed to reduce risk of fire, electric shock, and injury to persons.

CAUTION - INVISIBLE LASER RADIATION

WHEN THIS COVER OPEN. DO NOT OPEN THIS COVER.

VORSICHT - UNSICHTBARE LASERSTRAHLUNG,

WENN ABDECKUNG GE FFNET . NICHT DEM STRAHL AUSSETZEN.

ATTENTION - RAYONNEMENT LASER INVISIBLE EN CAS

D OUVERTURE. EXPOSITION DANGEREUSE AU FAISCEAU.

ATTENZIONE - RADIAZIONE LASER INVISIBILE IN CASO DI

APERTURA. EVITARE LESPOSIZIONE AL FASCIO.

PRECAUCION - RADIACION LASER IVISIBLE CUANDO SE ABRE.

EVITAR EXPONERSE AL RAYO.

ADVARSEL. - USYNLIG LASERSTR LNING VED BNING, N R

SIKKERHEDSBRYDERE ER UDE AF FUNKTION. UNDG UDSAETTELSE FOR STR LNING.

ADVARSEL. - USYNLIG LASERSTR LNING N R DEKSEL

PNES. STIRR IKKE INN I STR LEN.

UNNG EKSPONERING FOR STR LEN.

VARNING - OSYNLIG LASERSTR LNING N R DENNA DEL

R PPNAD OCH SP RREN R URKOPPLAD.

BETRAKTA EJ STR LEN. STR LEN R FARLIG.

VARO! - AVATTAESSA JA SUOJALUKITUS OHITETTAESSA

OLET ALTTIINA N KYM TT M LLE LASERS TEILYLLE L KATSO S TEESEEN.

1-3

Precautions

Service Manual

WorkCentre PE16 July 2003

Power Safety Precautions

Power Source

For 110 VAC units, 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 units, 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 equipment. You must also disconnect the unit 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 unit 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 equipment is exposed to any excess moisture,

■ if the equipment is dropped or damaged,

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

■ whenever you clean the product.

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Precautions

Service Manual

July 2003 WorkCentre PE16

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. W earing 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 conductiv e, you may ground the bag and use it as a conductive surface.

■ Do not us e 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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Precautions

Service Manual

WorkCentre PE16 July 2003

Note

Service Safety Summary

General Guidelines

The material presented here is intended as a safety reminder for qualified servi ce 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. T o av oid 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 products’s front panel are in place and all interlock switches are functioning correctly after you have completed a unit service call. If you bypass an interlock switch during a service call, use extreme caution when working on or around the product.

1-6

Precautions

Service Manual

July 2003 WorkCentre PE16

Warning

Servicing Electrical Components

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

Turning the power off by using the On/Off switch does not completely de-energize the unit. You must also disconnect the unit's power cord from the AC outlet. Position the power cord so that it is easily accessible during servicing.

Do not touch any electrical component unless you are instructed to do so by a service procedure.

S7300-0

Servicing Mechanical Components

When servicing mechanical components within the unit, manually rotate drive assemblies, rollers, and gears.

Do not try to manually rotate or manually stop the drive assemblies while any unit drive motor is running.

S7300-0

Servicing Fuser Components

This product uses heat to fuse the toner image to media. The Fuser Assembly is VERY HOT. Turn the unit power off and wait at least 5 minutes for the Fuser to cool before you attempt to service the Fuser Assembly or adjacent components.

2-1

Reference Information

Service Manual

WorkCentre PE16 July 2003

2. Reference Information

This chapter provides reference information for this service manual consisting of the tool list, a list of acronyms and abbreviations, and examples of test patterns.

2.1 Tool for Troubleshooting

The following tools are recommended for perfomance of the troubleshooting functions described in this service manual.

DVM(Digital Volt Meter)

Standard: Indicates more than 3 digits.

T weezers

Standard: For general home use, small

type.

Software(Driver) installation CD ROM

Cotton Swab

Standard : For general home use, for

medical service.

Cleaning Equipment IPA (Isopropyl Alcohol) dry cloth or a liquid neutral detergent.

Driver

Standard : "-" type, "+" type (M3 long, M3

short, M2 long, M2 short).

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Reference Information

Service Manual

July 2003 WorkCentre PE16

2.2 Acronyms and Abbreviations

The table below explains the acronyms and abbreviations used in this service manual. These are used throughout the text of this service manual. Please refer to the table.

AC Alternating Current ADF Automatic Document Feeder ASIC Application Specific Integrated Circuit ASSY assembly BIOS Basic Input Output System CCD Charge Coupled Device CMOS Complementary Metal Oxide Semiconductor CN connector CON connector CPU Central Processing Unit dB decibel dbA decibelampere dBM decibel milliwatt DC direct current DCU Diagnostic Control Unit DPI Dot Per Inch DRAM Dynamic Random Access Memory DVM Digital Voltmeter ECP Enhanced Capability Port EEPROM Electronically Erasable Programmable Read

Only Memory EMI Electro Magnetic Interference EP electrophotographic EPP Enhanced Parallel Port F/W firmware GDI graphics device interface GND ground HBP Host Based Printing HDD Hard Disk Drive HV high voltage HVPS High Voltage Power Supply I/F interface I/O Input and Output IC integrated circuit

IDE Intelligent Drive electronics or Imbedded

Drive Electronics

IEEE Institute of Electrical and Electronics

Engineers. Inc IPA Isopropy Alcohol IPM Images Per Minute Kg Kilogram LAN local area network lb pound(s) LBP Laser Beam Printer LCD Liquid Crystal Display LED Light Emitting Diode LSU Laser Scanning Unit MB Megabyte MHz Megahertz NVRAM Nonvolatile random access memory OPC Organic Photo Conductor PBA Printed Board Assembly PCL Printer Command Language , Printer Control

Language PDL Page Discription Language PPM Page Per Minute PTL Pre-Transfer Lamp Q’ty Quantity RAM Random Access Memory ROM Read Only Memory SCF Second Cassette Feeder SMPS Switching Mode Power Supply SPGP Samsung Printer Graphic Processor SPL Samsung Printer Language Spool Simultaneous Peripheral Operation Online SW Switch Sync Synchronous or synchronization USB Universal Serial Bus

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Reference Information

Service Manual

WorkCentre PE16 July 2003

2.3 The Sample Test Patterns

The following test patterns are the standard patterns used to test the product in the factory. Cartridge life span and printing speed are measured with the patterns shown below.

(The picture in the manual is 70% size of the actual A4 size.)

2.3.1 A4 5% Pattern

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Reference Information

Service Manual

July 2003 WorkCentre PE16

2.3.2 A4 2% Pattern

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Reference Information

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WorkCentre PE16 July 2003

2.3.3 A4 IDC 5% Pattern

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Reference Information

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July 2003 WorkCentre PE16

3-1

Specifications

Service Manual

WorkCentre PE16 June 2003

3. Specifications

Specifications are correct at the time of printing. Product specifications are subject to change without notice. See below for product specifications.

3.1 General Specifications

Items Descriptions Remarks

Major Features Copier, Print, Scan, Fax With ADF Size (W*D*H) 474 X 436 X 417 mm w/o Hand Set Weight 13 Kg (28.8 lbs) With Toner Cartridge LCD 16*2 Char I/O Interface USB1.1 & IEEE1284 Power Consumption Printing 350W

Sleep Mode 20W Power Switch Yes Noise Operating 55 dBA

Standby 35 dBA Warm Up Less than 42 seconds Approval Class B Device Memory 16 MB

(Printer : 8M, Fax : 4M,

Scan : 2M, System : 2M)

Internal N/W Connectivity N/A

3.2 Print Specification

Items Descriptions Remarks

Print Speed 17ppm(Letter) 5% Character

16pp,(A4) Pattern Print Method Laser Scanning Unit + Electro Photography Print Language SPL Power Save Yes(5/10/15/30/45min.) Resolution Normal 600 *600dpi

RET No Toner Save Yes Memory 8 MB FPOT Stand by Approx. 12 seconds

Power Save Less than 54 seconds Printable Area 208 X 271 mm (Letter)

202 X 289 mm (A4)

Toner Save Yes

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Specifications

Service Manual

June 2003 WorkCentre PE16

3.3 Scan Specification

Items Descriptions Remarks

Halftone(Gray Scale) 256 level Scan Method Color CCD ITU-T #1 Chart Scan Speed ADF Letter : 25 sec, A4 : 28 sec Text/Mixed Mode : (seconds/scan) Platen Letter : 25 sec, A4 : 28 sec B/W & 300dpi. (USB)

ADF Letter : 55 sec, A4 : 60 sec Photo Mode : Gray Platen Letter : 55 sec, A4 : 60 sec & 300dpi. (USB) ADF Letter : 125 sec, A4 : 130 sec Photo Mode : Color Platen Letter : 125 sec, A4 : 130 sec & 300dpi.(USB)

Resolution Optical 600 dpi

Enhanced 4800 dpi Halftone 256 level Scan Width Width Max.216mm (8.5")

Length(Adf) Max. 356mm (14.0")

Length(Platen) Max. 297mm (11.7") Scan-to E-mail, Image, OCR, FAX, WEB From SmarThru3

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Specifications

Service Manual

WorkCentre PE16 June 2003

3.4 Copy Specification

Items Descriptions Remarks

Copy Quality Selection Text 600x300dpi or Original Image type Auto 600x300dpi selection Mode Photo 600x600dpi for Platen / 600x300dpi for ADF

Other -

FCOT Platen Power Save Approx. 54 seconds

Stand by Approx. 12 seconds

ADF Power Save Approx. 54 seconds

Stand by Approx. 17 seconds

Copy Speed Text Mixed SDMC 16 cpm/A4, 17 cpm/LTR

MDMC 7 cpm/A4, 7 cpm/LTR

Photo SDMC 16 cpm/A4, 17 cpm/LTR

MDMC 7 cpm/A4, 7 cpm/LTR

Resolution Scan 600*600dpi

Print 600*600dpi Zoom Range 25% to 400 % for platen, 25% to 100% for ADF Multi Copy 1~99 Preset Yes Contrast Control 3 level(by LED) Copy Mode TEXT/MIXED/PHOTO Collation Copy Yes(300dpi only) Auto return to default mode Yes(after 1 minute) N-up copy 2-up, 4-up ADF Only AutoFit Copy Yes Platen Only Clone Yes Platen Only Poster Yes Platen Only

3-4

Specifications

Service Manual

June 2003 WorkCentre PE16

3.5 Telephone Specification

Items Descriptions Remarks

Handset No On hook Dial Yes Search Yes (Phone Book) by using Phone Book Button 1-Touch Dial 10EA(3*4 Numeric Key) Auto dial 100 locations (Using 3*4 buttons) TAD I/F No Tone/Pulse Selectable in Tech Mode Pause Y es Auto Redial Yes Last Number Redial Yes Distinctive Ring No Caller ID No External Phone Interface No Report & List Print out Tx/Rx Journal Yes

Confirmation 2 types available

(with Image TCR, w/o image TCR) Help List No Auto Dial List Yes System Data List List all user setting

Sound Control Ring Volume Yes(Off,Low,MED,HIGH)

Key Volume Yes(On,Off) Speaker Yes(On,Off)

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Specifications

Service Manual

WorkCentre PE16 June 2003

3.6 Fax Specification

Items Descriptions Remarks

Compatibility ITU-T G3 Communication System PSTN/PABX Modem Speed 33.6 Kbps TX Speed Approx. 3 sec Compression MH/MR/MMR/JPEG ECM Y es Resolution Std 203 x 98 dpi

Fine 203 x 196 dpi S.Fine 300 x 300 dpi

Scan Speed(ADF) Std Approx. 5sec/LTR (6 sec/A4)

Fine Approx.7.5sec/L TR (8 sec/A4)

S.Fine Approx.7.5sec/LTR (8 sec/A4) Rx fax duplex print out No Multiple page scan speed Approx. 7 ppm/LTR (7.5 ppm/A4) Receive Mode Fax, TEL Memory Capacity 4 MB (320 pages)

Optional Memory No

Max locations to 99 locations

store to 1 Group Dial

Fax Forward Yes (On/Off)

Broadcasting Up to 99 locations

Forced Memory TX

No Cover page No Delayed fax Yes Memory RX Yes

Functions Voice Request No

TTI Y es RTI Yes Polling No Earth/Recall No Auto Reduction Yes RDC No Junk Fax barrier Yes Security Mode Yes Battery Backup Yes (Min. 15 minutes) Not Battery

(Using Super Cap.)

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Specifications

Service Manual

June 2003 WorkCentre PE16

3.7 Paper Handling

3.8 Software

Items Descriptions Remarks

Capacity Main Tray 250sheets (20lbs) Bypass Single Sheet

Optional Cassette No Output Capacity 150Sheets/20lb, 1Sheet/Face up Output Control Face down/Face up Paper Size Main Tray

CST : A4,Letter,Legal, Folio,Executive,B5

Bypass Bypass : Envelope6 3/4,7 3/4, #9, #10,

DL,C5,B5

Paper Weight Main Tray 60 ~ 90 GSM / 16 ~ 24 lb.

Bypass 60 ~ 150 GSM / 16 ~ 40 lb.

Paper Path Standard output Bottom to Middle Front (FIFO)

Straight Through Face up, Single Sheet

Paper Size Max 216 x 356mm(8.5"x14")

Min 76 x 127mm(3"x5")

Output Stacker Paper Extension

Document Fixed

Input Guide Bypass Tray Adjustable

Main Tray Universal Document Adjustable

ADF Paper Weight 60 ~ 105 GSM / 12.5~28lb

Capacity 30 sheets(80 GSM / 20lb) Document Size Width 148mm - 216mm(5.8" - 8.5") Document Size Length 127 mm - 356mm(5" - 14.0")

Items Descriptions Remarks

Compatibility DOS No

Win 3.x No Win 95 Yes Win 98&WinME Yes Win NT 4.0 Yes Win 2000 Yes Win XP Yes WHQL for Printer Only Mac Yes Mac Printer Only Linux No

Driver Printer SPL(GDI)

TWAIN Yes PC-FAX No PC Fax is only avail-

able through PC Modem

3-7

Specifications

Service Manual

WorkCentre PE16 June 2003

3.9 Consumables

Items Descriptions Remarks

Type Single Cartridge How to install Front door open and front loading Toner Life Initial 2,000 sheets IDC 5%

running 3,500 sheets character printing Level Sensor No Toner Count Yes

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Specifications

Service Manual

June 2003 WorkCentre PE16

4-1

WorkCentre PE16 July 2003

Summary of product

Service Manual

4. Summary of Product

This chapter describes the functions and operating principals of the main components.

4.1 Printer Components

4.1.1 Front View

Document Guides

Document Input Tray

Document Output Tray

Control Panel

Paper Tray

Front Cover

Paper Level Indicator

Bypass Tray

Paper Output Extension

Automatic Document Feeder

Document Cover

Document Glass

4-2

Summary of Product

WorkCentre PE16July 2003

Service Manual

4.1.2 Rear View

AC Power Cord

Connector

Parallel

Connector

Power Switch

USB Connector

Telephone Line Connector

Rear Output Slot

(Face up)

Rear Cover

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WorkCentre PE16 July 2003

Summary of product

Service Manual

4 653

4.1.3 Control Panel

C O

P Y

Adjusts the brightness of the documents for the current copy job.

Selects the document type for the current copy job.

Allows you to use special copy features, such as Clone, Collation, Auto fit, 2-side, N-up (multiple pages on a sheet) and Poster copying.

Makes a copy smaller or larger than the original.

Selects the number of copies.

Displays the current status and prompts during an operation.

Turns on when the toner cartridge is empty.

Scrolls through the options available for the selected menu item.

Confirms the selection on the display.

Enters Menu Mode and scrolls through the menus available.

Sends you back to the upper menu level.

Stops an operation at any time. In Standby Mode, clears/cancels the copy options, such as the contrast, the image setting, the copy size and the number of copies.

Starts a job.

4-4

Summary of Product

WorkCentre PE16July 2003

Service Manual

F A X

S A V E

Dials a number or enters alphanumeric characters.

Adjusts the resolution of the documents for the current fax job.

Allows you to send a fax to multiple destinations.

Allows you to store frequently-dialed fax numbers using a one or two-digit speed dial or group number for automatic dialing and edits the stored numbers.

Allows you to print a Phonebook list. Redials the last number in Standby Mode or inserts a pause into a fax number in edit mode.

Engages the telephone line.

Allows you to save on toner by using less toner to print a document.

Allows you to save on call costs by sending a fax at a preset toll-saving time. Using this feature, you can take advantage of lower long distance rates at night, for example.

4-5

WorkCentre PE16 July 2003

Summary of product

Service Manual

4.2 System Layout

4.2.1 Feeding section

Paper for the machine is supplied from a universal cassette or from the manual feeder, for single sheet feeding. The cassette contains a friction pad, to separate the paper and prevent multi-sheet feeding.

There is a sensor to detect the presence of paper in the cassette.

- Feeding Method: Universal Cassette Type

- Feeding Standard: Center Loading

- Feeding Capacity: Cassette-250 sheets (80g/m2, 20lb paper standard) Manual 1 sheet (Paper, OHP, Envelope, etc.)

- Paper detecting sensor: Photo sensor

- Paper size sensor: None

4.2.2 Transfer Ass’y

The Transfer Ass'y consists of the PTL (pre-transfer lamp), OPC Drum, and the Transfer Roller. The PTL lights the surface of the OPC Drum, reducing the charge on the drum surface to improve transfer efficiency.

The Transfer Roller transfers toner from the OPC Drum surface to the paper.

- Life span: 60,000 sheets (in 15~30°C)

4.2.3 Drive Ass’y

The Drive Ass'y is a motor driven gear unit, that drives the paper feed, the Fuser, and the distributing unit.

4.2.4 Fuser

The Fuser consists of the Heat Lamp, Heat Roller, Pressure Roller, Thermistor, and Thermostat. It melts

the toner to the paper using pressure and heat to complete the printing job.

4.2.4.1 Thermostat

The thermostat is a temperature-sensing device, that cuts off the power to prevent overheating or a fire when the heat lamp or the heat coil of the heat roller becomes too hot.

4.2.4.2 Thermistor

The Thermistor detects the surface temperature of the heat roller. The information from the Thermistor provides the on/off control that maintains the selected temperature of the heat roller.

4.2.4.3 Heat Roller

The heat roller transfers the heat from the heat lamp coil to the surface of the paper. The melted toner cannot stick to the Teflon coated heat roller.

4.2.4.4 Pressure roller

The pressure roller mounted right under the heat roller is made of the silicon resin. The toner fuses onto the paper when it passes between the heat roller and the pressure roller.

4-6

Summary of Product

WorkCentre PE16July 2003

Service Manual

4.2.4.5 Safety Relevant Facts

• Protecting device when overheating

- 1st protecting device: H/W cuts off when an overheat condition is detected.

- 2nd protecting device: S/W cuts off when an overheat condition is detected.

- 3rd protecting device: Thermostat cuts off the power.

• Safety device

- The power to the fuser is cut off when the front cover is open.

- The overheating safety device for customer safety.

- Maintains the surface temperature of the Fuser Cover below 80°C. A customer caution label is attached on the inside of the rear cover.

4.2.5 Scanner

Uses a photosensitive device to read an image. The Scanner consists of a CCD module, Connection board, ADF board, AFE (Analog Front End), Image Processor (located in the CPU), platen glass, and ADF.

• CCD Module Specification

1.Resolution: 600dpi/A4

2.Maximum scan wide: 8.5”

3.Color filter: Red, Green, Blue

4.Output channel: 3 channels (R, G, B)

5.Effective pixel: 5,400 pixel *3

6.Voltage: 24V & 5V

7.Pre-heating time: Maximum 30 seconds (70% of light reach to it)

8.The life span of a lamp: 30,000 hours (25oC)

• Image Processor Specification

1.Operating frequency: 66 MHz

2.Image sensor interface: 200/300/600 dpi CIS or CCD

3.Line time: Copy, FAX, Binary (Lineart, Halftone) PC Scan: 1.5ms/Line Color PC Scan (Grey, 256

Color, True Color): 4.5ms/Line

4.A/D conversion: 10bit conversion

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WorkCentre PE16 July 2003

Summary of product

Service Manual

4.2.6 LSU (Laser Scanner Unit)

The LSU is controlled by the video controller. It converts the received video data to pulsed laser light that is scanned onto the surface the OPC drum using a rotating polygon mirror. This creates the latent image on the drum surface. The OPC drum rotates at the same speed as the paper is fed. When the edge of the polygon mirror is detected, the LSU generates the /HSYNC signal. The CPU syncs the left margin of the image to this signal. After detecting the /HSYNC signal, the image data is sent to the LSU to begin transfer of the image left margin to the paper.

Each surface of the polygon mirror provides one line for scanning.

4-8

Summary of Product

WorkCentre PE16July 2003

Service Manual

4.2.7 Toner Cartridge

The xerographic process creates a visual image from the latent image. The Toner Cartridge contains the OPC Drum, developer, and toner components in one unit. The OPC unit contains the OPC drum and charging roller.

The developer unit contains toner, toner cartridge, supply roller, developing roller, and blade (Doctor blade).

- Developing Method: Non magnetic 1 element contacting method

- Toner: Non magnetic 1 element shatter type toner

- The life span of toner: 3,000 sheets (IDC Pattern/A4 standard)

- Toner remaining amount detecting sensor: None

- OPC Cleaning: Collect the toner by using electric charge + FILM OPC

- Management of excess toner: Collect the toner by using electric charge (Cleanerless Type- No excess toner)

- OPC Drum protecting Shutter: None

- Classifying device for toner cartridge: ID is classified by interruption of the frame channel.

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WorkCentre PE16 July 2003

Summary of product

Service Manual

4.3 Main PBA

The Main PBA is the functional center of the product. It controls all basic machine operations including fax, scan, and printer operations, sensor detection, and power levels.

U41

U74

OSC3

U47

CN10 CN8 CN7

CN9

U118

U135

U113/U114

CN4

OSC5

CN12

CN3

CN5

U120CN6U68U134

U125

U115

U75/ U95/

U123

U10

U41

CN14

OSC2

U58

U43/

U68

U44/

U69

CN1

CN2

CN13 U11 U16 U63 U64 U15

U48

FLASH MEMORY

MODEM

SDRAM

SUPER1284 BUFFER

(INVERTER)

(HCT273)

EXPANSION I/O MODEM CLOCK MOTOR DRIVE IC

ASIC74LVX161284

4-10

Summary of Product

WorkCentre PE16July 2003

Service Manual

4.3.1 ASIC

Samsung’s S3C46Q0X 16/32-bit RISC micro controller is designed to provide a cost-effective, low power, small die size and high performance micro-controller solution for MFP. The S3C46Q0X is developed using ARM7TDMI core, 0.18(m CMOS standard cell, and memory cell.

•Main function block

• 1.8V internal, 3.3V external (I/O boundary) microprocessor with 4KByte Cache

• Image Processor

• On-chip clock generator with PLL

• Memory & External Bank Control

• DMA Control (5-channel)

• Interrupt Control

• 2-port USB Host /1- port USB Device (ver 1.1) Interface Control

• Parallel Port Interface Control

• UART (2 Channel)

• Synchronous Serial Interface Control

• Timer (4 Channel)

• Watch Dog Timer

• Power control: Normal, Slow, Idle, Stop and SL_IDLE mode

• A/D Converter (10-bit, 2 Channel)

• General I/O Port Control

• Print Head Control

• Carrier Motor Control

• Paper Motor Control

• Tone Generator

• RTC with calendar function

• S/W Assistant function( Rotator )

4.3.2 Flash Memory

The Flash Memory stores the system program and downloads the system program through the PC interface.

• Capacity : 0.5 M Byte

• Access Time : 70 nsec

4.3.3 SDRAM

The SDRAM is used as a buffer, system working memory area, etc. while printing.

• Access Time : 60 nsec

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WorkCentre PE16 July 2003

Summary of product

Service Manual

4.3.4 Sensor input circuit

1) Paper Empty Sensor

The Paper empty sensor (Photo Interrupter) on the engine board notifies the CPU when the cassette is empty. The empty signal to the CPU sets the D0 Bit in the CPU, which results in the CPU turning on the second LED (yellow) on the front panel.

2) MP Sensing

The MP Sensor (Photo Interrupter) on the engine board notifies the CPU if there is paper present at the MP. It reads the D0 Bit of the CPU to recognize paper in MP, and the paper is fed from MP if present.

3) Paper Feeding

When paper passes the actuator (Feed Sensor), the circuit detects the signal from the photo interrupter, sends a status signal to the CPU, and enables image data after a certain delay. If it doesn't detect the feed sensor within 1 sec. after paper is fed, paper Jam0 occurs (Red and Yellow LEDs will be turned on at the Front Panel ). Developer insertion is detected using the same principle. When the developer is mounted, it operates the actuator and the signal from the photo interrupter is detected by the sensor input circuit. That process is called developer ID sensing.

4) Paper Exit Sensing

The system detects the paper exiting the unit with the exit sensor and actuator attached to the frame. The circuit detects the on/off time of the exit sensor, and the normal operation or jam information is passed to the CPU. If exit is not detected, JAM2 occurs.

5) Cover Open Sensing

The Cover Open sensor is located on the front cover. When the front cover is opened, +24V to the DC fan, solenoid, main motor, polygon motor in the LSU, and HVPS is cut off. The cover-open sensing is read from the D0 bit of CPU, and initiates developer ID sensing.

6) DC FAN / SOLENOID Driving

This function is driven by a transistor and controlled by the D6 bit of the CPU. When the bit is high, the fan is driven by turning on the transistor, and it is off when the sleep mode is selected. There are two solenoids, and they are driven by the paper pick-up and MP signal. The drive time is 300ms. The diode protects the driving transistor from the noise pulse, which is emitted when the solenoid is de-energizing.

7) Motor Driving

The motor driving circuit is formed when the Driver IC is selected. The A3977 (Motor driver IC) is used in this case. The resistance Rs value of sensing and the voltage value of the V reference can be changed by the motor driving voltage value.

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Service Manual

4.4 SMPS & HVPS

The SMPS supplies DC power to the system. The supply receives 110V/220V input, and outputs 5V, 12V, and 24V to supply the power to the main board and ADF board.

The HVPS creates the high voltage for THV/MHV/Supply/Dev and supplies it to the developer to be used in optimizing the image display. The HVPS uses the 24V as an input and outputs the high voltage for THV/MHV/BIAS, toner, OPC cartridge, and transfer roller.

MAIN PBA CON.

CN3

(FAN CON.)

CN1

(H/L CON.)

F101

250V L2A

EXIT SENSOR

MHV

OPC

DEV

SUPPLY

THV

COVER OPEN SWITCH

MANUAL SENSOR

FEED SENSOR

PAPER-EMPTY SENSOR

110V : 125V/8A

220V : 250V T 5A H

110V : 125V/3A

220V : 250V 2A H

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Service Manual

4.4.1 HVPS (High Voltage Power Supply)

1) Transfer High Voltage (THV+)

- Function : Voltage to transfer developed toner image on OPC drum to paper.

- Output voltage : +1300V DC±20V

- Error : If THV (+) doesn't output, a ghost (same character is printed after one cycle (76mm) of OPC) with low density occurs due to toner on OPC drum not transferring normally to media.

2) Charge Voltage (MHV)

- Function : Charges entire surface of OPC with -900V ~ -1000V.

- Output voltage : -1550V DC ± 50V

- Error : If MHV doesn't output, solid black print out occurs because toner on developing roller moves to OPC drum due to the surface of OPC not being charged.

3)Cleaning Voltage (THV-)

- Function : Removes excess toner on transfer roller surface by negative voltage on OPC

drum to recover toners.

- Output Voltage : +300V/-150V

- Error : Toner contamination occurs at the backside of a printed-paper.

4) Developing Voltage (DEV)

- Function: Develops a toner image using a difference of electronic potential between the part

of the OPC drum exposed by the LSU and the part not exposed.

* Generally, the electronic potential of exposed OPC is -180V and exposed developer is -350V

when printing, so toner with minus (-) is developed on an exposed part.

- Output voltage: -430V DC ± 20V

- Error: 1. If DEV is GND, density is reduced significantly.

2. If DEV is floating due to poor ground contact, etc.,

density is increased significantly.

5) Supply Voltage (SUP)

- Function: Voltage to supply toner to developing roller.

- Output voltage: : -630V DC ± 50V (Use ZENER, DEV Gear)

- Error: 1. If SUP is GND, a density is reduced significantly.

2. If SUP is floating due to poor ground contact, etc., density drops to to almost non-existant levels.

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Service Manual

4.4.2 SMPS (Switching Mode Power Supply)

This is the power source for the whole system. It is an independent module, so it can be used for common use. It is mounted at the bottom of the set. The module contains the SMPS, which supplies the DC power for driving the system, and the AC heater control, which supplies the power to the Fuser. The SMPS has four outputs (+5V, +12V, +12V, and +24Vs).

There are three kinds of power, 120V exclusive (America), 220V exclusive (Europe), and 220V for China (nations with unstable power supply).

1) AC Input

- Input rated voltage : AC 220V ~ 240V AC 100~127V

- Input voltage range : AC 198V ~ 264V AC 90V ~ 135V

- Rated frequency : 50/60 Hz

- Frequency range : 47 ~ 63 Hz

- Input voltage : Under 4.0 Arms/2.0 Arms (The state when lamp is off or rated voltage is input/output)

2) Rated Power Output

3) Consumption Power

4) Length of Power Cord :

1830 ± 50mm

5) Power Switch :

Use

NO Item CH1 CH2 CH3 CH3 System

(+5V) (+12V) (+24V) (+24VS)

1 Stand-By 1.0 A 0.05A 1.0 A 0.5 A A VG : 95 Wh 2 PRINTING 1.5 A 0.5A 1.5 A 1.0 A AVG : 350 Wh 3 Sleep-Mode 0.3A 0.0A 0.0A 0.06A AVG : 20 Wh

NO Item CH1 CH2 CH3 CH4

1 Channel name +5V +12V +24.0V +24.0VS 2 CONNECTOR PIN CON 2 CON2 CON2 CON2

3.3V PIN: 3, 4 5V PIN : 8 24V PIN: 13, 16 24V PIN: 11, 12 GND PIN: 5, 6 GND PIN: 7 GND : 9, 10 GND : 18

3 Rated outputting voltage +5V ±5% +12V ±5% +24V ± 10% +24V ± 10%

(4.75 ~ 5.25V) (11.4 ~ 12..6V) (21.6 ~ 26.4V) (21.6 ~ 26.4V) 4 Rated outputting current 1.0 A 0.05A 1 0 A 0.5 5 Ripple noise voltage 150mVp-p 150mVp-p 500mVp-p 500mVp-p 6 Maximum output 7.5W 0.6W 36.0W 24.0W

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Summary of product

Service Manual

6) Feature

- Insulating resistance : over 50MΩ (at 500 VDC )

- Insulating revisiting pressure : Must be no problem within 1 min. (at 1500 Vzc, 10 mA)

- Leaking voltage : under 3.5mA

- Running voltage : under 40 A peak (at 25°c, Cold start) Under 60 A peak (in other conditions)

- Rising Time : Within 2 Sec.

- Falling Time : Over 20 mSec.

- Surge : Ring Wave 6 KV-500 A (Normal, Common)

7) Environment Condition

- Operating temperature range : 0°c ~ 40°c

- Maintaining temperature range : -25°c ~ 85°c

- Maintaining humid range : 30% ~ 90% RH

- Operating atmospheric pressure range : 1

8) EMI Requirement :

CISPR ,FCC, CE, MIC, C-Tick,

9) Safety Requirement

- IEC950, C-UL, TUV, Semko, iK, CB, CCC, EPA,

4.4.3 Fuser AC Power Control

Fuser (HEAT LAMP) gets heat from AC power. The AC power controls the switch with the Triac, a semiconductor switch. The 'On/Off control' is operated when the gate of the Triac is turned On/Off by Photo Triac (insulting part). In the other words, the AC control is a passive circuit, so it turns the heater On/Off using a signal from the Engine Control. When the 'HEATER ON' signal is turned on at Engine Control, the LED of PC1 (Photo Triac) turns on. The blinking light, the Triac part (light receiving part) takes the voltage, and the voltage is supplied to the gate of Triac and flows into the Triac. As a result, the AC current flows in the heat lamp, supplying heat to the heat roller. On the other hand, when the signal is off, the PC1 is off, the voltage is cut off at the gate of Triac, the Triac remains off, and the heat lamp is turned off.

1) Triac (THY1) feature

- 12A,600V SWITCHING

2) Phototriac Coupler (PC3)

- Turn On If Current : 15mA~ 50mA(Design: 16mA)

- High Repetitive Peak Off State Voltage : Min 600V

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Summary of Product

WorkCentre PE16July 2003

Service Manual

4.5 Engine F/W

4.5.1 Feeding

If feeding from the cassette, the pickup roller drive is controlled by the solenoid. The solenoid is switched on and off by contro signals from either the general output port or the external output port. If feeding from the manual feeder, paper presence is sensed by the manual sensor, and paper is fed by driving the main motor, insert the paper in front of the feed sensor. While paper moves, occurrence of jam is judged as below. (Refer to 6.2 Clearing Paper Jams])

4.5.1.1 Jam 0

• Paper is picked up, but cannot enter path due to paper feed failure.

• Paper is picked up and enters path, but it cannot reach the feed sensor in specified time due to slip, etc.

• After pick up, if the feed sensor is not on, pick up is repeated. After repeating pick up, if the feed sensor

is still not on after the specified time, Jam 0 is set.

- Jam 0 status indicates that the leading edge of the paper doesn’t pass the feed sensor.

• Even though the paper reaches the feed sensor, the feed sensor doesn’t turn on.

- It is a status that the leading edge of the paper already passes the feed sensor.

4.5.1.2 Jam 1

• After the leading edge of the paper passes the feed sensor, the trailing edge of the paper does not pass the feed sensor after the specified time. (The feed sensor cannot be Off)

• After the leading edge of the paper passes the feed sensor, the paper does not pass the exit sensor after the specified time. (The exit sensor cannot be On)

- The paper remains between the feed sensor and the exit sensor.

4.5.1.3 Jam 2

• After the trailing edge of the paper passes the feed sensor, the paper does not pass the exit sensor after the specified time.

4.5.2 Drive

By gearing, the main motor drives the rollers such as feeding roller, developing roller, fuser roller, and distributing roller. The step motor is controlled for the sections, acceleration section and fixed speed section. In the initial stage of the motor run, appoint the acceleration section to prevent the isolation of the motor. It is controlled by the A3977 motor driver IC. The step signal and the enable signal are sent to make the phase for driving the motor in CPU.

4.5.3 Transfer

The charging voltage, developing voltage and the transfer voltage are controlled by PWM (Pulse Width Modulation). Each output voltage is changeable due to the PWM duty. The transfer voltage admitted when the paper passes the transfer roller is decided by environment recognition. The resistance value of the transfer roller is changed due to the surrounding environment or the environment of the set, and the voltage value, which changes due to the environments, is changed through AD converter. The voltage value for impressing to the transfer roller is decided by the changed value.

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Summary of product

Service Manual

4.5.4 Fusing

The temperature of the heat roller’s surface is changed due to the resistance value of the thermistor. By converting the voltage value to a digital value, through the AD converter, the temperature is selected. The AC power is controlled by comparing the target temperature to the value from the thermistor. If the value from the thermistor is out of the controlling range while controlling the fusing, the error stated in the table occurs.

4.5.4.1 Error Type

4.5.5 LSU

The LSU is consists of the LD (Laser Diode) and the polygon motor control. When the printing signal occurs, it turns on the LD and drives the polygon motor. When the light sensor detects the beam, Hsync occurs. When the polygon motor reaches normal speed, LReady occurs. If the two conditions are satisfied, the status bit of the LSU controller register becomes 1, the LSU is ready. If the two conditions are not satisfied, the error shown in the table below occurs.

Error Description

Open heat error When warming up, it has been lower than 68 °C over 25 sec

Lower heat error • Standby:

It has been lower than 100°C over 25 sec

• Printing:

- 2 consecutive pages: it has been lower than 145°C over 5 sec

- 3 consecutive page; it has been 40°C lower than the fixed fusing temperature over 4 seconds.

Over heat error It has been higher than 220°C over 3 seconds

Error Description

Polygon motor error When the polygon motor does not reach normal speed Hsync error The polygon motor speed is normal, but the Hsync signal is not created.

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WorkCentre PE16July 2003

Service Manual

4.6 LIU PBA

LIU board is a Line interface unit, and it is a circuit for interfacing a telephone line with a modem. The circuit consists of matching transfer to conform to impedance of a receiving telephone line and a circuit to conform to impedance of a modem. Also, there is a ring detect circuit to detect a ring signal from a switchboard and a surge absorber to protect it from an external high voltage supply applied to a line input unit.

Ring Detect Circuit (PC814)

Relay

Tel-Line Jack

Surge Absorber

4.7 OPE PBA

OPE board consists of various function keys and LCDs to display key operations. MICOM creates a circuit using HT48R50 MICOM of HOLTEC CO. and applies LED and LCD. The communication method with the Main Board CPU is a UART, and related signals are /Reset, TXD, and RXD.

5-1

Disassembly and Reassembly

Service Manual

WorkCentre PE16 July 2003

5. Disassembly and Reassembly

5.1 General Precautions on Disassembly

When you disassemble and reassemble components, you must use extreme caution. The close proximity of cables to moving parts makes proper routing essential. If components are removed, any cables disturbed by the procedure must be restored as close as possible to their original positions. Before removing any component from the machine, note the cable routing that will be affected.

Whenever servicing the machine, you must perform the following:

1. Check to verify that documents are not stored in memory.

2. Be sure to remove the toner cartridge before you disassemble parts.

3. Unplug the power cord.

4. Use a flat and clean surface.

5. Replace only with authorized components.

6. Do not force plastic-material components.

7. Make sure all components are in their proper position.

8. Observe ESD precautions when handling sensitive electronic components.

Releasing Plastic Latches

Many of the parts are held in place with plastic latches. The latches break easily; release them carefully. To remove such parts, press the hook end of the latch away from the part to which it is latched.

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July 2003 WorkCentre PE16

5.2 Rear Cover

1. Remove the four screws securing the Rear Cover.

2. Remove the Rear Cover from the Frame Ass'y and

Scanner Ass'y .

3. Unlatch the (Cover Face Up) securing the Rear cover, as shown below.Then lift the (Cover Face Up) out.

Cover Face Up

Rear Cover

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Disassembly and Reassembly

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WorkCentre PE16 July 2003

5.3 Side Cover (LH, RH)

1. Before you remove the Side Cover (LH, RH), you should remove:

- Rear Cover (see page 5-2)

2. Unplug the Speaker Harness, as shown below.

3. Pull down and back on the LH and RH Side Covers and lift them out in the direction of the arrows.

Side Cover(RH)

Side Cover(LH)

Speaker Harness

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Disassembly and Reassembly

Service Manual

July 2003 WorkCentre PE16

5.4 Front Cover

1. Take out the Cassette.

2. Open the Front Cover.

3. Unlatch the Front Cover securing the Frame Ass'y. Then remove the Front Cover, as shown below.

Cassette

Front Cover

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Disassembly and Reassembly

Service Manual

WorkCentre PE16 July 2003

5.5 Scanner Ass'y

1. Before you remove the Scanner Ass'y, you should remove:

- Rear Cover (see page 5-2)

- Side Cover (LH, RH) (see page 5-3)

2. Remove the two screws securing the Scanner Ass'y, as shown below.

3. Unplug the four connectors from the Connector PBA , as shown below, and remove the ground wire. Platen Cover upward and remove it.

4. Pull up the Scanner Ass'y, as shown below.

5. Disconnect the cover wiring harness then pull the

Scanner Ass’y

Connection BoardConnection Board

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Disassembly and Reassembly

Service Manual

July 2003 WorkCentre PE16

6. Remove the three screws securing the Scan Ass’y.

7. Lift the OPE Unit out. Then unplug the two connectors from the OPE Unit and remove it.

8. Remove the four screws securing the Scan Upper.

9. Unlatch the Scan Upper securing the Scan Ass’y Then pull the Scan Upper upward and remove it.

This can be done with the scanner attached.

Scan Upper

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WorkCentre PE16 July 2003

10. Disconnect the CCD Ass'y end of the CCD Cable.

11. Push the Belt Holder and take out the Belt, as shown below.

12. Pull up the CCD Shaft and take out the Scanner Module.

CCD Cable

Scanner Module

CCD Shaft

Belt Holder

Belt

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Disassembly and Reassembly

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July 2003 WorkCentre PE16

14. Remove the two screws and take out the Motor Bracket.

15. Unplug the one connector from the Open Sensor Ass'y .

16. Unlatch the Open Sensor and remove it, as shown below.

Open Sensor

Motor Bracket

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Disassembly and Reassembly

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WorkCentre PE16 July 2003

5.6 ADF Motor Ass'y

1. Before you remove the ADF Motor Ass'y, you should remove:

- Four screws securing the Tray and remove the Tray

- Two screws securing the ADF Ass'y

- Wiring harness from cover

2. Remove the ADF Ass'y.

3. Remove the Open Cover, as shown below.

4. Pull the White Bush, then rotate it until it reaches the slot, as shown below. Then lift the Pick-Up Ass'y out.

5. Remove the two screws securing the Upper Cover and remove it, as shown below.

6. Unplug the one connector and remove four screws and one ground screw securing the ADF Motor Ass'y. Then take out the ADF Motor Ass'y.

ADF Ass’y

Open Cover

Release Tabs

Upper Cover

ADF Motor Ass’y

Pick up Ass’y

White Bush

ADF Lower Ass’y

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Disassembly and Reassembly

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July 2003 WorkCentre PE16

5.7 OPE Unit

1. Remove the seven screws securing the OPE PBA to the OPE Cover.

2. Remove the Contact Rubber from the OPE Cover.

3. Remove the Key Pad from the OPE Cover.

OPE Cover

OPE PBA

Key Pad

Contact Rubber

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WorkCentre PE16 July 2003

5.8 Middle Cover & Exit Roller

1. Before you remove the Exit Roller , you should remove:

- Rear Cover (see page 5-2)

- Front Cover Ass’y (see page 5-4)

- Side Cover (LH, RH) (see page 5-3)

- Scanner Ass’y (see page 5-5)

2. Remove the six screws securing the Middle Cover.

3. Unlatch the Middle Cover Securing the Frame Ass'y, using a proper tool as shown below. Then lift the Middle Cover out.

4. Remove the two screws securing the Rear-Upper Cover, as shown below

5. Remove the Exit Gear, Bearing and Exit Roller as shown below.

Middle Cover

Exit Gear

Bearing

Exit Roller

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Disassembly and Reassembly

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July 2003 WorkCentre PE16

1. Before you remove the Engine Shield Ass'y, you should remove:

- Rear Cover (see page 5-2)

- Side Cover(LH, RH) (see page 5-3)

- Scanner (see page 5-5)

2. Remove the two screws securing and unplug the FPC cable From the Main PBA. Then remove the LIU PBA

3. Unplug the two connectors.

4. Remove the ten screws securing the Engine Shield Ass'y and remove it. Then unplug the all the connectors from the Main PBA and SMPS.

Engine Shield Ass’y

5.9 Engine Shield Ass’y

LIU PBA

Fan Connector

Thermistor connector

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Disassembly and Reassembly

Service Manual

WorkCentre PE16 July 2003

1. Before you remove the Main PBA, you should remove:

- Engine Shield Ass’y(see page 5-12)

2. Unplug the one connector and remove the five screws securing the Main PBA. Then lift the Main PBAout, as shown.

Main PBA

5.10 Main PBA

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Disassembly and Reassembly

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July 2003 WorkCentre PE16

5.11 SMPS

1. Before you remove the SMPS, you should remove:

- Engine Shield Ass’y(see page 5-12)

2. Remove the three screws securing the Inlet Bracket and remove it

3. Unplug the one connector and remove the one screw securing the Engine Shield.

4. Remove the three screws securing the SMPS. Then lift the SMPS out, as shown below.

Inlet Bracket

SMPS

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WorkCentre PE16 July 2003

5.12 Fuser Ass'y

1. Before you remove the Fuser Ass'y, you should remove:

- Rear Cover (see page 5-2)

2. Unplug the two connectors from the Main PBAand SMPS, as shown below. Then remove the four screws securing the Fuser Ass'y and remove it.

3. Remove the two screws securing the Thermostat. Then lift the Thermostat out

4. Remove the two screws securing the Halogen Lamp. Then take out the Halogen Lamp from the Heat Roller

5. Remove the one screw securing the Idle Gear and remove it.

6. Remove the four screws securing the Fuser Cover and remove it, as shown below.

Fuser Ass’y

Halogen Lamp

Heat Roller

Idle Gear

Thermostat

Claw

Fuser Cover

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Disassembly and Reassembly

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July 2003 WorkCentre PE16

Thermister Harness

7. Unwrap the Thermister Harness, as shown below. 8. Remove the one screw securing the Thermister and remove it, as shown below.

Thermister

5.13 Fan

1. Before you remove the Fan, you should remove:

- Rear Cover (see page 5-2)

- Side Cover (RH) (see page 5-3)

2. Unplug the connector from the SMPS and remove the one screw. Then take out the Fan.

DC Fan

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WorkCentre PE16 July 2003

5-18

Disassembly and Reassembly

Service Manual

July 2003 WorkCentre PE16

1. Before you remove the LSU, you should remove:

- Rear Cover (see page 5-2)

- Side Cover (LH, RH) (see page 5-3)

- Scanner Ass’y (see page 5-5)

- Front Cover (see page 5-4)

- Middle Cover (see page 5-11)

2. Unplug the two connectors.

3. Remove the three screws securing the LSU and remove it.

5.15 Drive Ass'y

1. Before you remove the Drive Ass'y, you should remove:

- Rear Cover (see page 5-2)

- Side Cover (LH) (see page 5-3)

2. Remove the six screws securing the Drive Ass'y.

3. Take out the Drive Ass'y, then unplug the connector from the Main PBA, as shown below.

5.14 LSU

Drive Ass’y

LSU

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Disassembly and Reassembly

Service Manual

WorkCentre PE16 July 2003

1. Before you remove the Transfer Ass'y, you should remove:

- Rear Cover (see page 5-2)

- Side Cover (LH, RH) (see page 5-3)

- Scanner Ass’y (see page 5-5)

- Front Cover (see page 5-4)

- Middle Cover (see page 5-11)

- LSU (see page 5-18)

2. Remove the three screws securing the Transfer Earth and remove it.

3. Unplug the PTL Holder connector, then remove the PTL Holder and PTL Lens, as shown below.

4. Unlatch the Bushing and remove it. Then lift the Transfer Roller out, as shown below.

Transfer Earth

5.16 Transfer Ass'y

PTL Holder

PTL Lens

Bushing

Transfer Roller

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July 2003 WorkCentre PE16

5.17 Feed Ass'y

1. Before you remove the Feed Ass'y, you should remove:

- Rear Cover (see page 5-2)

- Side Cover (LH, RH) (see page 5-3)

- Scanner Ass’y (see page 5-5)

- Front Cover (see page 5-4)

- Middle Cover (see page 5-11)

- Drive Ass’y (see page 5-18)

2. Remove the two screws securing the Guide Paper and remove it.

3. Pull up the Feed Idle Bushing and Feed Idle Shaft, as shown below.

4. Remove the three screws securing the Feed Bracket and remove it.

5. Remove the Idle Gear and Feed Gear2.

Guide paper

Feed Bracket

Bushing

Feed Idle Shaft

Feed Gear2

Idle Gear

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WorkCentre PE16 July 2003

6. Remove the Feed Gear1 Ass'y. 7. Pull up the Feed Roller and Feed Roller1.

Feed Gear1 Ass’y

Feed Roller

Feed Roller1

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July 2003 WorkCentre PE16

5.18 Pick-Up Ass'y & Solenoid

1. Before you remove the Pick-Up Ass'y, you should remove:

- Rear Cover (see page 5-2)

- Side Cover (LH, RH) (see page 5-3)

- Front Cover (see page 5-4)

- Scanner Ass’y (see page 5-5)

- Middle Cover (see page 5-11)

- Engine Shield Ass,y (see page 5-12)

- Drive Ass’y (see page 5-18)

2. Remove the three screws securing the Feed Bracket and remove it.

3. Remove the Pick-Up Gear Ass,y.

4. Take out the Pick-Up Ass'y, as shown below.

5. Remove the two screws securing the Manual Solenoid and Pick-Up Solenoid. Then remove Manual Solenoid and Pick-Up Solenoid.

Feed Bracket

Bush

Pick up Gear Ass’y

(Pick up) Solenoid

(Manual) Solenoid

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ALIGNMENT & ADJUSTMENTS

Service

Manual

WorkCentre PE16 June 2003

6. Alignment and Adjustments

This chapter describes the main functions for service, such as the product maintenance method, the test output related to maintenance and repair, DCU using method, Jam removing method, and so on.

6.1 Paper path

Scanner Part

PTL

TR FR

OPC

L S U

Fuser

Toner Cartridge

Sensor-DocSensor-Doc

ADF-Roller

Pickup-Roller

Exit-Roller

Doc-Paper(30Sheets)

ADF-Idle Roller

Sensor-Regi

Feed-Roller

CCD-Module

White-SheetWhite-Sheet

Sensor-Regi

Sensor-ScanSensor-Scan

Engine Part

6-2

ALIGNMENT & ADJUSTMENTS

Service

Manual

July2003 WorkCentrePE16

6.1.1 Copy & Scan Document Path

6.1.2 Printer Paper Path

1) After receiving a print job, the printer feeds the paper from the cassette or manual feeder.

2) The fed paper passes the paper feeding sensor. (Jam 0 occurs if the sensor is not operated after a certain time passes)

3) The paper passes the paper feeding sensor moving to the paper exit sensor via printing process. (Jam 1 occurs if the paper exit sensor is not operated after a certain time passes)

4) The paper passes the paper exit sensor moving out of the set. (Jam 2 occurs if the sensor is still operated after a certain time passes.)

Scanner Part

CCD-Module

White-SheetWhite-Sheet

5 6 7

Sensor - Scan

Sensor - Regi

Feed Roller

Exit Roller

1 2 3 4

Doc. Paper (30 Sheets)

Pickup Roller

ADF Roller

Sensor - Doc.

Engine Part

1 2 3 4

Paper Input (Cassette)

Paper Input (Manual Feeder)

Paper Out (Face Down)

5 6 7

Paper Empty Sensor (Cassette)

Paper Feeding Sensor

Paper Exit Sensor

Paper Empty Sensor (Manual)

PTL

TR FR

OPC

L S U

Fuser

Toner Cartridge

6-3

ALIGNMENT & ADJUSTMENTS

Service

Manual

WorkCentre PE16 July 2003

6.2 Clearing Paper Jams

Occasionally, paper can be jammed during a print job. Some of the causes include:

• The tray is loaded improperly or overfilled.

• The tray has been pulled out during a print job.

• The front cover has been opened during a print job.

• Paper was used that does not meet paper specifications.

• Paper that is outside of the supported size range was used.

If a paper jam occurs, the On Line/Error LED on the control panel lights red. Find and remove the jammed paper. If you don’t see the paper, open the covers. Do not use a tweezers or a sharp metal tool when removing a jam. The covering of a metal part can be removed which can cause an electric leakage.

Paper Jam0

PTL

TR FR

Empty Sensor

OPC

L S U

Fuser

Toner Cartridge

EXIT Sensor

Feed

Sensor

MP Sensor

Paper Jam1

PTL

TR FR

Empty Sensor

OPC

L S U

Fuser

Toner Cartridge

EXIT Sensor

Feed

Sensor

MP Sensor

Paper Jam2

PTL

TR FR

Empty Sensor

OPC

L S U

Fuser

Toner Cartridge

EXIT Sensor

Feed

Sensor

MP Sensor

Bypass Jam

L S U

Fuser

EXIT

Sensor

Empty Sensor

OPC

PTL

TR FR

Toner Cartridge

MP Sensor

Feed

Sensor

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July 2003 WorkCentre PE16

6.2.1 Clearing Document Jams

If a document jams while it is feeding through the ADF (Automatic Document Feeder),“DOCUMENT JAM ” appears on the display.

6.2.1.1 Input Misfeed

1) Open the ADF top cover.

2) Pull the document gently to the right and out of the

ADF.

3) Close the ADF top cover. Then load the documents back into the ADF.

NOTE : To prevent document jams,use the document

glass for the thick, thin or mixed documents.

1) Open the document cover. 2) Turn the release knob so that you can easily remove the misfed document. Remove the document from the ADF or the feed area by carefully pulling it towards the right by using both hands.

3) Close the document cover. Then load the documents back into the ADF.

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WorkCentre PE16 July 2003

6.2.1.2 Exit Misfeed

1) Open the document cover and turn the release knob to remove the misfed documents from the exit area.

2) Close the document cover. Then load the documents back into the ADF.

6.2.1.3 Roller Misfeed

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July 2003 WorkCentre PE16

6.2.2 Clearing Paper Jams

If paper jams occur, “PAPER JAM ” appears on the display. Refer to the table below to locate and clear the paper jam.

PAPER JAM 0 : In the paper feed area PAPER JAM 2 : In the paper exit area PAPER JAM 1 : In the fuser area or around the toner cartridge BYPASS JAM : In the Bypass tray

Follow the steps below to clear a jam. To avoid tearing the paper, pull the jammed paper out gently and slowly.

6.2.2.1 JAM0 (In the Paper Feed Area)

1) Open and close the front cover. The jammed paper automatically exits the machine. If the paper does not exit, continue to Step 2.

2 Pull the paper tray open.

3) Remove the jammed paper by gently pulling it straight out.

If there is any resistance when you pull the paper, or the paper is not seen in this area, skip to the fuser area around the toner cartridge

4) Insert the paper tray into the machine until it snaps into place.

5) Open and close the front cover to resume printing.

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WorkCentre PE16 July 2003

6.2.2.2 JAM 2 (In the Paper Exit Area)

1) Open and close the front cover. The jammed paper automatically exits the machine.

If the paper does not exit, continue to Step 2.

2) Gently pull the paper out of the front output tray.

3) If there is any resistance when you pull the paper, or

the paper is not seen in the front output tray, open the rear cover.

4) Remove the jammed paper by gently pulling it straight out.

5) Close the rear cover.

6) Open and close the front cover to resume printing.

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July 2003 WorkCentre PE16

6.2.2.3 JAM1 (In the Fuser Area of Around the Toner Cartridge Area)

NOTE : The fuser area is hot. Be careful when removing paper from the machine.

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

2) Remove the jammed paper by gently pulling it straight out.

3) Replace the toner cartridge and close the front cover. Printing automatically resumes.

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ALIGNMENT & ADJUSTMENTS

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WorkCentre PE16 July 2003

6.2.2.4 BYPASS JAM (In the Bypass Tray)

“BYPASS JAM ” appears on the display when the machine does not detect paper in the Bypass tray due to no paper or improper paper loading when you try to print using the Bypass tray.

“BYPASS JAM ” also may occur when the paper is not properly fed into the machine through the Bypass tray. In that case, pull the paper out of the machine.

6.2.2.5 Tips for Avoiding Paper Jams

By selecting the correct paper types, most paper jams can be avoided. If a paper jam occurs, follow the steps outlined in “Clearing Paper Jams ”

• Follow the procedures in “Loading Paper ”. Ensure that the adjustable guides are positioned correctly.

• Do not overload the paper tray. Ensure that the paper is below the paper capacity mark on the inside wall of the paper tray.

• Do not remove the paper from the tray while printing.

• Flex, fan and straighten the paper before loading.

• Do not use creased, damp, or highly curled paper.

• Do not mix paper types in the paper tray.

• Use only recommended print materials. See “Paper Specifications ”

• Ensure that the recommended print side is facing down when loading paper in the paper tray and facing up in the Bypass tray.

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ALIGNMENT & ADJUSTMENTS

Service

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July 2003 WorkCentre PE16

1.Paper Setting

Paper Tray Paper Size

2.Copy Setup

Change Default Timeout

3.Fax Setup

Receive Mode Ring to Answer Contrast Redial Term Redials MSG Confirm. Auto Report Auto Reduction Discard Size

4.Fax Feature

Delay Fax Priority Fax Add / Cancel

5.Advanced Fax

Send Forward RCV Forward Toll Save Junk Fax Setup Secure Receive Prefix Dial No Stamp RCV Name ECM Mode

6.Reports

Phone Book Send Report RCV Report System Data Scheduled Jobs Tx Confirm. Junk Fax List

7.Sound/Volume

Speaker Ringer Key Sound Alarm sound

8.Machine Setup

Machine ID Date&Time Clock Mode Dial Mode Language Power Save CCD Power Save USB Mode

9.Maintenance

Clean Drum Notify toner Clear Memory

6.3 User Mode

The figure below shows the possible user function settings. Usage details are provided in the user manual. In the service manual, the items are about the possible set-up by user.

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6.4 Tech Mode

6.4.1 How to Enter Tech Mode

In service (Tech) mode, the technician can check the machine and perform various tests to isolate the cause of a malfunction.

While in Tech mode, the machine still performs all normal operations.

To enter the Tech mode

To enter the Tech mode, press in sequence, and the LCD briefly displays ‘TECH’, the machine has entered service (Tech) mode.

6.4.2 Setting-up System in Tech Mode

WorkCentre PE16

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July 2003 WorkCentre PE16

6.4.3 Data Setup

SEND LEVEL

You can set the level of the transmission signal. Typically, the Tx level should be under -12 dBm.

Caution : The Send Fax Level is set for optimum performance when shipped from the factory. Never

change settings arbitrarily.

MODEM SPEED

You can set the maximum modem speed. Modem speed is automatically set to the lower speed when communicating with a slower speed modem since communication is done using the standard of lowest speed unit to ensure proper transmission/reception. Speed is best set 33.6Kbps as the default setting.

ERROR RATE

When the error rate is about to exceed the set value, the Baud rate automatically adjusts to 2400 bps. This ensures that the error rate remains below the set value. You can select the rate between 5% and 10%.

CLEAR ALL MEMORY

The function resets the system to the factory default settings. This function is used to reset the system to the initial values when the product is functioning abnormally. All the values are returned to the default values, and all the information, which was set by the user, will be erased.

< Method >

1. Select the [MEMORY CLEAR] in the TECH MODE.

2. Push the ENTER button.

3. Select your country. (There are four country groups. Refer to the table below.)

4. Push the ENTER button then it will clear all memory.

NOTICE : Always perform a memory clear after replacing the main board. Otherwise, the system

may not operate properly.

Country Group USA/Canada UK Russia Southafrica

USA/Canada UK Russia Southafrica Mexico Germany india Brazil France Oman

Italy Poland Spain Bangladesh Austria Kuwait Netherlands Moroco Belgium Algeria

Country Portugal Pakistan

Sweden UAE Norway Bahrain Denmark Srilanka Finland SaudiArabia Switzerland Chile Greece Peru Ireland Argentina Turkey Hungary

Romania Bulgaria Czech

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WorkCentre PE16 July 2003

FLASH UPGRADE

The Firmware Upgrade function and has two methods, Local and Remote.

(1) Local Machine

• RCP (Remote Control Panel) mode

This method is for Parallel Port or USB Port. Connect to PC and activate RCP (Remote Control Panel) to upgrade the Firmware.

< Method > How to Update Firmware using RCP

1. Connect PC and printer with Parallel Cable or USB Cable.

2. Execute RCP and select Firmware Update.

3. Search Firmware file to update with Browse Icon.

4. Click Update icon, firmware file is transmitted to the printer automatically and the printer is initialized when transmission is complete.

5. Click the Refresh icon to check what is updated.

• DOS Command mode This method is just for Parallel Port. Connect to PC with Parallel cable and enter DOS Command to upgrade the Firmware.

< Method >

1. First, ensure that you have the following files : down.bat, down_com.bin, fprt.exe, and Rom File: file name for upgrade. Save the files in the same folder.

2. In DOS, input as below and push the Enter key. Then, it will be automatically upgraded.

3. There are two commands for the conditions of product.

* When the product is in idle condition down "rom file" * When the product is in Ready condition (TECH MODE → DAT A SETUP →FLASH UPGRADE→ LOCAL)

fprt "rom file"

4. Do not turn off the power while in the upgrade process.

(2) Remote FAX

This function allows a fax with the latest firmware to send files to another fax over the telephone line.

< Method >

1. Setup the fax with the latest firmware to prepare for the upgrade.

(TECH MODE →DA TA SETUP→FLASH UPGRADE→REMOTE)

2. Input the fax number, which needs to be upgraded.

(Several faxes can be upgrade at the same time. In that case, enter each fax number.)

3. After you push the Enter button, the firmware file is sent by calling the number(s) entered.

(It takes 10~15 minutes to send the file.)

< Caution >

1. sending and receiving fax must be the same model.

2. A sending fax must be set up in ECM mode, and receiving memory must be set up as 100%. If not, the function will operate abnormally.

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ALIGNMENT & ADJUSTMENTS

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July 2003 WorkCentre PE16

6.4.4 Machine Test

SWITCH TEST

Use this feature to test all keys on the operation control panel. The result is displayed on the LCD window each time you press a key.

MODEM TEST

Use this feature to hear various transmission signals to the telephone line from the modem and to check the modem. If no transmission signal sound is heard, it means the modem part of the main board malfunctioned.

DRAM TEST

Use this feature to test the machine's DRAM. The result appears in the LCD display. If all memory is working normally, the LCD shows << O K >>

ROM TEST

Use this feature to test the machine'S ROM. The result and the software version appear in the LCD display.

• FLASH VER : 1.00 V

• ENGINE VER :1.00V

PATTERN TEST

Using this pattern printout, you can check if the printer mechanism is functioning properly. this feature is needed during production, it is not required for service.

SHADING TEST

The function is to get the optimum scan quality by the specific character of the CCD (Charge Coupled Device). If the copy image quality is poor, perform this function to check the condition CCD unit.

< Method >

1. Select the [ADJUST SHADING] at the TECH MODE.

2. Push the SET UP button then an image will be scanned.

3. After the scan, CCD SHADING PROFILE will be print out.

4. If the printed image is different to the image, the CCD is defect.

NOTE : When you test CCD, make sure

that the cover is closed.

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WorkCentre PE16 July 2003

6.4.5 Report

PROTOCOL LIST

This list shows the sequence of the CCITT group 3 T.30 protocol during the most recent sending or receiving operation. Use this list to check for send and receive errors. If a communication error occurs while the machine is in TECH mode, the protocol list will print automatically.

SYSTEM DATA

This feature provides a list of the user system data settings and tech mode settings.

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July 2003 WorkCentre PE16

6.5 Engine Test Mode

The Engine Tests Mode supplies useful functions to check the condition of the engine. It tests the condition of each device and displays the result of the test on the LCD. It is classified into 5 functions (0~4), that are shown below.

6.5.1 To enter the Engine Test Mode

To enter the Engine Test mode

Press in sequence, and the LCD briefly displays

‘Engine Test’, the machine has entered Engine Test Mode.

6.5.2 Diagnostic

NO. Sub No. Engine test Remark

0 1 Motor Test 1 : On, 2 : Of f

2 PickUp Test 1 : On, 2 : Off 3 Fan Test 1 : On, 2 : Off 4 Manual Clt Test 1 : On, 2 : Off 5 PTL Test 1 : On, 2 : Off

1 1 LSU Motor Test 1 : On, 2 : Off

2 LSU Hsync Test 1 : On, 2 : Off 3 LD Test 1 : On, 2 : Off

2 1 Feed Sen Test Check : Check Start

Next : Next Sensor Check

2 Exit Sen Test Check : Check Start

Next : Next Sensor Check

3 Cover Sen Test Check : Check Start

Next : Next Sensor Check

4 Empty Sen Test Check : Check Start

Next : Next Sensor Check

5 Manual Sen Text Check : Check Start

Next : Next Sensor Check

3 1 Therm ADC 180 1 : On, 2 : Off (maintain the fusing temp. 80C)

2 Therm ADC 140 1 : On, 2 : Off (maintain the fusing temp. 135C) 3 Therm ADC 120 1 : On, 2 : Off (maintain the fusing temp. 160C) 4 Therm ADC 100 1 : On, 2 : Off (maintain the fusing temp. 191C)

4 1 MHV Test 1 : On, 2 : Off (-1550V ± 50V)

2 Dev Bias Test 1 : On, 2 : Off (-430V ± 20V) 3 THV EN/NEG Test 1 : On, 2 : Off (-1000V +300V/-150V) 4 THV ON (1300V) 1 : On, 2 : Off (+1300V ± 20V) 5 THV ADC 1300V 1 : On, 2 : Off (ADC Value : 101 ±5) 6 THV ADC 600V~3500V 1 : On, 2 : Off (Compare each ADC Value)

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6.6 Identify Sale Date

This function confirms the date the consumer bought the product and used it for the first time. When the consumer first operates the machine, it will start a scan and page count. The time the machine was first used is stored in memory.

These settings are retained after memory delete (Clear All Memory).

< Method >

Press MENU, #, 1, 9, 3, # in sequence.Firmware version is displayed on LCD. Press 1( in the number keypad) : The LCD display shows "Updated date" Press 2( in the number keypad) : The LCD display shows "Product first use date"

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July 2003 WorkCentre PE16

6.7 Consumables and Replacement Parts

The cycle periods listed below are a general guideline for maintenance. The example list is for an average usage of 50 transmitted and received documents per day. Environmental conditions and actual use may cause these periods to vary. The cycle periods given below are for reference only.

COMPONENT REPLACEMENT CYCLE

ADF Rubber 20,000 Pages ADF Roller 60,000 Pages Pick-up Roller 60,000 Pages Friction Pad 60,000 Pages Transfer Roller 60,000 Pages Fuser 60,000 Pages Toner Cartridge 3,500 Pages (A4 IDC 5% Pattern)

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WorkCentre PE16 July 2003

6.8 Abnormal Image Printing and Defective Roller

If abnormal image prints periodically, check the parts shown below.

No Roller Abnormal image period Kind of abnormal image

1 OPC Drum 75.5mm White spot, Black spot 2 Charge Roller 37.7mm Black spot 3 Supply Roller 37.0mm Horizontal density band 4 Develop Roller 35.2mm Horizontal density band 5 Transfer Roller 45.3mm Black side contamination/transfer fault 6 Heat Roller 66.3mm Black spot and fuser ghost 7 Pressure Roller 75.5mm Black side contamination

1 2 3 4

OPC Drum

Charge Roller

Supply Roller

Developing Roller

5 6 7

Transfer Roller

Heat Roller

Pressure Roller

L S U

Fuser

OPC

TR FR

Toner Cartridge

PTL

MP Sensor

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July 2003 WorkCentre PE16

6.9 Error Messages

The display on the front panel shows printer status and error messages. Refer to the following material for explanations of the messages and possible solutions to the problems. The messages are listed in alphabetical order, with numbered messages following.

BYPASS JAM

Meaning : The machine detected a non-feeding condition from the BYPASS Tray. Solution : Open the side Cover and clear the jam.

COMM. ERROR

Meaning : A problem with the facsimile communications has occurred. Solution : Try again.

DOCUMENT JAM

Meaning : Loaded document has jammed in the ADF. Solution : Clear the document Jam.

DOOR OPEN

Meaning : The side cover is not securely latched. Solution : Clear the cover until it clicks in place.

DRUM WARNING

Meaning : Nearing end of drum life, the machine page count has exceeded 14000 print pages. Solution : Drum has 1,000 pages remaining. When the “REPLACE DRUM” message appears in the display,

the drum must be replaced.

GROUP NOT AVAILABLE

Meaning : You have tried to select a group location where only a single location number can be used, such

as when adding locations for a multi-dial operation.

Solution : Try again, check location for group.

Heating Error

Meaning : During operation, t emperature does not go up. Solution : Check thermister contact point & Heating Lamp.

LINE BUSY

Meaning : The remote FAX didn’t answer Solution : Try again.

LINE ERROR

Meaning : Your unit cannot connect with the remote machine, or has lost contact because of a problem on

the phone line. When the machine has a problem in cause of fax data reception step

Solution : Try again. Try connecting a phone to the socket to check the line. If failure persists, wait an hour

or so for the line to clear then try again.

LOAD DOCUMENT

Meaning : You have attempted to set up a sending operation with no document loaded. Solution : Load a document and try again.

MEMORY FULL

Meaning : The memory has become full. Solution : Either delete unnecessary documents, or retransmit after more memory becomes available, or

split the transmission into more than one operation.

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NO ANSWER

Meaning : The remote machine did not answer after all the redial attempts. Solution : Try again. Make sure the remote machine is OK.

NO CARTRIDGE

Meaning : The machine has detected that no toner cartridge is installed. Solution : Install the Cartridge.

NO. NOT ASSIGNED

Meaning : The speed dial location you tried to use has no number assigned to it. Solution : Dial the number manually with the keypad, or assign the number.

NO PAPER [ADD PAPER]

Meaning : The paper tray is empty. The printer system stops. Solution : Load new paper in the paper tray.

OPEN HEAT ERROR

Meaning : Thermister is not connected to main board or contact point is loose at power on. Solution : Check thermister contact point, Heating Lamp & Thermostat.

OVERHEA T

Meaning : The printer has overheated. Solution : Your unit will automatically return to the standby mode when it cools down to normal operating

temperature. If failure persists, check the ELAHOU-FUSER.

PAPER JAM 0 OPEN/CLOSE DOOR

Meaning : Paper has jammed in paper feeding area. Paper is jammed in pick-up unit Solution : Press STOP and clear the jam.

PAPER JAM 1/2 OPEN/CLOSE DOOR

Meaning : Paper has jammed inside the unit. Paper has jammed in paper exit unit. Solution : Clear the jam.

RETRY REDIAL?

Meaning : The machine is waiting for the programmed interval to automatically redial. Solution : You can press START to immediately redial, or STOP to cancel the redial operation.

TONER EMPTY

Meaning : When the machine has encountered the Toner Empty. Solution : Replace the Toner Cartridge.

TONER LOW

Meaning : Toner may be low Solution : Toner may be unevenly distributed. Remove the toner cartridge and shake it gently to evenly dis-

tribute the toner. Then replace the toner cartridge and retry.

Scanner Locked

Meaning : Scanner is locked by locker. Solution : Check locker. Connect the Flat-Cable.

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July 2003 WorkCentre PE16

7-1

WorkCentre PE16

Troubleshooting

Service Manual

July 2003

7. Troubleshooting

7.1 Paper Feeding Problems

7.1.1 Wrong Print Position

• Description Printing begins when the paper is in the wrong position.

Check and Cause Solution

A defective feed sensor actuator can cause incorrect timing.

Replace the defective actuator

7.1.2 JAM 0

• Description

1. Paper has not exited from the cassette.

2. Jam-0 occurs if the paper feeds into the printer.

PTL

TR FR

Empty Sensor

OPC

L S U

Fuser

Toner Cartridge

EXIT Sensor

Feed

Sensor

MP Sensor

Check and Cause Solution

1. Check the Solenoid by using Engine Test Mode : Diagnostic Mode code 0

2. Check if the pad is loose due to bad sealing of the side-pad.

3. Check the surface of the roller-pickup for foreign matter.

4. If the paper feeds into the printer and Jam 0 occurs, perform DCU to check feed-sensor of the engine board.

1. Replace the solenoid.

2. Replace the side-pad Assembly Lor R, if necessary.

3. Clean with soft cloth dampened with IPA(Isopropyl Alcohol) or water.

4. Replace the Housing-Pickup and/or Shaft-Pickup.

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Troubleshooting

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Service Manual

July 2003

7.1.4 JAM 2

• Description

1. Paper exits the printer but Jam 2 occurs.

2. Paper is stuck in the fuser roller.

PTL

TR FR

Empty Sensor

OPC

L S U

Fuser

Toner Cartridge

EXIT Sensor

Feed

Sensor

MP Sensor

Check and Cause Solution

1. If the paper exits the printer completely but Jam 2 occurs : Exit sensor is defective.

• After the paper is completely discharged, the Exit actuator should

return to the original position to shut off the photo-sensor.

2. If the paper is rolled in the Fuser Roller:

• This occurs when a Guide claw is broken away or distorted.

• It occurs when the Heat-Roller or Pressure-Roller is seriously contaminated with toner.

3. Concertina paper jam in the fuser.

1. Check if the exit sensor actuator is defective.

• Check if the actuator exit is distorted (Check if the lever part is distorted). Replace Actuator Exit.

• Check whether burrs occur on the assembly part of the actuator exit and if the actuator operates smoothly. Replace Actuator Exit.

• Check if foreign matters and wire are interfering with the operation of the actuator exit’s.

2. If the paper is stuck in the fuser : disassemble the fuser and remove the jammed paper, and clean the surface of the pressure roller with dry gauze.

3. Remove the jammed paper after disas-

sembling the fuser : Clean the surface of the pressure roller with dry gauze.

• Remove the toner particles stained on the rib.

• Check the assembly and performance of the exit.

7.1.3 JAM 1

• Description

1. Paper is jammed in front of or inside the fuser.

2. Paper is stuck in the discharge roller and in the fuser just after passing through the ActuatorFeed.

PTL

TR FR

Empty Sensor

OPC

L S U

Fuser

Toner Cartridge

EXIT Sensor

Feed

Sensor

MP Sensor

Check and Cause Solution

1. If the paper is jammed in front of or inside the fuser.

2. If the paper is stuck in the discharge roller and the fuser just after passing through the Actuator-Feed, Feed Actuator may be defective.

1. Replace the SMPS.

2. Reassemble the Actuator-Feed and Spring-Actuator.

7-3

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Troubleshooting

Service Manual

July 2003

7.1.5 Multi-Feeding

• Description Multiple sheets of paper are fed at once.

Check and Cause Solution

1. Solenoid malfunction(the solenoid does not work properly): Perform Engine Test Mode : Diagnostic Mode code 0.

2. Friction-Pad is contaminated with foreign matter.(oil..)

3. Paper is curled.

1. Replace the solenoid if necessary.

2. Clean the friction-pad with soft cloth dampened with IP A(Isopropyl Alcohol).

3. Remove curled paper.

7.1.6 Paper rolled in the fuser

• Description If contaminated at intervals of 57mm on the back of a paper.

Check and Cause Solution

1. Contamination of the pressure roller. (Background, Hot off set)

1. Disassemble the fuser, clean the area between the Heat-roller and and remove the foreign matter off of the pressure roller.

2. If background appears badly in the printing, fix it by referring to the solutions for background. (See 7.3.8 Background)

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Troubleshooting

WorkCentre PE16

Service Manual

July 2003

7.1.7 Paper rolled in the OPC

• Description Paper is rolled up in the OPC.

Check and Cause Solution

1. Paper is out of specification.

2. Paper is curled.

1. Use recommend paper.

2. How to remove the rolled paper in the OPC.

• Remove the paper while turning the OPC against the ongoing direction.

• Clean fingerprints on the OPC softly with soft cloth dampened with IPA(Isopropyl Alcohol) or tissue.

7.1.8 Defective ADF

• Description

ADF (Automatic document Feeder) is not operating properly.

Check and Cause Solution

1. Check if ADF rubber and HOLDER rubber are damaged.

2. Check if the document sensors of ADF Ass’y (3 paper sensors) are normal.

1. Replace the contaminated or damaged part.

2. Replace the ADF ASS’Y.

7-5

WorkCentre PE16

Troubleshooting

Service Manual

July 2003

7.2. Printing Problems (malfunction)

7.2.1 Defective Operation (LCD WINDOW ) Display

• Description

Strange characters are displayed on the OPE Panel and buttons do not operate.

Check and Cause Solution

1. Clear the memory.(see page 6.5.3)

2. Check if OPE Harness is connected to the Connection B'd correctly.

1. Try again after clearing the memory.

2. After confirming that OPE Harness is connected to the Connection B'd correctly, replacethe OPE Ass’y and Main Board in sequence.

7.2.2 Defective LCD Operation

• Description

Defective LCD Operation

Check and Cause Solution

1. Clear the memory. (See page 6.4.3).

2. Confirm you can hear a click sound, while pressing a key on the OPE panel.

1. Disassemble and reassemble the OPE Ass'y. Replace defective part.

2. Replace the OPE Ass'y and the Main PBA in sequence.

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Troubleshooting

WorkCentre PE16

Service Manual

July 2003

7.2.3 Not functioning of the fuser gear due to melting away

• Description

The fuser gear melts and breaks.

Check and Cause Solution

1. Check the Heat Lamp. 1. Replace the Fuser.

2. Replace the Main PBA.

3. Replace the SMPS.

7.2.4 Paper Empty

• Description

The paper lamp on the operator panel is on even when paper is loaded in the cassette.

Check and Cause Solution

1. Bending or deformation of the actuator of the paper sensor.

2. The function of the Main PBA is defective Perform Engine Test Mode : Perform Engine Test Mode diagnostic code 2.

1. Replace the defective actuator.

2. Replace the Main PBA.

7.2.5 Paper Empty without indication

• Description

The paper lamp on the operator panel does not come on when the paper cassette is empty.

Check and Cause Solution

1. Bending or deformation of the actuator of the paper sensor.

2. The function of the Main PBA is defective Perform Engine Test Mode : Perform Engine Test Mode diagnostic code 2.

1. Replace the defective actuator.

2. Replace the Main PBA.

7-7

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Troubleshooting

Service Manual

July 2003

7.2.6 Door Open

• Description

The ERROR lamp is on even when the print Door is closed.

Check and Cause Solution

1. The hook lever in the Front Cover may be defective.

2. Check the Connector(CN1) and Circuit of the Cover Switch department in the Main PBA.

1. Replace the hook lever, if defective.

2. Check the insertion of the Door Open S/W Connect.

3. Replace the Main PBA or Door Open S/W.

7.2.7 No lamp on when the Door is open

• Description

The ERROR lamp does not come on even when the printer Door is open.

Check and Cause Solution

Check the Connector(CN1) and Circuit of the Cover Switch department in the Main PBA.

1. Check the insertion of the Door S/W Connect.

2. Replace the Main PBA or Door Open S/W.

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Troubleshooting

WorkCentre PE16

Service Manual

July 2003

7.2.8 Defective Motor operation

• Description

Main Motor is not driving when printing, and paper does not feed into the printer, resulting 'Jam 0'.

Check and Cause Solution

1. Motor harness may be defective.

2. Perform Engine Test Mode diagnostic code 0 and Check the Motor operation.

1. Check the Motor harness, replace it, if defective.

2. Replace the SMPS or Main Board, if necessary.

7.2.9 No Power

• Description

When system power is turned on, all lamps on the operator panel do not come on.

Check and Cause Solution

1. Check if the power input and SMPS output are normal.

2. Check inside the LED-Panel on the front-cover, if the LED-Panel does not appear after normal warm-up.

1. Replace the power supply cord or SMPS.

2. Replace the control board.

3. Replace the LED-panel.

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Service Manual

July 2003

7.2.10 Vertical Line Getting Curved

• Description

When printing, vertical line gets curved.

Check and Cause Solution

1. If the supply of +24v is unstable in the Main Control board linking with LSU, check drive by Engine Test Mode : Diagnostic Code 1 LSU Motor on.

1. Replace LSU.

2. Replace the Main Control board.

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Service Manual

July 2003

7.3.1 Vertical Black Line and Band

• Description

1. Straight thin black vertical line occurs in the printing.

2. Dark black vertical band occurs in the printing.

Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer

Check and Cause Solution

1. Damaged developer roller in the developer. Deformed Doctor-blade or cleaningblade.

2. Scratched surface of the discharge roller in the developer.

3. Partial depression or deformation on the surface of the transfer roller.

1. If causes 1 and 2 occur in the developer cartridge, replace the developer and try to print out.

2. Replace the transfer roller if occurred as No. 3.

7.3.2 Vertical White Line

• Description White vertical voids in the image.

Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer

Check and Cause Solution

1. Foreign matter stuck onto the window or internal lenses of LSU mirror.

2. Foreign matter or toner particles between the developer roller and blade. (In case the life of the developer has expired, white lines or light image occur in front of the image.)

3. It may occur when a burr and foreign substances are on the window of the developer frame.

4. If the fuser is defective, voids occur periodically at the top of a black image.

1. Foreign matter stuck onto the window : Clean the LSU window with recommended cleaner(IPA) Clean the window with a clean cotton swab.

2. Foreign matter in the LSU : Open the cover of LSU and clean with a cotton swab on the surface of the reflex mirror.

3. Remove the foreign matter and burr of the exposure window. (Developer cartridge)

4. Open the front cover and check that the ribs corresponds to the position of the lines.

5. If the problems are not solved, replace the developer cartridge.

7.3 Printing Quality Problems

7.3.3 Horizontal Black Band

• Description

1. Dark or blurry horizontal stripes occur in the printing periodically. (They may not occur periodically.)

Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer

Check and Cause Solution

1. Bad contact of the voltage terminals to developer.

2. The rollers of developer may be stained.

Charge roller = 37.7 mm Supply roller = 37 mm Develop roller = 35.3 mm Transfer roller = 45.3 mm

1. Clean each voltage terminal of the Charge, Supply, Develop and Transfer roller.

(remove the toner particles and paper particles)

2. Measure the interval of the black bands,

refer to the measurements shown opposite and clean the appropriate gear in the OPC.

3. If the malfunction persists, replace the

developer.

7.3.4 Black/White Spot

• Description

1. Dark or blurry black spots occur periodically in the printing.

2. White spots occur periodically in the printing.

Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer

Check and Cause Solution

1. If dark or blurry black spots occur periodically, the rollers in the Developer may be contaminated with foreign matter or paper particles.

( Charge roller : 37.7 mm interval

OPC drum : 75.5 mm interval)

2. If faded areas or voids occur in a black image at intervals of 75.5 mm, or black spots occur elsewhere, the OPC drum surface is damaged.

3. If a black image is partially broken, the transfer voltage is abnormal or the transfer roller's life has expired.

1. Run OPC cleaning Mode Print and run the Self-test 2 or 3 times.

2. In case of 75.5 mm interval unremovable in 1, remove any foreign substances stuck on the OPC location equivalent to black spots and white spots with a dry duster.

3. The transfer roller guarantees 60,000 sheets printing. If the roller's life is expired, replace it.

4. In case of 37.7 mm interval not removable in 1, replace the developer cartridge and try to print out.

5. Clean paper particles and foreign matter from the inside of the machine.

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July 2003

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Service Manual

July 2003

7.3.5 Light Image

• Description The printed image is light, with no ghost.

Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer

Check and Cause Solution

1. Developer roller is stained when the toner is almost used up.

2. Ambient temperature is below than 10°C.

3. Bad contact caused by the toner stains between the high voltage terminal in the HVPS and the one in the set.

4. Abnormal output from the HVPS. (Run self-test and check 1~4)

1. Check if the Toner Save Mode is off.

2. No 1 : R

eplace the developer cartridge and

try to print out.

3. No 2 : Wait 30 minutes after printer is powered on before you start printing.

4. No 3 : Clean up the contaminated area by

the toner.

5. Replace the HVPS if the problems are not

solved by the above four directions.

7.3.6 Dark Image or a Black

• Description The printed image is dark.

Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer

Check and Cause Solution

1. No charge voltage in the Main PBA. ( Perform Engine Test Mode : Diagnostic

code 4 HVPS check.)

2. Charge voltage is not turned on due to the bad contacts between power supply in the side of the Developer and charge terminal of HVPS.

1. Clean the high voltage charge terminal.

2. Check the state of the connector which connects the engine board and HVPS.

3. If steps 1 and 2 above did not correct the problem, replace the HVPS .

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Service Manual

July 2003

7.3.7 Uneven Density

• Description Print density is uneven between left and right.

Check and Cause Solution

1. The pressure force on the left and right springs of the transfer roller is not even, the springs are damaged, the transfer roller is improperly installed, or the transfer roller bushing or holder is damaged.

2. The life of the Toner Unit has expired.

3. The toner level is not even on the developer roller due to the bad blade.

1. Replace both the left and right Spring Holder.

2. Problem with the toner cartridge, replace the toner cartridge and try to print out.

7.3.8 Background

• Description Background appears in whole area of the printing.

Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer

Check and Cause Solution

1. Recycled recording paper has been used.

2. The life of the Developer has expired.

3. The vertical movement of the transfer roller is too great?

4. The HVPS is normal? (Perform Engine Test Mode diagnostic code 4)

1. Quality is not guaranteed when using recycled paper.

2. Replace the toner cartridge.

3. Clean the bush part of the transfer roller.

4. Replace the HVPS.

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Service Manual

July 2003

7.3.9 Ghost (1)

• Description Ghost occurs at 75.5 mm intervals of the OPC drum in the whole printing.

Digital Printer

75.5 mm

Check and Cause Solution

1. Bad contacts caused by contamination from toner particles between high voltage terminal in the main body and the electrode of the Toner Unit..

2. Bad contacts caused by contamination from toner particles between high voltage terminal in the main body and the one in the HVPS board.

3. The life of Toner Unit has expired.

4. Transfer roller lifetime (60,000 sheets) has expired.

5. Abnormal low temperature(below 10°C).

6. Damaged cleaning blade in the Toner Unit.

1. Clean the contaminated terminals.

2. Problem in the toner cartridge, replace the toner cartridge and try to print out.

3. Replace the engine board if not solved by the above Steps 1 and 2.

4. If not solved by Step 3, check the transfer roller lifetime and replace it.

5. Wait about 30 minutes after power on before using printer.

6. Problem in the toner cartridge, replace the toner cartridge and try to print out.

7.3.10 Ghost (2)

• Description

Ghost occurs at 75 mm intervals of the OPC drum in the whole printing. (When printing on card stock or transparencies using manual feeder)

Digital Printer

75 mm

Check and Cause Solution

When printing on card stock thicker than normal paper or transparencies such as OHP, higher transfer voltage is required.

Select 'Thick Mode' on paper type menu from the software application and after use, we recommend returning to the original Mode.

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7.3.11 Ghost (3)

• Description White ghost occurs in the black image printing at 32 mm intervals.

Digital Printer

32 mm

Check and Cause Solution

1. The life of Toner Unit has expired.

2. The abnormal voltage and bad contact of the terminal of the supply roller

1. Problem in the toner cartridge, replace the toner cartridge and try to print out.

2. Replace the SMPS PBA.

7.3.12 Ghost (4)

• Description Ghost occurs at 64 mm intervals.

Digital Printer

64 mm

Check and Cause Solution

Check if the Thermistor is connected correctly ..

1. Disassemble the fuser and remove the contaminated toner particles on the roller and clean the foreign matter between Thermistor and Heat roller. ( Caution: can be deformed)

7.3.13 Stains on the front of the page

• Description The background on the face of the printed page is stained.

Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer

Check and Cause Solution

1. Toner leakage due to improperly sealed developer.

2. If the transfer roller is contaminated, stains will occur on the front of the page.

1. Replace the toner cartridge.

2. If the transfer roller is contaminated, run PC Cleaning Mode Print 2 or 3 times. And perform Self-Test 2 or 3 times to remove contamination.

3. Replace the Transfer Roller..

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July 2003

7.3.14 Stains on back of the page

• Description The back of the page is stained at 56.1 mm intervals.

Digital Digital Pri

Digital Printer Digital Printer Digital Printer

Check and Cause Solution

1. Transfer roller is contaminated.

2. Pressure roller is contaminated.

1. Perform the OPC Cleaning Mode Print 2 or 3 times. Run Self-Test to remove the contamination of the transfer roller.

2. Replace the transfer roller if contaminated severely .

3. Disassemble the fuser and clean the H/R(Heat Roller) and P/R(Pressure roller). Check the area between H/R and Thermistor. If contaminated, clean the area. Replace the contaminated part.

7.3.15 Blank Page Print out (1)

• Description Blank page is printed.

Digital Printer Digital Printer Digital Printer Digital Printer Digital Printer

Check and Cause Solution

Bad ground contacts in OPC and/or developer.

Clean the terminals of the toner cartridge and the printer.

7.3.16 Blank Page Print out (2)

• Description

1. Blank page is printed.

2. One or several blank pages are printed.

3. When the printer turns on, several blank pages print.

Check and Cause Solution

1. Bad ground contacts in OPC and/or developer.

2. The Pick-up Solenoid is not working correctly.

1. Clean the terminals of the toner cartridge.

2. Perform the engine self test using Engine Test Mode diagnostic Mode code 0

if the Pick-up

Solenoid is normal.

3. If not solved by the Steps1-2, replace the

engine board.

4. Turn the power off, clear the print job on the

computer, and try printing again.

Xerox WorkCentre PE16 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Product Terms

Symbols Marked on the Product

Laser Safety Statement

Power Safety Precautions

Electrostatic Discharge (ESD) Precautions

Service Safety Summary

Rear Cover

Front Cover

Main PBA

SMPS