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Phaser 3600 Printer Service Manual

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1. Acronym Description IEC International Electrotechnical Commission VF Interface IP Image Processor IPM Image Per Minute IPP Internet Printing Protocol IQ Image Quality KB Kilo Byte LAN Local Area Network LCD Liquid Crystal Display LD Laser Diode LED Light Emitting Diode LEF Long Edge Feed LSU Laser Scan Unit LTR Letter Size Paper 8 5 x 11 inches LVPS Low Voltage Power Supply MAC Media Access Control MB Mega Byte MHz Mega Hertz MM Millimeters MOT Motor MPT Multi Purpose Tray NCS Non Contact Sensor NCU Network Control Unit NPP No Paper NVM Non Volatile Memory NVRAM Non Volatile Random Access Memory OHP Overhead Paper Transparency OPC Organic Photo Conductor OPT Optional 08 Operating System PBA Printed Board Assembly PC Personal Computer PCB Printed Circuit Board PCL Printer Command Language PDL Page Description Language P J Plug Jack electrical connections Phaser 3600 Printer Service Manual Reference Acronym Description PJL Printer Job Language PL Parts List PPD PostScript Printer Description PPM Pages Per Minute PPR Partial Page Request PPS Pages PPS Pulses Per Second PS PostScript PTL Pre transfer Lamp PV Print Volume Management PWB Printed Wiring Board PWBA Printed Wiring Board Assembly PWM Pulse Width Modulation RAM R
2. 3 11 Jam At Tray 1 2 3 Jam 0 222222 3 13 Jam At Top Jam T seins ceced Ree ti ueri ec bbe bes aie G nas 3 14 JAM ATEX JAM 2 82 224 Qed Re oS eee eb acer ERA de rese ies pee 3 15 Jam At Rear Duplex Jam 1 2228222 3 16 Jam At Duplex Duplex Jam 2 222222 3 17 Check Cartridge Invalid Print Cartridge Non Xerox Cartridge Replace Print Cartridge 3 18 Close Fuser DO rx 3 19 Close Lop Cover eher Se ta aa 3 19 Fuser Failure Engine Fuser Low Heat Error or Engine Fuser Over Heat Error 3 20 ELS rer A ORDEI 3 21 Output Tray IS F l EU 3 22 4 General Troubleshooting Servicing INS RUSIS HS eee A de b eed deae ec ode de dels 4 2 Preventive Maintenance Procedure 1 m nent eee eens 4 3 Recommended Tool 222 5 cide orita sorda heed N EEE ede Peu bande d e dde 4 3 Control Panel Troubleshooting 0 ccc o 4 4 No Control Panel Display after Power Is Turned ON 4 4 Control Panel LED is On Control Panel Display Is Blank 4 4 Power Supply Troubleshooting 4 5 Taking Voltage Measurements
3. 9 8 General Wiring Diagram 2 22 9 12 HVPS SMPS to Main Board Wiring Diagram 9 13 Sensor to Main Board Wiring Diagram 9 14 Main Drive Joint Board and Optional Tray Wiring Diagram 9 15 LSU and Main Motor to Main Board Wiring Diagram 9 16 Controller Unit and Duplex Board to Main Board Wiring Diagram 9 17 A Reference Acronyms and Abbreviations lecce a ia eee AA eame ere mie ee A 2 Index Phaser 3600 Color Laser Printer Service Manual 5 Phaser 3600 Printer Service Manual General Information In this chapter Printer Configurations Consumable and Service Part Life Expectancy Parts of the Printer Control Panel Printer Specifications Media and Tray Specifications Chapter General Information Printer Configurations Print Features and Configurations Printer Configurations Features 3600_B 3600V_B 3600_N 3600V_N Maximum Print Speed 40 ppm 40 ppm 40 ppm 40 ppm Letter Memory Optional 64 MB 64 MB 128 MB 128 MB Up to 512 MB Optional if the original DIMM is replaced with 256MB RAM DIMM and the second slot has a 256MB RAM DIMM PostScript and P
4. 4 5 5 Print Quality Troubleshooting Print Quality Problems Overview 5 2 Repeating Detects 5254888 dew ie ae e tabe LA ca oet Woes nae ut teat 5 3 Repeating Defects Measurement Table 5 4 Control Panel Internal Test Print 44 448 eens 5 4 2 Phaser 3600 Printer Service Manual Table Of Contents Image Quality Troubleshooting ooooocococoooro IRR HI 5 9 Blank Print No Print 0 0 02 IIIA A nr 5 9 Lightor Undertone PrInt oie PUR kak eel owed DES etes ee gae dad 5 11 AAN e iii tem ue aime on ous 5 13 Background Contamination 5 15 Residual Image or Ghosting 5 16 Faded or Missing Image 22 00 02 lb b eem eee beoe at a pan bee e eta 5 18 Random Spots ces cute Uere eater ak eiue Wd idi s de edad eee Read 5 20 Repeating Bands Lines Marks or Spots 5 22 UE 2 seine eee reese pP 5 24 SKEW hoki e PaO the cata oats he dada Ao a feu 5 25 Horizontal Band Voids or Streaks 5 27 6 Cleaning and Maintenance Service Maintenance Procedure 6 2 Recommended 0018 oca oe
5. Bearing Pick Up Gear s3600 049 7 34 Phaser 3600 Printer Service Manual Service Parts Disassembly Tray 2 Feed Roller PL1 3 59 5 1 Perform all steps for removing the Tray 2 Pick Up Assembly and Rollers page 7 30 2 From underneath the chassis depress the latch downward then slide the Feed Roller off of the shaft s3600 105 Tray 2 Pick Roller PL1 3 59 2 Note Since the Pick Roller is accessible directly underneath the chassis there is no need to remove any assemblies 1 From underneath the chassis depress the latch downward then slide the Pick Roller off of the shaft 11 a Se s3600 106 Phaser 3600 Printer Service Manual 7 35 Service Parts Disassembly Tray 2 PL2 1 0 and Optional Tray 3 PL2 2 0 Replacement Note If the printer includes the Optional Tray 3 It will be the bottom tray with a handle It is identical in appearance to Tray 2 located directly above Note No reconfiguration parameters are required when replacing the Optional Tray 3 1 Remove the defective tray 2 Remove the new tray from its plastic packaging and reinsert in the same slot s3600 107 7 36 Phaser 3600 Printer Service Manual Service Parts Disassembly Duplex Unit PL2 3 0 Note No reconfiguration parameters are required when replacing the Duplex Uni
6. 1 10 2 Theory of Operation Phaser 3600 Operational Overview sco dr idee Sen dac op Bod e opea dace adeo de pP ba dedi iit 2 2 Summary of the Printing Process 2 2 Print Cartridge and Print Modes 2 3 Printer Paper PA eco eI I E A EEE AEE EEE NAR e ER e EUER eo ane Mid 2 4 Paper Path Components sauna de a Pg 2 4 Duplex Paper Path ss a eet ae e nee ER RE hee ra 2 5 Print Engine Assemblies 24 seek beeen rere ban sans Ree A beled Gad deed Dodo P de gant Da 2 6 Image Processing Assembly and Main Board 2 6 Laser Scan Unit LSU aoro hb o bue lees tale pare ne ed dent ed 2 7 Motor Drive Assemblies 2 7 Feed Assembly Process and Components 2 7 Transfer Roller Assembly 2 8 Fuser Assembly 4 ue eren AA ded Seu Oe 2 0 Duplex and Tray Assemblies 2 9 Duplex Assembly saciar da eR RR Ra de eU ORE Beds ex Eee mat butin assauts 2 9 Tray 2 and Optional Tray 3 Assemblies 2 9 Printer COntiols iio ares st P eol eme waa eee Ee Lade a 2 10 Paper Size Control mr n 3 REX REY des AXE IS eI adi REA 2 10
7. Step Actions and Questions Yes No 1 Print a demo page Go to step 3 Go to step 2 Does the error still occur when printing 2 Print a customer application page Go to step 3 Complete Does the error still occur 3 Is the original document normal Go to step 4 Replace the original document 4 Check the Print Cartridge for damages Replace the Go to step 5 Is the Print Cartridge damaged Print Cartridge Phaser 3600 Printer Service Manual 5 15 Print Quality Troubleshooting Troubleshooting Procedure Table continued Step Actions and Questions Yes No 5 Check the Transfer Roller Replace the Go to step 6 Are there any damages to the Transfer Transfer Roller Roller page 7 43 6 Check the Registration Assembly Replace the Go to step 7 Is there any damage to the Registration Registration Assembly Assembly page 7 41 7 Check the HVPS for correct Complete Replace the installation Reseat the HVPS Printer page 7 75 Cartridge Does the image quality improve Residual Image or Ghosting There are faint ghostly images appearing on the page The images may be either from a previous page or from the page currently being printed Initial Actions m Check the paper transfer path m Ensure there are no debris on the transfer path 5 16 Phaser 3600 Printer Service Manual A Warning Phaser 3600 Printer Service Manual Print Quality Troubleshooting m
8. SES z rm Ca eo N02 CONO1 CONOS CONO CONOG CON04 CONOS 3600 078 2 17 Theory of Operation Switching Mode Power Supply SMPS The SMPS is mounted on the bottom of the printer and is the main power source of the entire system It converts the AC input line into two main output channels 3 3 volts DC and 24 Volts DC The SMPS then provides these output channels to various components throughout the system in a switching mode as instructed by the Main Board The SMPS also drives the AC heater unit which supplies controlled current levels to the Fuser assembly as an independent module 2 18 Phaser 3600 Printer Service Manual Error Messages In this chapter Troubleshooting Overview Service Diagnostics Service Diagnostics Menu Map Troubleshooting Error Messages Chapter Error Messages Troubleshooting Overview This section covers troubleshooting procedures for the Phaser 3600 Laser Printer When an error first occurs record the error message and code and then cycle power to the printer to see if the error recurs To troubleshoot image quality problems see Image Quality Troubleshooting on page 5 9 Using the Troubleshooting Procedures 3 2 Each Step in a Troubleshooting Procedure instructs you to perform a certain action or procedure The steps are to be followed sequentially
9. 2 Disconnect the connector CN11 from the Joint Board to the Tray 1 Solenoid 3 Remove 1 screw securing the Tray 1 Solenoid Ley ea s3600 044 Phaser 3600 Printer Service Manual 7 29 Service Parts Disassembly Tray 2 Pick Up Assembly and Rollers Note DIS asp 9 It is not necessary to remove the entire assembly in order to remove the Pick Rollers Also do not replace the feeder assembly unless drive components need to be replaced If replacing just the rollers the Feed Assembly does not need to be removed Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Remove the Tray 1 MPT Assembly page 7 14 Remove the Inner Cover page 7 16 Remove the Main Drive Assembly page 7 38 Remove Tray 2 and Tray 3 if installed Turn the printer onto its left side s3600 045 Before you can slide the Pick Up Camshaft in the next step you must first release the white locking mechanism from the white plastic bearing then lift free from the shaft 10 Remove the Pick Up Roller by lifting the black tab to slide it off the shaft 7 30 Phaser 3600 Printer Service Manual Service Parts Disassembly Bearing Feed2 Gear 3500 046 11 Remove the black locking tab to free and remove the purple gear on the Retard Shaft 12 Press the plastic release tab on
10. Chapter 4 General Troubleshooting This chapter contains general information on troubleshooting the printer In addition this chapter includes troubleshooting methods for situations where error indicators are not available Chapter 5 Print Quality Troubleshooting This chapter focuses on techniques to correct image quality problems associated with the printer output Chapter 6 Cleaning and Maintenance This chapter provides periodic cleaning procedures for the printer Chapter 7 Service Parts Disassembly This chapter contains removal procedures for spare parts listed in the Parts List A replacement procedure is included when necessary Chapter 8 Parts List This chapter contains exploded views of the print engine and optional Field Replaceable Units FRUs as well as part numbers for orderable parts Chapter 9 Plug Jack and Wiring Diagrams This chapter contains the plug jack locations and the wiring diagrams for the printer Reference This section provides a list of acronyms and abbreviations Xi Xii Phaser 3600 Printer Service Manual Table Of Contents Table Of Contents SONICO LEMNS ccoo ao aria iii Symbols Marked on the Product 2 iv Power Safety Precautions aa na V Electrostatic Discharge Precautions vi Service Safety Summary isilecss le
11. Parts List Phaser 3600 Printer Service Manual 8 9 Parts List PL 1 2 Cover Assembly s3600 012 Phaser 3600 Printer Service Manual 8 10 PL 1 2 Cover Assembly Parts List Table Phaser 3600 Printer Service Manual Parts List ID No Name Description Part Number 1 1 X AS UNIT COVER TOP 002N02411 1 1 COVER M TOP 002N02730 1 2 COVER M OPEN XRX 002N02729 1 3 PMO STACKER RX 002N02418 1 4 LEVER M STACKING 38 036N00030 1 5 STOPPER M HINGE OPEN 1 6 COVER M OP PANEL XRX 1 7 SHEET OVERLAY BUTTON 1 8 MEC BRUSH ANTISTATIC 1 9 PBA SUB PANEL B D 140N63320 1 10 KEY M BUTTON XRX 1 11 KEY M CANCEL 1 12 CAP M LED XRX 1 13 WINDOW M LCD 2 COVER M LEFT 002N02413 3 COVER M RIGHT 002N02414 4 COVER M CONTROL BOX 002N02419 5 COVER M FRONT INNER 002N02415 6 MEA UNIT COVER REAR 002N02416 6 1 COVER M REAR 6 2 PMO STACKER REAR 6 3 ICT BRKT REAR COVER 6 4 GUIDE M EXIT 6 5 PMO STRIPE 001N00462 6 7 PEX ROLLER F UP 2 6 8 SPRING ETC SEPARATION 6 9 LABEL P JAM REMOVAL 6 10 FAN 127N07569 7 CO VER M FRAME EXIT 002N02417 8 COVER M DUMMY DUP FILLER PANEL 002N02420 8 11 Parts List PL 1 3 Frame Assembly 1 of 2 L0 009 S Phaser 3600 Printer Service Manual 8 12 Parts List PL 1 3 Frame Assembly 2 of 2 s3600 014 8 13 Phaser 3600 Printer Service Manual
12. Test Print Phaser4400 011028 2 S 8 5x11 SEF We conduct many of ever these mail s coverage Would yo your time to read survey has been de time and effort T test athens en PROCESS HHHEHHH gt SCAN We conduct many of ever these mail s coverage Would yo your time to read survey has been de time and effort T test pattern a qu envelope are enclo s3600 084 5 8 Phaser 3600 Printer Service Manual Print Quality Troubleshooting Image Quality Troubleshooting The following table provides examples and descriptions possible causes and the solutions for troubleshooting various image or printing defects that may be observed in the Phaser 3600 Laser Printer Blank Print No Print The entire image area is blank Initial Actions m Check the paper transfer path m Ensure the transfer path is free of debris Troubleshooting Reference Table Applicable Parts Example Print a Transfer Roller PL1 1 7 Registration Assembly PL1 1 12 m Laser Scan Unit PL1 1 15 m Print Cartridge PL1 1 34 HVPS PL1 1 29 m Main Board PL1 1 19 Blank Print Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Print a Demo page Go to step 3 Go to step 2 Is the entire area still blank 2 Check the paper condition Go to step 3 Replace the Is the paper dry a recommended type paper and loaded in the correct position 3 Check the Print Cartrid
13. Parts List PL 2 2 Tray 3 Cassette Parts List Table continued 8 28 Item No Description Part Number 32 FOOT ML80 33 IPR GROUND TOP 34 MEA UNIT PICK UP HOU 34 1 PMO M IDLE PICK UP 34 2 RUBBER PICK UP 34 3 HOUSING M PICK UP 35 PMO BUSHING FEED 36 PMO M DUMMY SHAFT 37 SPRING ES 38 HOUSING M FEED1 39 RUBBER FEED1 40 CBF HARNESS MOTOR 41 CBF HARNESS SCF EMPTY 42 CBF HARNESS SCF CASSETTE 43 CBF HARNESS SCF P SIZE Phaser 3600 Printer Service Manual Parts List Phaser 3600 Printer Service Manual 8 29 Parts List PL 2 3 Duplex Assembly s3600 018 8 30 Phaser 3600 Printer Service Manual PL 2 3 Duplex Assembly Parts List Table Phaser 3600 Printer Service Manual Parts List Item No Description Part Number 0 ELA UNIT DUPLEX 022N02412 1 FRAME M DUPLEX 2 GUIDE M UPPER DUP 3 COVER M REAR DUP 4 MEA ETC ALIGN DUP 4 1 GUIDE M ALIGN DUP 4 2 SHAFT IDLE ROLL DUP 4 3 ROLLER M IDLE DUP 4 4 PCT SLIP WASHER 4 5 SPRING ETC DUP 4 6 PULLEY M 18 DUMMY DUP 4 7 PULLEY 18 DUP 4 8 BUSH M FEED DUP 4 9 BELT TIMMING 4 10 ROLLER FEED DUP 4 11 RING C 5 CAP M CONNECTOR DUP 6 DUCT M FAN DUP 7 FAN DC HAWK 8 PBA SUB DPX SCF 9 CABLE CLAMP 10 IPR TERMINAL GND DUP 11 LOCKER M DUP 12 SHEET FRAME DUP 13 SPRING TS
14. Remove the LSU Lower Cover page 7 72 Remove a single screw and lift the fan duct covering the Toner Sensor Board Disconnect the fan connector to the Toner Sensor Board 8 Remove 1 screw to remove the fan from the printer o0 BR wn J Stopper s3600 068 Phaser 3600 Printer Service Manual 7 73 Service Parts Disassembly 7 74 Cover Open Board an Noah whnd lo d Sensor PL 1 3 47 Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Remove the Laser Scan Unit page 7 70 Remove the LSU Lower Cover page 7 72 Remove 1 screw securing the cover open housing harness cover Release the latching tab and remove the cover open housing harness cover Disconnect the connector CN 13 from the Main Board Using a small flatblade screwdriver release the 4 tabs to remove the Cover Open Board Cover Open Board fur NC e Harness Cover E s3600 070 Phaser 3600 Printer Service Manual Service Parts Disassembly Power Supplies High Voltage Power Supply HVPS PL 1 1 29 1 Note Do not lose the three board retaining springs when removing the HVPS 1 Remove the Left Cover page 7 7 2 Remove the Rear Cover page 7 8 s3600 092 3 Remove 6 screws from the HVPS 4 Disconnect all connectors from the HVPS 5 Remove the HVPS from the printer Repla
15. On Off PTL The Pre transfer Lamp will be PTL either on or off On Off Erase Lamp The lamp will be either on or off Erase Lamp On Off TR Cur Read The Control Panel displays a digital TR Cur Read equivalent xxx of the analog value xxx CR Cur The Control Panel displays a digital CR Cur Read Read equivalent xxx of the analog value xxx Test Print Pattern Print The printer prints a pattern test page Print Test 8 into Tray MPT On Off T2 Version Displays Tray 2 version 2 00 T3 Version Displays Tray 3 version 1 00 T4 Version N A N A DPX Version 1 03 Phaser 3600 Printer Service Manual Error Messages Troubleshooting Error Messages The following list summarizes the Phaser 3600 error messages Jam At Tray 1 2 3 JAM 0 The leading edge of the paper doesn t pass the Feed Sensor or the sensor does not turn ON m After paper pick paper is not fed m After paper pick paper enters the printer but does not reach the Feed Sensor in the specified time m After paper pick the feed sensor turns ON and tries to pick again but the paper does not reach the Feed Sensor in the specified time Jam At Top JAM 1 The paper jams between the Feed Sensor and the Exit Sensor The Jams occur when m The leading edge of the paper passes the Feed Sensor but the trailing edge does not pass through the Feed Sensor in the specified time The Feed Sensor cannot be OFF m The le
16. Automatic Paper Pick Control 2 10 Laser Scan Unit LSU Control 2 11 Laser Light Intensity Control sii eb b were E eR be dtd 2 11 Toner Control eic mE e RIdce a aides 2 11 Fuser Temperature Control haa 2 12 Phaser 3600 Color Laser Printer Service Manual 1 Sensor FUNCTIONS ES di Re C E RAE Re CR e doe Re 2 13 SIE SIR O o mE 2 13 Sensors in the Paper Path HH Hm n 2 15 P wer Supplies Ve 2 17 High Voltage Power Supply HVPS 2 17 Switching Mode Power Supply SMPS 2 18 3 Error Messages Troubleshooting Overview 2 3 2 Using the Troubleshooting Procedures 3 2 Service DiaQnOStiCS 24e due dws dee ewes dense dede Dee 3 3 Service Diagnostics Menu Map 3 3 Entering Service Diagnostics 3 3 Service Diagnostic Control Panel Button Descriptions 3 4 Diagnostic Test Menu Map 3 5 Troubleshooting Error Messages
17. Developer Motor CN20 ES PTL CN21 LVPS CN19 X 0 E Power CN22 all Q WS Duplex CN17 mi e Main Motte di CN18 H Exit Sensor cn23 NI Joint Board CN24 Optional 3rd Tray CN25 Ethernet CN1 USB CN2 Parallel Port CN3 RAM DIMM 1 CN14 RAM DIMM 0 CN12 3600 077 Phaser 3600 Printer Service Manual Theory of Operation Laser Scan Unit LSU The Laser Scan Unit LSU is the core element of the image production process The LSU receives video data from the controller on the Main Board and converts the data to an electrostatic latent image on the OPC Organic Photo Conductor drum The laser beam exposes the OPC drum under direction of the controller The controller also turns the drum synchronously with a polygon mirror within the LSU The OPC drum also turns in relation to the speed of the paper feed process An HSYNC signal is created when the laser beam from LSU reaches the end of a polygon mirror and the signal is sent to the controller The controller detects the HSYNC signal to adjust the vertical line of the image on paper That is after the controller detects the HSYNC signal the image data is sent to the LSU to adjust the left margin of the media Motor Drive Assembl
18. Immediately before removing the protective material from the leads of a replacement device touch the protective material to the chassis or circuit assembly into which the device will be installed Minimize body motions when handling unpacked replacement devices Motion such as your clothes brushing together or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro statically sensitive device Handle IC s and Erasable Programmable Read Only Memories EPROM s carefully to avoid bending pins Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards PCB s Phaser 3600 Printer Service Manual Service Safety Summary General Guidelines and Safety precautions For qualified service personnel only Refer also to the preceding Power Safety Precautions on page v Avoid servicing alone Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present Use care when servicing with power Dangerous voltages may exist at several points in this product To avoid personal injury do not touch exposed connections and components while power is On Disconnect power before removing the power supply shield or replacing components Do not wear jewelry Remove jewelry prior to servicing Rings necklaces and other metallic objects could come into contact with dangerous voltages and cu
19. Parts List 8 14 PL 1 3 Frame Assembly Parts List Table ltem No Description Part Number 1 FRAME M BASE 2 MEA UNIT PICK UP MP Tray 1 Pick Up Rack 130N01536 2 1 SHAFT M PICK UP MP 2 2 PMO IDLE PICK UP MP 2 4 ELA UNIT ROLLER P UP MP 022N02182 2 4 1 HOLDER M PICKUP MP 2 4 2 HOUSING M PICK UP MP 2 4 3 RUBBER PICK UP MP 2 5 CAM M SHAFT 3 MEA UNIT GEAR IDLE 007N01362 3 1 BRACKET P GEAR IDLE 3 2 GEAR FUSER IDLE 3 3 3 GEAR M FUSER IDLE 2 3 4 GEAR M FUSER DRV IN 3 5 CLUTH M HUB 3 6 GEAR RDCN FUSER OUT 3 7 RING E 4 ELA HOU BASE HOLDER Separator Pad Assembly 022N02173 4 1 FRAME M HOLDER PAD 4 2 HOLDER M PAD 4 3 RPR FRICTION PAD MP 4 4 SPRING ETC PAD 4 5 PMO ACTUATOR EMPTY MP 4 6 SPRING ETC EMPTY 4 7 PHOTO INTERRUPTER 4 8 CBF HARNESS MP EMPTY 5 MEA RACK EXIT ROLLER 022N02081 5 1 PMO HOLDER EXIT ROLL 5 2 PMO ROLLER FD F 5 3 PMO ROLLER FD R 5 4 SPRING EXIT ROLL FD 6 ROLLER EXIT F DOWN 006N01264 7 8 PMO ACTUATOR OUT FULL Outbin Full Actuator 120N00479 9 GEAR M EXIT 217 007N01364 Phaser 3600 Printer Service Manual PL 1 3 Frame Assembly Parts List Table continued Parts List ltem No Description Part Number 10 HOLDER BUSHING EXIT F DOWN 013E25770 11 MEA UNIT ROLL
20. m Tray 1 Assembly PL1 2 35 Sensor to Main Board Wiring Diagram m Tray 1 Solenoid PL1 1 26 on page 9 14 Registration Assembly PL1 1 12 Map 2 Main Board on page 9 5 Pick Roller PL1 3 2 5 m Main Board PL1 1 19 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the side guides for the Replace the Tray Go to Step 2 inoperative tray for damage or page 7 14 improper seating Are guides damaged or loose 2 Check the surface of the Pick Clean rollers with a Go to Step 3 Roller for dirt or damage soft cloth very Are the rollers dirty or damaged slightly dampened with water or replace page 7 25 if damaged 3 Do the Registration Rollers turn Go to Step 4 Replace freely Registration Assembly page 7 41 4 Is the Feed Sensor Actuator Repair or replace Go to Step 5 damaged or binding the actuator and or sensor page 7 21 5 Use service diagnostics to check Replace the Main Replace the the operation of the tray solenoid Board page 7 39 inoperative Do the tray solenoids operate solenoid correctly page 7 29 Phaser 3600 Printer Service Manual 3 13 Error Messages Jam At Top Jam 1 Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References m Registration Assembly PL1 1 12 Main Drive Joint Board and Optional Paper Exit Sensor PL1 3 76 Tray Wiring Diagram on page 9
21. 15 Switched Mode Power Supply Map 3 SMPS Board on page 9 6 Troubleshooting Procedure Table Step Actions and Questions Yes No JE Clean the paper path of any Complete Go to Step 2 obstructions dirt or debris Did this correct the problem 2 Use service diagnostics to test Go to Step 3 Replace the the operation of the Registration Registration Assembly Assembly Does the Registration Assembly page 7 41 operate correctly 3 Use service diagnostics to test Go to Step 4 Replace the Exit the Exit Sensor Sensor page 7 56 Does the sensor operate correctly 4 Replace the Fuser Assembly Complete Replace the SMPS page 7 54 and retest page 7 76 Did this correct the problem 3 14 Phaser 3600 Printer Service Manual Jam At Exit Jam 2 Phaser 3600 Printer Service Manual Troubleshooting Reference Table Error Messages Applicable Parts Wiring and Plug Jack Map References Exit Roller PL1 3 6 m Paper Exit Sensor PL1 3 76 Fuser Assembly PL1 4 1 Switched Mode Power Supply PL1 1 29 2 m Main Board PL1 1 19 Map 3 SMPS Board on page 9 6 Main Drive Joint Board and Optional Tray Wiring Diagram on page 9 15 Step Action and Questions Yes No Is the Paper Exit Sensor or the Repair or replace Go to Step 2 actuator damaged or binding the actuator and or Paper Exit Sensor page 7 56 2 Inspect the Exit Roller Replace th
22. 9 12 Phaser 3600Printer Service Manual Plug Jack and Wiring Diagrams HVPS SMPS to Main Board Wiring Diagram Main Board CN19 CON4 S i LVPS SMPS con DL 9 14 HOT AC Inlet 2 IC 13 NEUTRAL A NE Ku CON2 FSR1 gt C 10 I HOT Fuser gt gt 9 NEUTRAL c gt 8 D k 21 24VAC DA 6 SA 5 CON5 4 5 24VAC 1 Jam Cover E Microswitch E Y 3 2 gt RS R AN isavac f 2 SL N22 CON3 ON6 CN1 HVPS DEV AC PWM gt DO 28 IC 16 24VDC 57 ig gt DEV AC V e D a 9g LC 14 424VDC 5 Cn DEV AC CON 54 K _ 24VDC_ 23 Cn I DEV vbc PWM 35 di D havne e RA P 21 9 FUSER BIAS PWM I 20 Ic 8 3 3VDC 19 C 7 MHV_PWM gt 3 3VDC 18 KI 8 ES 17 5 EL 16 fal aes 15 KC 3 TH PI id Ico gt h 13 r 1 THV_READ ia gt I THV READ j VCC gt a 11 I nTHV_EN 10 2 GND i gt gt X 9 I FUSER COVER YA le A GND 7 GND 5 S GND i I FUSER ON D 4 GND 3 2 1 3600 024 2 GND m P FEED a Registration 2 3 3VDC ca E sensor 2 P_MARGIN
23. Duplex Assembly 2 9 disassembly 7 37 Duplex paper path 2 5 Duplex Roller disassembly 7 47 Duplex Unit Sensor 2 16 parts list 8 31 view of parts 8 30 Duplex board to Main Board Wiring Diagram 9 17 E ENERGY STAR 1 ii error message list 3 11 Exit Assembly Exit Gear disassembly 7 44 Exit Roller disassembly 7 44 Exit rollers 2 5 Exit Solenoid disassembly 7 48 F faded image defects 5 18 Fan tests 3 9 fastener types Posi Drive screw types 7 4 precautions 7 4 Feed Assembly Feed Roller 2 5 Feed Sensor 2 5 Idle Unit disassembly 7 49 process 2 7 Frame Assembly parts list 8 13 view of parts 8 12 Functional specifications 1 7 Fuser Assembly 2 5 2 8 defects 5 3 disassembly 7 54 Exit Sensor theory 2 16 Fuser control tests 3 9 Fuser Exit Sensor disassembly 7 56 Fuser Interlock Switch disassembly 7 55 parts list 8 21 view of parts 8 20 G general wiring diagram 9 12 ghosting defects 5 16 H High Voltage Power Supply disassembly 7 75 horizontal image defects 5 27 HVPS board locator map 9 7 theory 2 17 to Main Board Wiring Diagram 9 13 image quality defects 5 2 Inner Cover disassembly 7 16 input capacity tray 1 10 J Joint Board disassembly 7 52 K Knock Up Plate disassembly 7 17 L Laser Scan Unit LSU disassembly 7 70 Laser exposure 2 2 LSU Control tests 3 10 LSU Lower Cover disassembly 7 72 Pre transfer lamp 2 2 theory 2 7 Left Cov
24. Go to Step 7 binding Roller page 7 47 6 Is there damage to the duplex Replace the Duplex Replace Main Board assembly Unit page 7 37 page 7 39 Phaser 3600 Printer Service Manual Jam At Duplex Duplex Jam 2 Phaser 3600 Printer Service Manual Troubleshooting Reference Table Error Messages Applicable Parts Wiring and Plug Jack Map References Transfer Roller PL1 1 7 Duplex Exit Sensor PL2 3 15 Duplex Roller PL2 3 4 Main Board PL1 1 19 HVPS Board PL1 1 29 1 Sensor to Main Board Wiring Diagram on page 9 14 m Main Drive Joint Board and Optional Tray Wiring Diagram on page 9 15 Map 4 HVPS Board on page 9 7 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Does the paper jam after reversal Replace the Go to Step 2 but before reaching the Duplex Transport Roller Exit Sensor page 7 43 2 Use service diagnostics to testthe Go to Step 3 Replace the Duplex Exit Sensor Duplex Unit Does the sensor operate page 7 37 correctly 3 Inspect the Exit and Duplex Replace the Duplex Go to Step 4 Rollers for any signs of damage Roller page 7 47 or binding 4 Replace the Duplex Unit Replace the Main Replace the HVPS Does the problem still occur Board page 7 39 Power Supply Board page 7 75 3 17 Error Messages 3 18 Check Cartridge Invalid Print Cartridge Non Xerox Cartridg
25. HOLDER 10 PMO CAP TR 021N02248 11 12 ELA UNIT REGI Registration Assembly 146N00131 13 GEAR REGI Z25 007N01360 14 CAP M GEAR 007N01599 15 UNIT LSU Laser Scan Unit 122N00276 16 ELA UNIT EXIT SOLENOID 121N01100 17 ELA UNIT DEVE MOTOR 127N07389 18 ELA UNIT MAIN MOTOR 127N07571 19 PBA MAIN Base 140N63317 PBA MAIN Network 140N63333 20 MEA UNIT GEAR PICK UP 007N01598 20 1 GEAR M PICK UP CAM 20 2 GEAR M PICK UP 20 3 SPRINT ETC CAM MP 21 MEA UNIT GEAR P UP MP CARDINAL Feed Unit 007N01600 2 8 7 Parts List 8 8 PL 1 1 Main Assembly Parts List Table continued ID No Name Description Part Number 21 1 GEAR MP HOLDER CAM 21 2 GEAR MP PICK UP 21 3 SPRING ETC CAM MP 22 BEARING PICK UP 23 BRACKET P SHAFT MP 25 SOLENOID MAIN 121N01167 26 SOLENOID MP Tray 1 MPT Pick Solenoid 121N01102 27 RING E 28 SHIELD P SMPS 29 SMPS V1 110V 105N02144 SMPS V2 220V 105N02146 30 BAR P CROSS BOTTOM Front Bottom Cross Bar 31 FAN DC Left Side Cooling Fan 127N07569 32 STOPPER M FAN80 34 ELA UNIT DEVE Print Cartridge 7K Toner Cartridge 106R01370 14K Toner Cartridge 106R01371 35 ELA UNIT CASSETTE Tray 2 109R00756 36 ELA UNIT SCF Optional Tray 3 097N01673 37 ELA UNIT DUPLEX 097N01679 38 BRACKET P DUMMY CTRL 39 HVPS 105N02145 39 1 BRACKET NIC 39 2 PBA SUB NIC BOARD 40 STOPPER M NETWORK 41 40MM FAN 127N07568 Phaser 3600 Printer Service Manual
26. High Capacity 20 000 pages Metered Pagepack 20 000 pages Service Parts Fuser Assembly 150 000 pages Transfer Roller 150 000 pages Feed Roller Kit 150 000 pages Retard Roller 150 000 pages Separator Pad 150 000 pages Note The service parts are not tracked with an NVRAM counter and there is no replace or low warnings associated with these service parts General Information Parts of the Printer Front View Print Cartridge SIUE May Control Panel E Caper OMR RERO Control Board QL Cover Tray 1 MPT Tray 1 MPT Release Tray 2 On Off Switch Paper Gauge 5600 001 Rear View A Rear Door Network Port gt IL 4 optional for 3500B 3 1 Duplex Unit USB Port TR SLANK IEEE 1284 Parallel Port Tray 3 Optional Cable Connector Power Cord Receptacle al Phaser 3600 Printer Service Manual General Information Control Panel The Control Panel has three components m Multi colored Light Emitting Diode LED light m Alphanumeric display m Six button cluster Control Panel Buttons Button Function Return Returns to the prior higher level menu structure if available CANCEL Terminates the current action MENU Cycles through all of the top level menu items UP Scrolls up one menu item within a menu list If you continually press this control the menu items will wrap DOWN Scrolls up one menu item within a menu
27. O1 B W ND nRSTOUT GND N17 24VDC amp 1 D 3 3VDC Duplex Board 3 3VDC DUPLEX_RXD v DUPLEX DETECT y MDUPLEX_RXD GND GND CONDOR WD GND AIA m Qo O O 3600 023 9 17 Plug Jack and Wiring Diagrams 9 18 Phaser 3600Printer Service Manual Reference Contents m Acronyms and Abbreviations Reference Reference Acronyms and Abbreviations Acronym Description 3TM Three Tray Module A3 Paper size 297 millimeters 11 69 inches x 420 millimeters 16 54 inches A4 Paper size 210 millimeters 8 27 inches x 297 millimeters 11 69 inches A5 Paper size 148 millimeters 5 82 inches x 210 millimeters 2 10 inches AC Alternating Current is type of current available at power Source for the printer AMPV Average Monthly Print Volume APC Auto Power Control ASIC Application Specific Integrated Circuit ASSY Assembly ATM Adobe Type Manager BCR Bias Charge Roller BLDC Brush Less Direct Current BOOTP Boot Parameter Protocol BSD Block Schematic Diagram BTM Bottom BTR Bias Transfer Roller CAM Cam Shaft CCD Charged Coupled Device Photoelectric Converter CD Circuit Diagram CD Compact Disc CLT Clutch CN Connector CON Connector CRU Customer Replaceable Unit CRUM C
28. Parts Disassembly Outbin Full Actuator PL 1 3 8 Phaser 3600 Printer Service Manual Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 To remove the Actuator carefully separate the two plastic tabs on the actuator and lift free from the Exit Roller indentation BE OO ND 7 45 Service Parts Disassembly Outbin Full Sensor PL1 3 21 Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Disconnect the 3 wire harness connector CN3 from the Toner Sensor Board BE OO ND mm 5 Pinch two black mounting tabs from underneath the sensors to release and remove the sensor 7 46 Phaser 3600 Printer Service Manual Service Parts Disassembly Duplex Roller PL 1 3 11 Phaser 3600 Printer Service Manual BE OO NN Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Using a small flatblade screwdriver spread apart the bearings on both side of the duplex roller and remove from the printer Phare M ia o SU de SY s3600 060 7 47 Service Parts Disassembly Exit Solenoid PL 1 1 16 Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Disconnect connector CN10 from the Main Board Remove 3 screws s
29. Speed ppm pages per minute Letter Up to 40 ppm A4 Up to 38 ppm First Print Out in seconds 10 seconds or less Warm Up Time Power on Boot 40 seconds or less 1 7 General Information 1 8 Print Quality Property Characteristic Specification Resolution Normal Up to 1200 x 1200 dpi effective output Line Width 600dpi Line Width 1200dpi Dot Diameter 600dpi Dot Diameter 1200dpi RET Yes Halftone Gray Scale 256 levels Blackness gt 1 20 Homogeneity of Halftone at five points on page must be 0 1 Halftone 20 0 17 50 0 49 80 0 91 Printable Area Letter 208 x 271 mm A4 200 x 289 mm Non Printable Area Envelope 10mm 0 4 from edge Top Bottom Left Right Other Media 4mm 0 16 from edge Top Bottom Left Right Toner Fixing Black 100 Solid 80 Halftone 70 Magnification Horizontal applied to lt 1 0 mm 0 04 0 5 177 8mm length Vertical applied to 241 3mm length 3 0 mm 0 12 1 2 Printing Skew Tray 1 MPT 1 5 mm 0 06 Simplex amp Horizontal 2 0 mm 0 08 Duplex amp Horizontal 2 0 mm 0 08 Simplex amp Vertical 2 5 mm 0 10 Duplex amp Vertical Tray 2 1 5 mm 0 06 Simplex amp Horizontal 2 0 mm 0 08 Duplex amp Horizontal 2 0 mm 0 08 Simplex amp Vertical 2 5 mm 0 10 Duplex amp Ve
30. Visually inspect the fuser door close tab for damage Is the tab broken Replace the Fuser page 7 54 then go to Step 3 Go to Step 2 2 Is the sensor and actuator on the Fuser operating correctly Replace the Main Board Replace the Fuser page 7 54 then page 7 39 go to Step 3 3 Is the Printer operational Complete Replace the SMPS page 7 76 Close Top Cover Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Top Cover PL1 4 1 a Main Board PL1 1 19 m Map 2 Main Board on page 9 5 Troubleshooting Procedure Table Step Action and Questions Yes No la Visually inspect the top cover and the Replace the Top Go to Step 2 top cover actuator Cover page 7 10 Is the Top Cover or actuator damaged 2 Use diagnostics to test the Cover Replace the Main Replace the Open Board Board Cover Open Does the Cover Open board function page 7 39 Board properly page 7 74 Phaser 3600 Printer Service Manual 3 19 Error Messages 3 20 Troubleshooting Reference Table Fuser Failure Engine Fuser Low Heat Error or Engine Fuser Over Heat Error Applicable Parts Wiring and Plug Jack Map References Fuser Assembly PL1 4 1 Switched Mode Power Supply PL1 1 29 2 a Main Board PL1 1 19 Map 3 SMPS Board on page 9 6 zx Main Drive Joint Board and Optional Tray Wiring Di
31. and displaying the current On Off xxx temperature on the panel The target temperature is 160 degrees Fuser Temp The Control Panel displays a digital Fuser Temp equivalent xxx of the analog value xxx Inner Temp The Control Panel displays a digital Inner Temp equivalent xxx of the analog value xxx Phaser 3600 Printer Service Manual 3 9 Diagnostic Menu Map Options Main Menu Sub Menu Description Function Control Panel Display LSU Ctrl LD Power1 The display shows the previously LD Power Test 6 saved value On Off LD Power2 The display shows the previously LD Power2 saved value On Off Laser Motor The motor will run or stop Laser Motor On Off Laser Ready When the LSU is ready to print Laser Ready laser diode ON with a stable motor Normal Fault speed the message Normal displays Dev Control THV Plus The panel displays the previously THV Plus Bias Test 7 Bias saved bias value On Off THV Minus The panel displays the previously THV Minus Bias Bias saved bias value On Off DEV Bias The panel displays the previously DEV Bias saved bias value On Off DEV AC Bias The panel displays the previously DEV AC Bias saved bias value On Off DEV Vpp The panel displays the previously DEV Vpp Bias Bias saved bias value On Off MHV Bias The panel displays the previously MHV Bias saved bias value
32. and or other countries Adobe and PostScript are trademarks of Adobe Systems Incorporated in the United States and or other countries Apple Bonjour ColorSync EtherTalk Macintosh amp and Mac OSO are trademarks of Apple Computer Inc in the United States and or other countries PCL is a trademark of Hewlett Packard Corporation in the United States and or other countries Microsoft Windows Windows Server and Windows Vista are trademarks of Microsoft Corporation in the United States and or other countries Novell NetWare and IPX SPX are trademarks of Novell Incorporated in the United States and or other countries SunSM Sun Microsystems and Solaris are trademarks of Sun Microsystems Incorporated in the United States and or other countries UNIXO is a registered trademark in the US and other countries licensed exclusively through X Open Company Limited As an ENERGY STARO partner Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency The ENERGY STAR name and logo are registered U S marks rang ENERGY STAR Service Terms Manual Terms A Product Terms Phaser 3600 Printer Service Manual Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action Be aware of all symbols and terms when they are used and always re
33. beams The Laser Scan Unit monitors the output to determine if variations in the light intensity from the laser beam variations in the optical system such as mirrors and lenses or variations in drum sensitivity are preventing the system from obtaining a proper electrostatic image and if necessary adjusts the light intensity to attain a stable electrostatic image Error Description Error Message Polygon Motor The polygon motor speed cannot Laser Failure Error obtain a steady state Hsync Error The polygon motor speed is steady Laser Failure but the Hsync signal is not generated Toner Control Print Cartridge installation and Toner Level are detected by the Print Cartridge Interconnect Board and the associated signals are supplied to the Main Board The CRUM not only detects cartridge presence it also determines whether it is a genuine Xerox cartridge When the toner remaining falls to 1596 the printer displays a low toner message on the Control Panel display Phaser 3600 Printer Service Manual 2 11 Theory of Operation Fuser Temperature Control During Fuser temperature control the printer s target temperature is set The Heat Roller surface temperature is controlled to match the target temperature by turning the heat element ON OFF The Heat Roller surface temperature is detected by a Thermistor lf the Thermistor shows that the temperature is higher than the target the heat element is turned OFF If the de
34. bottom of the printer remove the screws holding the sensor to Disconnect the connector from CONS of the SMPS Power Supply the chassis Remove the Fuser Interlock Switch and wire harness s3600 102 7 55 Service Parts Disassembly Fuser Exit Sensor PL 1 3 76 A Warning Be sure you turn off the Printer and let the Fuser cool for 5 minutes le 2 3 NO OR 7 56 Remove the Left Cover page 7 7 Remove the Rear Cover page 7 8 Pull the locking lever and take out the Fuser Assembly Note Press the two green tabs towards the center of the machine to pull out the Fuser From the left side of the printer disconnect CN24 from the Main Board Free the CN24 harness and carefully pull into the interior of the printer Follow the instructions for removing the SMPS Power Supply page 7 76 From the bottom of the printer remove a single screw holding the sensor to the chassis Remove the Fuser Exit Sensor and wire harness s3600 103 Phaser 3600 Printer Service Manual Service Parts Disassembly Fuser Thermostat PL 1 4 3 AN Warning Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1 Remove the Fuser Assembly from the Printer page 7 54 2 Remove two screws 6mm securing the Thermostat to the Fuser assembly 3 Slide one wire connector off each end of the Thermostat
35. cold status Less than 40 sec General Information 1 12 Phaser 3600 Printer Service Manual Media Print Speed Toner save setting unit SWS Support PSU Support 30 LUI Local Ul Support Ul2 0 Duplex Print Simplex Support Manual Duplex N A Duplex Optional Theory of Operation In this chapter m Phaser 3600 Operational Overview m Printer Paper Path m Printer Controls Chapter 2 Theory of Operation Phaser 3600 Operational Overview Summary of the Printing Process 2 2 The Phaser 3600 Laser Printer is a desktop monochrome laser printer applying the principals of an electrophotographic system to place a monochrome image onto the print media The system contains a drum and developing unit which places the toner image onto print media producing monochrome prints through the transfer unit The printing process is composed of the following Charging The charge roller is negatively charged at approximately 1400 VDC by the high voltage power supply HVPS The charge roller is kept in contact with the drum surface to provide a uniform negative charge of approximately 800 VDC on the drum surface as it rotates at a constant speed Exposure The Laser Scan Unit LSU emits laser beams in response to image data from the Main board The laser beams are directed onto the drum surface through a system of mirrors and lenses A rotating polygonal mirror causes the laser beams to scan the drum sur
36. display Registration Status Sensor before touching the sensor and the Sensor Test 1 second value lists normal display Without Paper after touching the sensor With Paper T1Feed The first value lists normal display T1 Feed Sensor Sensor before touching the sensor and the Without Paper second value lists normal display With Paper after touching the sensor T2 Feed The first value lists normal display T2 Feed Sensor Sensor before touching the sensor and the Without Paper second value lists normal display With Paper after touching the sensor T3 Feed The first value lists normal display T3 Feed Sensor Sensor before touching the sensor and the Without Paper second value lists normal display With Paper after touching the sensor T4 Feed The first value lists normal display T4 Feed Sensor Sensor before touching the sensor and the Without Paper second value lists normal display With Paper after touching the sensor Exit Sensor The first value lists normal display Exit Sensor before touching the sensor and the Without Paper second value lists normal display With Paper aftertouching the sensor DJam 1 The first value lists normal display DJam1 Sensor Sensor before touching the sensor and the Without Paper second value lists normal display aftertouching the sensor With Paper Phaser 3600 Printer Service Manual Phaser 3600 Printer Service Manual Diagno
37. so you can swing the crossbar out of the Way 5 From the bottom of the printer remove 2 screws 6mm holding the Paper Size Sensor assembly to the chassis and lift free from the printer 6 To remove the sensor board from the Paper Size Sensor assembly remove two screws that secure the Paper Size Sensor to the assembly s3600 075 Replacement Note Do not lose the copper mounting shield that connects the assembly to the chassis Phaser 3600 Printer Service Manual 7 53 Service Parts Disassembly Fuser Assembly 1 3 80 A Warning Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1 Remove the Rear Cover page 7 8 2 Pull the locking lever and take out the Fuser Assembly Note Press the two green tabs towards the center of the machine to pull out the Fuser hermistor onnector 4 7 ZAN 1 i 7 P 3600 065 When you replace the Fuser run the Clean Fuser cycle from the Control Panel page 6 4 Replacement Note 7 54 Phaser 3600 Printer Service Manual Service Parts Disassembly Fuser Interlock Switch PL 1 3 77 A Warning Be sure you turn off the Printer and let the Fuser cool for 5 minutes Phaser 3600 Printer Service Manual 1 6 Remove the Left Cover page 7 7 2 Remove the Rear Cover page 7 8 3 Follow the instructions for removing the SMPS Power Supply page 7 76 4 5 From the
38. tabs P y 4 Pull the Thermostat free from the Fuser Assembly Replacement Note Be sure to insert the Thermostat with the Foil side near the edge of the Assembly Phaser 3600 Printer Service Manual 7 57 Service Parts Disassembly Fuser Thermistor PL 1 4 40 A Warning Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1 Remove the Fuser Assembly from the Printer page 7 54 2 Remove two screws from the Fuser assembly see inset below s3600 114 7 58 Phaser 3600 Printer Service Manual Phaser 3600 Printer Service Manual Service Parts Disassembly 3 Unfold the Fuser Assembly to expose the Heat Roller and the Pressure Roller s3600 124 4 Disconnect the 4 wire Thermistor plug from the Fuser Connector 5 Remove one screw holding each of the two Thermistors and remove both thermistors with plug wiring harness from the Fuser Assembly 7 59 Service Parts Disassembly Heat Roller PL 1 4 53 and Bushing PL 1 4 44 AN Warning Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1 Remove the Fuser Assembly from the Printer page 7 54 2 Remove two screws from the Fuser assembly see inset below s3600 114 7 60 Phaser 3600 Printer Service Manual Service Parts Disassembly 3 Unfold the Fuser Assembly to expose the Heat Roller and the Pressure Roller s3600 124 4 Facing the Fuser Connector disconnect the single wire
39. the left cover towards the rear of the printer to release the 3 tabs on the top and 3 bottom hooks securing it to the printer a ron s3600 028 Replacement Note Before reinstalling the cover remove the duplex unit When reinstalling the cover insert the 3 bottom hooks first then slide the cover from the rear to the front Make sure the cover is securely behind the 3 tabs Phaser 3600 Printer Service Manual 7 7 Service Parts Disassembly Rear Cover PL 1 2 6 1 Open the Rear Cover 2 Release the Restraining Strap tie stopper lt SS YA G ELI s3600 040 3 While facing the Rear Cover lift up on the right hinge pin slide the Rear Cover to the right to free the left hinge pin then remove the Rear Cover from the printer 7 8 Phaser 3600 Printer Service Manual Service Parts Disassembly Rear Cover Fan PL1 2 6 10 1 Remove the Rear Cover page 7 8 2 Use a flatblade screwdriver to flex one side of the paper guide then lift and remove to expose the fan s3600 108 3 Disconnect the interim connector P J4 from the three wire harness to the fan 4 Flex two hooks on one side of the fan to release and remove s3600 109 Phaser 3600 Printer Service Manual 7 9 Service Parts Disassembly Top Cover PL 1 2 1 Note Since the top cover is being redesigned the following instructions will cha
40. the sensor T3 PSize2 The first value lists normal display T3 Psize2 Sen Sensor before touching the sensor and the Low High second value lists normal display aftertouching the sensor T4 PSize0 The first value lists normal display T4 Psize0 Sen Sensor before touching the sensor and the Low High second value lists normal display after touching the sensor T4 PSize1 The first value lists normal display T4 Psize1 Sen Sensor before touching the sensor and the Low High second value lists normal display aftertouching the sensor T4 PSize2 The first value lists normal display T4 Psize2 Sen Sensor before touching the sensor and the Low High second value lists normal display aftertouching the sensor DPX Detect The first value lists normal display DPX Detect Sen Sensor before touching the sensor and the Low High second value lists normal display after touching the sensor Motors Main Mtr The motor will run on the forward Main Mtr Fwd Test 2 Fwd direction or stop On Off Main Mtr The motor will run on the forward Main Mtr Slow Slow direction in half speed mode On Off Dev Mtr Nor The motor will run on the forward Dev Mtr Nor direction in normal speed On Off Dev Mtr The motor will run on the forward Dev Mtr Slow Slow direction in half speed On Off Duplex Mtr The motor will run on the forward Duplex Mtr Fwd Fwd direction On Off T2 Feed The motor will run on the forward T2 Feed Moto
41. until the problem is fixed or resolved The Actions and Questions box contains additional information and or additional procedures you must follow to isolate the problem When a procedure instructs you to test a component using service diagnostics see the Service Diagnostics Menu Map on page 3 3 for the detailed steps and functions for testing parts of the printer The action is followed by a question If your response to the question is Yes then follow the instructions for a Yes reply If your response to the question is No then follow the instructions for a No reply Troubleshooting Procedures may ask you to take voltage readings or test for continuity at certain test points within the printer For detailed diagrams see Plug Jack and Connector Locators and Maps on page 9 3 for complete information on test point locations and signal names Troubleshooting Procedures often ask you to replace a printer component see Service Parts Disassembly on page 7 1 for detailed steps in removing and replacing all major components of the printer The Parts List on page 8 1 details the location quantity and part number for all spared printer components Phaser 3600 Printer Service Manual Error Messages Service Diagnostics The printer has built in diagnostics to aid in troubleshooting problems The Service Diagnostics Menu provides a means to test sensors motors switches clutches fans and solen
42. 00Printer Service Manual Phaser 3600Printer Service Manual Plug Jack and Wiring Diagrams Symbol Description Represents an interconnection between parts es using a conductive part such as a Plate Spring Interconnection Conductive Part 5 VDC Denotes DC voltage 3 3 VDC SG Denotes signal ground AG Denotes analog ground RTN Denotes return Plug Jack and Wiring Diagrams General Wiring Diagram Tray Empty i Tray 1 Feed Sensor i CM Ethernet on en Sensor USB Lt CN2 CN1 Parallel Port iu Paper Full Sensor ml meg Sensor Thermistor T ZI End 7 Ll pu SMPS LVPS Ta cm cue Fan m Duplex CN11 Erase Lamp Solenoid Em Temp2 RAM Cover Open CN12 DIMM RAM DIMM CN14 XI Main Ni CN18 Motor Derdo AC Inlet Per en H ono Motor CN19 CON4 conz prL2 PTL1 n SMPS Jam Cover CONS a ies Sensor Main Joint CONG aem n MP CN12 H CN24 TER CN11 Solenoid CN25 H CN7 Optional 3rd Tray Board Tray 1 MPT Paper Empt CN4 P J8 r4 P Ja Sensor s3600 019
43. 0N63023 96 CBF HARNESS SENSOR 97 PBA SUB FEED SENSOR Tray 1 FeedSensor 140N63024 98 CAP M HV Phaser 3600 Printer Service Manual Parts List Phaser 3600 Printer Service Manual 8 19 Parts List PL 1 4 Fuser Assembly s3600 015 8 20 Phaser 3600 Printer Service Manual PL 1 4 Fuser Assembly Parts List Table Parts List Item No Description Part Number 1 ELA UNIT FUSER 110V 126N00293 ELA UNIT FUSER 220V 126N00294 2 SCREW TAPTITE 3 THERMOSTAT 130N01537 4 SCREW TAPTITE 5 HARNESS FUSER 6 COVER FUSER UP LAMP 7 PMO BUSHING TX 8 HOLDER IDLE ROLLER 9 SPRING ETC ACTUATOR 10 PMO ROLLER UPPER DP 11 PMO ACTUATOR EXIT 12 GEAR EXIT 13 HOLDER REAR LEVER 14 LABEL HOLD REOPEN 15 ROLLER EXIT F UP 16 PLATE ACTUATOR COVER 17 HOLDER LEVEL R 18 GEAR IDLE 19 CAP ACTUATOR 20 GREASE BEARING 21 RING E 22 GEAR FUSER 2 LAMP 23 BRACKET LAMP RIGHT 24 BEARING BALL 25 BRACKET FUSER LAMP 26 RING CS 28 SPRING ETC SEPARATION 29 GUIDE CLAW POLY 30 COVER SLIDE SENSOR 31 TEX SHAFT IDLE F UP 32 PEX ROLLERF UP 33 SPRING TS 34 HOLDER LEVER L 35 GROUND FUSER BRUSH Phaser 3600 Printer Service Manual 8 21 Parts List PL 1 4 Fuser Assembly Parts List Table continued 8 22 Item No Descr
44. 1 iii product terminology 1 iii skew defects 5 25 SMPS board locator map 9 6 theory 2 18 to Main Board Wiring Diagram 9 13 Specifications environmental 1 9 media and tray 1 10 Sub Toner Low Sensor Board disassembly 7 24 Switched Mode Power Supply disassembly 7 76 switching mode 2 18 T Test print deletions 5 4 fusing 5 5 registration and skew 5 6 resolution 5 5 skips or smears 5 8 Thermistor 2 2 2 5 2 8 2 14 toner development 2 2 Tools recommended 4 3 Top Cover disassembly 7 10 Transfer Roller defects 5 3 disassembly 7 43 theory 2 2 2 8 transfer subsystem 2 8 Tray 1 MPT disassembly 7 14 Feed Sensor 2 15 Feed Sensor disassembly 7 21 Paper Empty Sensor 2 15 replacement 7 15 Solenoid disassembly 7 29 Tray 2 assembly parts list 8 25 Cassette view of parts 8 24 Feed Roller disassembly 7 35 Pick Roller disassembly 7 35 Pick Up Assembly disassembly 7 30 Tray 3 disassembly 7 36 Tray 3 Cassette parts list 8 27 view of parts 8 26 Troubleshooting Control Panel 4 4 image defects 5 9 Power supplies 4 5 print quality 5 2 U unfused image defects 5 24 V voltage measurements 4 5 W Wiring diagrams Controller Unit and Duplex Board to Main Board 9 17 HVPS SMPS to Main Board 9 13 LSU and Main Motor to Main Board 9 16 Main Drive Joint Board and Optional Tray 9 15 notation 9 8 Sensor to Main Board 9 14 Phaser 3600 Printer Service Manual 701P4782
45. 14 CN12 s3600 096 Phaser 3600Printer Service Manual 9 5 Plug Jack and Wiring Diagrams 9 6 Map 3 SMPS Board palslclolelrlelalilulxlt c py N n o lee TE CONO3 CONO2 CONO1 CON06 CONO4 CONO5 s3600 097 Phaser 3600Printer Service Manual Plug Jack and Wiring Diagrams Map 4 HVPS Board iA eje oje rja mir s t s3600 098 Phaser 3600Printer Service Manual 9 7 Plug Jack and Wiring Diagrams Wiring Diagrams Notations Used in the Wiring Diagrams The following table lists the symbols used in the wiring diagrams Symbol Description ST Plug Denotes a Plug Denotes a Jack 51 Jack Denotes Pin yy and Jack yy of the connector Pxx P Jxx and JXX Plug and Jack Denotes a Jumper Point JPxxx xxx Each end of JPXxX the Jumper connection has a numeric designation Jumper Denotes the parts PL X Y Z implies the item Z of plate PL X Y Fuser in Parts List PL X Y Z Subassembly 1 Denotes functional parts attached with functional pu parts name Subassembly 2 9 8 Phaser 3600Printer Service Manual Plug Jack and Wiring Diagrams Description Subassembly 3 Denotes the control and its outline in the Board DEVE_A Connection Wire Denotes a connection bet
46. 14 PMO ACTUATOR FEED DUP 15 PBA SUB MP SEN Duplex Exit sensor 16 CBF HARNESS POWER GND 17 MOTOR STEP 18 BRACKET P MOTOR DUP 19 PULLEY M 30 DUP 20 BELT TIMING GEAR 21 PULLEY M 30 DUMMY DUP 22 RING E 23 CBF HARNESS D JOINT 8 31 Parts List 8 32 Phaser 3600 Printer Service Manual Plug Jack and Wiring Diagrams m Plug Jack Diagrams and Designators Chapter O Plug Jack and Wiring Diagrams Plug Jack Diagrams and Designators 9 2 This chapter contains the Plug Jack or Connector Designators Locators and wiring diagrams for the print engine and all options The diagrams following the Plug Jack table show the P J Plug Jack and CN connector locations on boards in the printer Optional 550 Sheet Feeder Duplex Unit Fax Copier and Scanner Use these illustrations to locate connectors called out in the Troubleshooting procedures presented in Sections 3 4 and 5 The Plug Jack and CN locators consist of the P J Designator Table and the Locator Diagrams m The P J column lists the Plug Jack or CN numbers in numerical order m The Map column provides the map number of the specific areas i e Electrical Laser Scan Unit etc m The Coordinates column lists the diagram coordinates for the location of the connector m The Remarks column provides a brief description of each connection 1 Locate the P J connector designator in the first column of the table 2 With this information go to the map
47. 2
48. 4 Remove the 3 screws shown below and then remove the Separator Pad Assembly from the printer Caution Be careful not to break the MP actuator flag Also do not lose the spring located underneath the Friction Pad of the separator 3600 039 Replacement Note Before installing the three screws be sure to snug the spring between the friction pad and the plastic base 7 20 Phaser 3600 Printer Service Manual Service Parts Disassembly Tray 1 MPT Feed Sensor PL1 3 97 Caution When removing the plastic cover in the step 5 lift the edge nearest the sensor first then the other end being careful not to bend the actuator Remove the Tray 1 MPT Assembly page 7 14 Remove the 6 screws from the HVPS board to expose the connectors Disconnect CN3 from the HVPS board Unlace the 3 wire harness of CN3 from the HVPS Remove the plastic cover covering the sensor O O1 BR wn Gently push the plastic hook away from the sensor board to remove the TS L s3600 111 Phaser 3600 Printer Service Manual 7 21 Service Parts Disassembly Paper Tray Empty Sensor PL1 3 95 The Paper Tray Empty Sensor is soldered in the High Voltage Power Supply HVPS If the sensor is defective follow the instructions to replace the power supply board page 7 75 s3600 094 7 22 Phaser 3600 Printer Service Man
49. 50 theory 2 2 preventive maintenance procedure 4 3 Print cartridge defects 5 3 theory 2 3 print modes 2 3 aser inter service Manua Printer 1 4 location and clearance 1 6 options and supplies 1 2 orientation 7 5 parts 1 4 Physical specifications 1 7 Print quality table 1 8 Print resolution 1 8 printer configurations 1 2 specifications 1 5 printer serial number 8 2 Printing process 2 2 Process Control fuser temperature 2 12 laser scan 2 11 light intensity 2 11 paper pick 2 10 paper size 2 10 toner 2 11 product symbols 1 1v pulse width modulation 2 8 R RAM DIMM 2 6 random spo defects 5 20 Rear Cover disassembly 7 8 Registration Assembly disassembly 7 41 Regulatory Information 1 ix repeating image defects 5 22 Retard Assembly disassembly 7 19 theory 2 5 Right Cover disassembly 7 6 S Safety precautions disconnecting power 1 v electrostatic discharge 1 vi general guidelines 1 vii power safety 1 v servicing compponents 1 viii Sensors Sensor status 3 6 to Main Board Wiring Diagram 9 14 types 2 13 Separation process 2 7 Separator Pad Assembly disassembly 7 20 serial number location 8 2 Service Diagnostic Front Panel Key Descriptions 1 5 3 4 service diagnostics menu 3 3 service diagnostics control panel 3 3 service diagnostics entering 3 3 aser inter service Manua service flowchart 4 2 service procedures 6 2 Service Terms manual terminology
50. A Measurement Standby Less than 35 0 dBA Warm up Less than 50 0 dBA Maximum Less than 60 0 dBA Phaser 3600 Printer Service Manual 1 9 General Information Media and Tray Specifications Media Tray Capacity Property Media Specification Input Size Max Custom Paper W H 216 x 356 mm 8 5 x 14 Min Custom Paper W H 76 x 127 mm 3 0 x 5 0 51059 Input Capacity Standard 500 sheet Cassette Tray 100 sheet Multi Purpose Tray 975g Maximum 1 to 100 sheets Output Capacity Face Down Capacity 250 sheets Face Up Capacity 100 sheets Output Full sensing Yes Paper Outbin Full Sensor Output path change Face Up Down controlled manually by opening rear cover Multi Purpose Plain Paper Capacity 100 sheets Tray Envelope Capacity 10 sheets Card Stork Capacity 10 sheets Labels Capacity 25 sheets Transparencies 50 sheets Capacity Media sizes A4 A5 A6 Letter Legal Oficio Folio Executive ISO B5 JIS B5 3 x5 Monarch No 10 DL C5 C6 Media type Transparencies Envelopes Labels Card stock Media weight 16 43lb 60 to 163g Sensing Paper Empty Sensor Standard Capacity 500 sheets Cassette Tray Media sizes A4 A5 Letter Legal Executive Folio Oficio ISO B5 JIS B5 Media types Plain paper Media weight 16 28lb 60 to 105g Sensing Paper Empty Sensor and Paper Size Sensor 1 10 Phaser 3600 Printer Service Manual Phaser 3600 Printer Service
51. CL Fonts Yes Yes Yes Default Resolution 600 x 600 dpi 600 x 600 dpi Maximum Resolution 1200 x 1200 1200 x 1200 dpi dpi 500 Sheet Feeder Tray 3 Optional Optional Optional Optional Network Interface Not Optional Not Optional Standard Standard Automatic 2 Sided Printing Optional Optional Optional Standard Separate Duplex Unit USB Parallel Interface Yes Yes Yes Yes Printer Options and Supplies Options and Supplies Printer Option Item Part Number Memory 64 MB additional RAM memory 097803759 128 MB additional RAM memory 097803760 256 MB additional RAM memory 097803761 Optional Units Duplex Unit 097503387 500 Sheet Feeder 097503385 Cartridges Standard Capacity Print Cartridge 106R01370 7 000 pages High Capacity Print Cartridge 14 000 106R01371 pages Extra High Capacity Print Cartridge 106R01372 20 000 pages Metered Pagepack Print cartridge 106R01369 20 000 pages Gear Lubricant Xerox lubricant Plastislip grease 043E00550 Phaser 3600 Printer Service Manual Consumable and Service Part Lite Expectancy Phaser 3600 Printer Service Manual General Information Consumable toner print cartridge usage is tracked by the CRUM and monitored by the Main Board in order to display the near end of life and end of life messages Life ratings are based on 5 coverage and an average 4 page job length Consumables Print Life Print Cartridge Standard Capacity 7 000 pages High Capacity 14 000 pages Extra
52. D 3X5 022N02174 48 1 HOLDER M SAW 48 2 GUIDE P TRANSFER FRONT 48 3 PLATE P SAW 48 4 SHAFT M ROLLER BELT 48 5 ROLLER M IDLE BELT 48 6 IEX SHAFT IDLE F UP 48 7 RUBBER BELT FEED 48 8 GUIDE M SHAFT BELT 49 ELA UNIT ROLLER IDLE 022N02349 49 1 FRAME M RETARD 49 2 HOLDER M RETARD 49 3 SPRING ETC PAD 49 4 BUSH M RETARD 2 49 5 HOUSING M RETARD 49 6 SHAFT RETARD 49 7 RING E 49 8 PMO HUB OUT RETARD 49 9 SPRING TS 49 10 PMO HUB IN RETARD 49 11 RUBBER RETARD 50 ELA UNIT FEED2 IDLE Feed 2 Idle Unit 022N02176 50 1 HOLDER IDLE FEED2 50 2 CAP M IDLE FEED2 8 16 Phaser 3600 Printer Service Manual PL 1 3 Frame Assembly Parts List Table continued Parts List Item No Description Part Number 50 3 SPRING ETC PAD 50 4 BUSH M RETARD 50 5 SHAFT IDLE FEED2 50 6 RING E 50 7 ROLLER M IDLE FEED2 50 9 SHAFT HUB IN 51 STOPPER M KNOCK UP MP L 52 STOPPER M KNOCK UP MP R 53 RAIL M LEFT DUPLEX 032N00441 54 RAIL M RIGHT DUPLEX 032N00442 55 PMO BEARING SHAFT 013N13841 56 GEAR REGI E25 57 BEARING PICK UP 58 PMO ACTUATOR EMPTY Paper Tray Empty Actuator 120N00519 59 ELA UNIT PICK UP 022N02183 59 1 SHAFT PICK UP 59 2 MEA UNIT P UP HOUSING Pick Roller 022N02177 59 2 1 PMO M IDLE PICK UP 59 2 3 RUBBER PICK UP 59 3 PMO M CAM PICKUP 59 4 SHAFT FEED 1 59 5 AS FEED 1 ROLL ASSY 022N02187 59 5 1
53. Does the image quality improve page 7 54 Phaser 3600 Printer Service Manual 5 21 Print Quality Troubleshooting Repeating Bands Lines Marks or Spots Recurring lines marks or spots appear on the page Initial Actions m Check the paper transfer path m Ensure there are no debris on the transfer path Troubleshooting Reference Table Applicable Parts Example Print Registration Assembly PL1 1 12 Transfer Roller PL1 1 7 m Laser Scan Unit PL1 1 15 m Print Cartridge PL1 1 34 Repeating Defects A Warning Ensure to wait for the Fuser to cool down before starting the procedure Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Print a demo page Go to step 3 Go to step 2 Does the error still occur when printing 2 Print a customer application page Go to step 3 Complete Does the error still occur 3 Check the document path Remove the Go to step 4 Is there any debris on the document debris path 4 Check for band or spot s regular Refer to Go to step 5 intervals Repeating Are there any bands or spots on the defects info on page page page 5 3 5 Check the Print Cartridge for damages Replace the Go to step 6 Is the Print Cartridge damaged Print Cartridge 5 22 Phaser 3600 Printer Service Manual Phaser 3600 Printer Service Manual Troubleshooting Procedure Table continued Print Quality Troubl
54. EXIT DUPLEX Duplex Roller 006N01265 11 1 SHAFT M EXIT DUPLEX 11 2 RMO RUBBER EXIT DUP 12 BUSH M EXIT D7 013N13839 13 GEAR M EXIT DUP 721 007N01363 14 ELA HOU CST SENSOR Paper Size Sensor 130N01461 14 1 PBA SUB CASSETTE 14 2 IPR PLATE SENSOR 14 3 IPR BRACKET SENSOR 15 CBF HARNESS PSIZE 16 GUIDE P REGI UPPER 17 SPRING ETC LEVER 18 HOLDER M BUSHING TX 19 GUIDE PLATE PAPER 20 IPR P GROUND PLATE PAPER 21 PHOTO INTERRUPTER Outbin Full Sensor 130N01274 23 CBF HARNESS THERM 24 PMO HOUSING TERMINAL 25 IPR TERMINAL FU 26 CBF HARNESS FUSER 27 CAP M HOUS TERM 28 SHIELD P CTRL 29 GROUND P MOTOR DEVE 30 GROUND P GUIDE TR 31 GROUND P REGI ROLLER 32 GROUND P PICK UP MP 33 GROUND P SCF MAIN 34 GROUND P MOTOR MAIN 35 GROUND P GUIDE DUP 36 CAP M GUIDE HARNESS 37 PMO DUMMY DEVE 38 ELA HOU VARISTOR 39 FOOT ML80 40 PMO REMOVE LOCK CST Phaser 3600 Printer Service Manual 8 15 Parts List PL 1 3 Frame Assembly Parts List Table continued Item No Description Part Number 41 SHAFT M GEAR RETARD 42 SHAFT M COUPLING RETARD 43 PMO BEARING SHAFT 013N13841 44 GEAR REGI Z25 45 47 MEA UNIT FRAME LSU LOW Sub toner Low Sensor 001N00500 47 1 FRAME M LSU LOWER LSU Lower Cover 47 2 PBA TONER SENSOR 47 3 TERMINAL P DEVE 47 4 PBA SUB COVER OPEN 130N01399 47 5 CAP M COVER OPEN 002N02729 48 ELA UNIT FEE
55. Gee ne Ma ae Wd ee we a Ss Ga neon idee 6 2 General Cleaning hh sna 6 2 Cleaning the Laser Scan Unit 22 6 3 Cleaning the Print Cartridge 2 6 3 Control Panel Maintenance 2220 6 4 Cleaning the Drum Rh aan 6 4 Cleaning th FUSER 5 eeu ER dale oad RAR Ree MUR RARE RAR A omis 6 4 7 Service Parts Disassembly Service OVerviBW cora ie 7 2 General Notes on Disassembly a 7 2 Preparation 35 cimo dyes orbs due ert ares c ane sra Astana et dit tint Aa C E ste s a mings 1 2 Fastener Types io icc ie duce diee pot badd ded putes PR Peli bd adex Pao sab Ben ve doa 7 4 Notations in the Disassembly Text 7 5 Standard Orientation of the Printer 7 5 Covers and Control Panel 20 7 6 Right Cover PL 1 2 8 224 idiote sens perse erra bead rennes daube he Pens dera 7 6 Left Cover PE 1 22 ca e one RR ee 7 7 Rear Cover PL1 2 6 s scm li eh domi ka nade way Bens 7 8 Rear Cover Fan PL1 2 6 10 7 9 Top Cover PL 1 21 coss Eod urRREX Rer eda re
56. HOLDER PAD 019N00947 20 1 HOLDER M PAD 20 2 SHEET HOLDER PAD R2 20 3 RPR FRICTION PAD 20 4 IPR PLATE PAD 21 SPRING EXIT ROLL FD 25 PMO LOCKER PLATE 26 SPRING LOCKER PLATE 27 GUIDE M PAPER SIZE Phaser 3600 Printer Service Manual 8 25 Parts List PL 2 2 Tray 3 Cassette s3600 017 8 26 Phaser 3600 Printer Service Manual PL 2 2 Tray 3 Cassette Parts List Table Parts List Item No Description Part Number 0 ELA UNIT SCF Tray 3 500 sheet feeder 050N00543 1 FRAME M SCF 2 COVER M RIGHT SCF 3 COVER M LEFT SCF 4 COVER M DUMMY SCF 5 PBA SCF 140N63300 6 CBF HARNESS OPE 8 BUSH CABLE 9 CBF HARNESS SCF INTERFACE 152N11714 10 SOLENOID MAIN 11 ELA UNIT MOTOR SCF 127N07570 11 1 BRACKET P SCF MOTOR 11 2 MOTOR STEP 7 5 DEG 11 3 GEAR M SCF RDCN RETARD 11 4 GEAR M SCF RDCN FEED 11 5 GEAR M SCF RDCN PICK UP 12 CBF HARNESS OPE 13 IPR GROUND SPRING FEED 14 PMO BEARING SHAFT 15 MEP CLUTCH FEED SCF 16 RING E 17 SHAFT M COUPLING RETARD S 18 SHAFT M GEAR RETARD 19 GEAR REGI 225 20 BAR P CROSS BOTTOM 21 PMO REMOVE LOCK CST 22 ELA UNIT IDLE SCF 022N02350 23 24 25 SHAFT PICK UP SCF 27 PBA SCF COVER OPEN 140N63025 28 ELA HOU CST SENSOR 29 PHOTO INTERRUPTER 30 PMO ACTUATOR EMPTY SCF 120N00520 31 GEAR SCF PICK UP CAM 007N01366 Phaser 3600 Printer Service Manual 8 27
57. HOUSING M FEED 59 5 2 RUBBER FEED1 59 6 GROUND P PICK UP MAIN 59 7 BEARING PICK UP 59 8 PMO BUSHING FEED 59 9 GUIDE P FRONT DUP PICKUP 59 10 GUIDE M SUPPORT PICKUP 60 ELA UNIT FEED2 022N02178 60 1 FRAME M PICK UP 60 2 PMO BUSHING FEED 60 3 SHAFT M FEED2 60 4 BEARING PICK UP 60 5 RUBBER ROLLER FEED2 Phaser 3600 Printer Service Manual 8 17 Parts List PL 1 3 Frame Assembly Parts List Table continued 8 18 ltem No Description Part Number 61 PBA SUB JOINT Joint Card 140N63022 62 CBF HARNESS TRAY OUT 63 CAP M POWER 64 CBF HARNESS INLET 152111756 65 SHAFT M BELT GEAR 66 PMO BEARING SHAFT 67 GEAR M EXIT 717 68 CAP M DEVE MOTOR 69 CBF HARNESS DUPLEX 71 CAP M WIRE PTL LOWER 021N02249 72 TERMINAL P PTL 116N00243 73 CBF HARNESS PTL 74 76 PBA SUB EXIT SENSOR Fuser Exit Sensor 130N01400 77 PBA FUSER SW Fuser Interlock Switch 130N01401 78 GUIDE M FRONT 79 TERMINAL P GUIDE FRONT 80 ELA UNIT FUSER 110V 126N00293 ELA UNIT FUSER 220V 126N00294 81 PMO GUIDE DEVE L 82 PMO GUIDE DEVE R 83 SPRING ETC GUIDE DEVE 84 TERMINAL P TR KESTREL 86 TERMINAL SPRING TR 87 PBA MAIN ZENER 88 CBF HARNESS EARTH 89 GROUND P ZENER 90 GROUND P FUSER 91 TERMINAL P HV CARDINAL 92 MEA UNIT TERMINAL TR 93 CBF HARNESS HVPS 94 IPR P GROUND OPC 95 PBA SUB EMPTY SENSOR Paper Tray Empty Sensor 14
58. L 14 ON ON OFF US FOLIO LEGAL 13 OFF OFF OFF A4 OFF ON ON LETTER ON OFF OFF EXECUTIVE OFF ON OFF B5 ON OFF OFF B5 JIS B5 OFF OFF ON A5 ON ON ON No Tray OFF OFF OFF Automatic Paper Pick Control The default paper pick selection at power ON is Tray 2 Auto Select ON is also default If the default tray is empty the printer will automatically switch to any other tray that contains paper unless Auto Select is set to OFF 2 10 Phaser 3600 Printer Service Manual Theory of Operation Laser Scan Unit LSU Control The Laser Scan Unit receives the bit mapped image data from the Main Board and uses that information to turn the laser beam on and off as required to correctly expose the drum Image data transfer from the Main Board is controlled by a synchronization signal from the LSU so the vertical scanning line is synchronized with the printed page The LSU contains the following components m Laser Diodes Generates the laser beams m Rotating Polygon Mirror Scans the laser beam across the drum axially m Beam Detector Synchronizes the left margin m Optical Lens System Focuses the laser beam onto the surface of the drum m Mirrors Reflect the laser beam onto the surface of the drum Laser Light Intensity Control Image data is transmitted to the laser diode in the Laser Scan Unit as digital signals The laser diode converts the image data from digital signals to optical signals data expressed by blinking laser
59. Manual Media Tray Capacity General Information Optional Cassette Capacity 500 sheets 75g May Media sizes A4 A5 Letter Legal Executive Folio Oficio ISO B5 JIS B5 Media types Plain paper Media weight 16 28lb 60 to 1059 Sensing Paper Empty Sensor Duplex Supporting Optional Media sizes A4 L etter Legal Folio Oficio Media types Plain paper Media weight 20 241b 75 to 90g Media Input Size Weight Source Media Types Media Sizes Media Weights Tray 1 Paper Envelope A4 Letter Legal Folio 16 Ib 28 Ib Paper Labels Executive ISO and JISB5 A5 60 176 gsm Transparency Tray 2 Paper Cardstock A4 Letter Legal Folio 16 Ib 43 Ib Min 76 mm x 127 Executive ISO and JISB5 A5 60 105 gsm mm A6 Statement Monarch COM 65 Cover 3 in x 5 in 10 C5 DL 3 x 5 Max Legal Tray 3 Paper A4 Letter Legal Folio 16 Ib 28 Ib Executive ISO and JISB5 A5 60 105 gsm Duplex Paper A4 Letter Legal Folio 20 Ib 24 Ib 75 90 gsm Media Print Speed Property Mode Specification Speed Simplex Up to 38 ppm in A4 40 ppm in Letter Duplex 26 ipm in A4 27 ipm in Letter Letter A4 Folio Oficio Legal First Page Output Time from standby Less than 9 sec FPOT from sleep power save mode Less than 40 sec from cold status Less than 49 sec Warm Up Time from sleep power save mode Less than 31 sec from
60. Number FOMM At u a uc cte ban a e eee oer er Dade does Sadho ladon anes d de 8 2 Serial Number Label Location 4444444 0 8 3 Usmathe Parts LISE TP A tue tie trois anis 8 4 PET TMalnASSembly ER ee oa 8 6 PL1 2 Cover Assembly cuand 8 10 PL 1 3 Frame Assembly 1 of 2 8 12 PL 1 3 Frame Assembly 2 Of 2 45e on durs he Re ae a a anak de pen na 8 13 PE Ed ICD ccn MP 8 20 PI 271 Tray 2 Cassette ied eleme hee eco ibus ede pA d Denis pA d Dach ibus SAGE 8 24 PL 2 2 Tray 3 Cassette aen 8 26 PL 2 3 Duplex Assembly 5 o we chewed ad A edd ERU Det bb rer aia 8 30 4 Phaser 3600 Printer Service Manual Table Of Contents 9 Plug Jack and Wiring Diagrams Plug Jack Diagrams and Designators 0 IIR ee etn eee ene es 9 2 Plug Jack and Connector Locators and Maps 9 3 Printer Plug Jack Connector Designators 9 3 Map 1 LSU and Fuser sssssesssssseseese e Hn 9 4 Map 2 Main Board tectonic as cases eee ode o e ded OR e ete SE e RI dee LE sei 9 5 Map 3 SMPS Board 9 6 Map 4 HVPS Board crire de Pese ane hit a aides Mar made un eked d fis boue la 9 7 Wirng DIAgrAMS ss epe hr a 9 8 Notations Used in the Wiring Diagrams
61. Unit for printing on the second side Paper Feed Drive The drive for all rollers is provided by the Main Drive Motor and a series of drive gears The Main Motor is used for paper feed fusing and the duplex exit roller reversal for 2 sided printing When the main motor turns all the paper path components also turn except the Pick Up Roller The Pick Up Roller assembly moves the paper along the path with the Feed Solenoid There is a separate Developer Motor for the Print Cartridge Phaser 3600 Printer Service Manual 2 5 Theory of Operation Print Engine Assemblies The print engine assemblies include the following m Image Processing and the Main Board m Laser Scan Unit m Main Drive Assembly m Feed assembly Process and Components m Transfer Roller Assembly m Fuser Assembly Image Processing Assembly and Main Board 2 6 The Main Board receives image data from the host computer converts it to a bitmap image and then transfers the image to the Laser Scan Unit LSU The Main Board combines the Image Processor and Engine Control functions It contains a 32 bit RISC processor and comes with a standard memory capacity of 64 Mbytes of RAM and 4 Mbytes of flash memory The board provides one expansion slot that allows available memory to be expanded up to 512 Mbytes with two 256Mbyte RAM DIMM Control Panel CN16 Cover Open CN26 Toner Sensor Board CN6 Duplex Solenoid CN11 Laser Unit CN9 aed CN8 Rear Fan CN4
62. Verify the paper is within the printer specifications refer to page 1 10 Troubleshooting Reference Table Applicable Parts Example Print a Transfer Roller PL1 1 7 Registration Assembly PL1 1 12 m Print Cartridge PL1 1 34 m Fuser PL1 4 1 Main Board PL1 1 19 Residual Image Ghosting Ensure to wait for the Fuser to cool down before starting the procedure Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the printing usage Go to step 2 Go to step 3 Did the user print the same image at a large volume 2 Check the Transfer Roller Replace the Go to step 3 Are there any damages to the Transfer Transfer Roller Roller surface page 7 43 3 Check the Registration Assembly Replace the Go to step 4 Is there any damage to the Registration Registration Assembly Assembly page 7 41 4 Check the Print Cartridge for correct Complete Go to step 5 installation Reseat the Print Cartridge Does the image quality improve 5 Replace the Print Cartridge Complete Go to step 6 Does the image quality improve 6 Replace the Fuser page 7 54 Complete Replace the Does the image quality improve Main Board page 7 39 5 17 Print Quality Troubleshooting Faded or Missing Image Areas of the image are extremely light or missing in limited areas on the paper Initial Actions m Check the paper transfer path m Ensure there are no debr
63. XE ROX Service Manual 701P47822 Phaser 3600 Laser Printer XEROX Service Manual 701P47882 Phaser 3600 Printer A Warning The following servicing instructions are for use by qualified service personnel only To avoid personal injury do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so First Printing September 2008 Prepared By Xerox Corporation XOG Worldwide Product Training and Information 26600 SW Parkway Wilsonville OR 97070 Unpublished rights reserved under the copyright laws of the United States Contents of this publication may not be reproduced in any form without permission of Xerox Corporation Copyright protection claimed includes all forms and matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted including without limitation material generated from the software programs which are displayed on the screen such as styles templates icons screen displays looks etc Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale These materials may not be distributed copied or otherwise reproduced without prior written consent from Xerox Corporation XEROXO CentreWare Phaser PrintingScout and Walk Up are trademarks of Xerox Corporation in the United States
64. a GND Tray 1 Feed 3 3VDC E sensor Empty Sensor s3600 025 Phaser 3600Printer Service Manual 9 13 Plug Jack and Wiring Diagrams Sensor to Main Board Wiring Diagram Main Board 24VDC CN6 CN6 Toner Sensor CN2 CN2 HVPS 24VDC Board 12e TE 20 1 l2 6 E P_SIZE3 212 9 2 5 3 FAN SMPS 3 P SIZE2 8 4 FAN_MAIN 6 D P_SIZE1 5 5 5 Ec 4 7 4 3 3VDC 8 F THERM IN a Paper Full Sensor 9 F5 TEMP 2 3 CN3 43 3VDC PFULL Pap id FUSER_ON 1 i sional 3 m 1 2 A 2 5l 0 3 Si 58D lt 1 jm 12 OUTBIN_FULL d 13 gt GART_CLK 8 CN4 PSIZE Paper Size Sensor 14 P_REGI 7 4 GND ric 4 a 15 55 CART DPUT DIN 2 P_SIZE1 3 im P_EMPTY 3 P_SIZE2 2 18 2 P_SIZE3 m 17 D 4 24VDC 415 lt 1 m 18 X 3 CN1 P J2 SMPS Fan 19 2 15 24VDC 3 20 gt 1 25 SIGNAL 2 3 Pi 1 CN5 P J1 Main Fan 24VDC 1 3 2 SIGNAL 2 2 m 3 gt m SERI CN26 Sipe CN n Cover D 24VDC Ci T 2 gt gt 8 24VDC 7 3 D 24VDC e 4 gt mre de E 6 rc 4 7 aC 3 8 gt afc 2 9 gt K s3600 022 9 14 Phaser 3600Printer Service Manual Plug Jac
65. ad Note Caution and Warning statements Note A note indicates an operating or maintenance procedure practice or condition that is necessary to efficiently accomplish a task A note can provide additional information related to a specific subject or add a comment on the results achieved through a previous action Caution A caution indicates an operating or maintenance procedure practice or condition that if not strictly observed results in damage to or destruction of equipment Warning A warning indicates an operating or maintenance procedure practice or condition that if not strictly observed results in injury or loss of life 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 iii Symbols Marked on the Product 0 35 C 32 F AE ay a ug Warning Danger invisible laser radiation when open Avoid direct exposure to beam Hot surface on or in the printer Use caution to avoid personal injury Warning Use caution to avoid personal injury Use caution or draws attention to a particular component Refer to the manual s for information Do not touch the OPC Drum Do not expose the item to sunlight Do not tilt the Print Cartridge Do not expose item to extreme temperature Recycle the item Phaser 3600 Printer Service Manual Power Safety P
66. ading edge of the paper passes the Feed Sensor but the paper cannot reach the Exit Sensor in the specified time The Exit Sensor cannot be ON Jam At Exit JAM 2 The trailing edge of the paper passes the Feed Sensor but the paper does not pass the Exit Sensor in the specified time Jam at Rear Duplex JAM 1 The trailing edge of the paper passes the Exit Sensor but does not reach the Duplex Sensor in the specified amount of time Jam at Duplex Duplex JAM 2 The leading edge of the paper passes the Duplex Sensor but the leading edge of the paper does not reach the Feed Sensor in the specified time Phaser 3600 Printer Service Manual 3 11 Error Messages Check Cartridge Invalid Print Cartridge Non Xerox Cartridge This message appears when W print cartridge is not detected m Anon Xerox print cartridge is installed m The Toner Sensor Board is malfunctioning Close Top Cover This message appears when the m Top cover is damaged m Sensor or actuator is damaged Fuser Failure Engine Fuser Low Heat Error Engine Overheat Error Fuser is damaged or malfunctioning Laser Failure The Laser Scan Unit is malfunctioning or damaged Outbin Tray is Full The Outbin Tray Full Sensor or actuator is malfunctioning or damaged 3 12 Phaser 3600 Printer Service Manual Error Messages Jam At Tray 1 2 3 Jam 0 Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References
67. agram on page 9 15 Troubleshooting Procedure Table Step Action and Questions Yes No 1 Does the error report Fuser Failure Go to Step 2 Go to Step 3 2 Check the thermistor Replace the Fuser Replace the Main Is the circuit open page 7 54 Board page 7 39 3 Check the line voltages across the Replace the Fuser Go to Step 4 thermostats page 7 54 Are they open 4 Is the Fuser getting power Replace the Fuser Replace the SMPS page 7 54 page 7 76 Replace the Main Board page 7 39 Phaser 3600 Printer Service Manual Laser Failure Phaser 3600 Printer Service Manual Troubleshooting Reference Table Error Messages Applicable Parts Wiring and Plug Jack Map References m Laser Scan Unit PL1 1 15 Map 1 LSU and Fuser on page 9 4 Main Board PL1 1 19 Main Drive Joint Board and Optional Tray Wiring Diagram on page 9 15 Step Actions and Questions Yes No 1 Reseat the connections to the laser Complete Go to Step 2 and visually inspect the Laser Scan Unit for damage Did this correct the problem 2 Use diagnostics to check the laser Replace the Laser Replace the Main motor function Scan Unit Board Is the Laser Scan Unit Operational page 7 70 page 7 39 3 21 Error Messages Output Tray is Full Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map Referen
68. ain Motor to Main Board Wiring Diagram 9 16 24VDC 24VDC A Main Board 1 E Thermistor1 Fy EL i E Thermistor 2 5 Thermistor2 2 Laser Unit CN9 T m 1 LSU 5V s 2 5 LD_POWER2 cs i 3 LD_POWERI Cal 4 5 VDO1_minus Seu VDO1 plus ES 15 VDO1_minus va 12 8 5 VDO1 plus XC 11 nLD_ENt o5 nSH1 cs 10 Mise nSH2 xc 3 al nSH2 dr 8 a nHSYNC_minus 2 LSU_CLK ge 4 gt x 2 nREADY ES LSU_MOT_ON 2l GND IC 3 7 C 2 5 2 24VDC I XD 1 T ps PDX SOL 1 gt 722222 A E Duplex Solenoid 2 5 24VDC p Main Motor vue 24VDC ra m 1 E 24VDC 9 i as c GND 7 2 GND as 6 gt 2 VCC cs 5 nMAIN_MOT_ON 4 3 5 MAIN MOT READY cs 3 2 MAIN_MOT_CLK 9 gt _MOT_ se 2 10 DI ne s3600 020 Phaser 3600Printer Service Manual Plug Jack and Wiring Diagrams Controller Unit and Duplex Board to Main Board Wiring Diagram Phaser 3600Printer Service Manual Main Board C C M4 T P J3 P J4 Rear Fan E SIGNAL com xm im RM cm N16 CNTI Control Panel 3 3VDC PANEL_TXD PANEL_RXD D
69. an object to detect its presence Photo receptive sensors use an actuator or the object itself to block the light path to detect an object or condition Photo reflective sensors have the light emitter and light receiver aligned on a single surface Output of the photo receptor is High gt 4 5 V when light is being reflected back and Low lt 3 V when it isn t Photo receptive sensors consist of a LED in one arm of a U shaped holder and a photo transistor in the other arm When the sensing area is vacant nothing is between the arms of the sensor light falls on the photo receptor sending the signal High If the light is interrupted the photo transistor goes Low J Actuator s3600 133 2 13 Theory of Operation Microswitches Microswitches are used primarily as paper size sensors and cover interlocks They are in a normally open state and close when actuated A bank of microswitches is used to detect paper size in the universal trays Microswitches also employ hooks or catches for retention in the bracket or frame Actuator Button Contact s3600 134 Thermistors Thermistors have a known value of resistance whose value varies with temperature Used primarily in the Fuser for temperature sensing 2 14 Phaser 3600 Printer Service Manual Theory of Operation Sensors in the Paper Path The following illustration shows the general physical location of the specified sensor Not all the sensors in the illustra
70. and the Heat Roller The toner is fused onto the print media by the combination of heat and pressure The Heat Roller is heated by a heat element The roller surface temperature is detected by a Thermistor The information is fed back to the heater control to maintain a surface temperature of 185 C during printing and 145 C during standby If the thermostats detect a Fuser overheat condition it disconnects AC power to the Fuser Cleaning After the image is transferred to the print media a cleaning blade inside the cartridge removes any remaining toner particles from the drum Phaser 3600 Printer Service Manual Theory of Operation Print Cartridge and Print Modes Print Cartridge The Print Cartridge receives image data in the form of pulsed laser light from the Laser Scan Unit LSU and creates the image via the xerographic process The Print Cartridge contains the following components m Charge Roller m Drum m Developer Roller D R m Supply Roller S R m Metering Blade m Cleaning Blade Cleaning Roller sy 0 20 mW 400 500 20V Doctor Blade 1 5 1 30KV 500 Charging Roller 600 20V Supply Roller A Developing Roller T Zener Diode Max 4 2kV 100V Transfer Roller 3600 004 Print Modes The Phaser 3600 Laser Printer provides two print modes 1 Draft mode Uses a combination of reduced toner output and the lowest resolution 300 x 300 dpi to extend print cartridg
71. andom Access Memory RH Relative Humidity RLS Release ROM Read Only Memory ROS Raster Output Scanner Laser Scan Unit SEF Short Edge Feed SMPS Switching Mode Power Supply SNR Sensor SOL Solenoid SOS Start of Scan SPOOL Simultaneous Peripheral Operations Online STS Soft Touch Sensor SYNC Synchronous or Synchronization TDC Toner Density Control THV Transfer High Voltage TNR Toner TRNS Transport UI User Interface USB Universal Serial Bus Phaser 3600 Printer Service Manual Ref 5 Reference Ref 6 Phaser 3600 Printer Service Manual A Access Door disassembly 7 12 acronyms and abbreviations A 2 black print defects 5 13 blank print defects 5 9 C Center Loading Process 2 7 charge roller 2 2 cleaning 2 2 Laser Scan Unit 6 3 printer 6 2 Cleaning blade 2 3 Clutches Solenoid tests 3 9 Consumables 1 3 contamination defects 5 15 Control 7 6 Control Panel components 1 5 disassembly 7 13 LED 1 5 menu map 1 5 messages 1 5 Controller Unit to Main Board Wiring Diagram 9 17 Cooling Supply Fan disassembly 7 73 coordinates column for designators 9 2 Cover Assembly Cover Open Board and Sensor 2 16 Cover Open Sensor disassembly 7 74 Cover status 3 5 parts list 8 11 view of parts 8 10 D Developer Drive disassembly 7 51 Developing Motor 2 7 Device control tests 3 10 Diagnostic Menu Map 3 5 Disassembly general notes 7 2 notation 7 5 Drum 2 3 aser inter service Manua Index
72. ating Defects Transfer Roller m Toner on the back side of the printed page simplex mode m Light Prints m Repeating Defects m Spots on Image Fuser Phaser 3600 Printer Service Manual m Hot or Cold Offsetting m Repeating Defects m Voids 5 3 Print Quality Troubleshooting Repeating Defects Measurement Table Repeating Defects Distance between Assembly Component Defects Typical Defect Print Cartridge Developer Roller 50 mm 1 97 in Horizontal image band Drum 94 mm 3 70 in White spots on black image or black spots on white Drum Charge 38 mm 1 50 in Black spots Rollers Supply Roller 42 mm 1 65 in Light or dark horizontal image bands Transfer Roller Transfer Roller 56 mm 2 20 in Image ghost Fuser Assembly Heat Roller 126 mm 4 96 in Black spots and image ghost Pressure Roller 126 mm 4 96 in Black spots on back Control Panel Internal Test Print A test print is available to aid in determining the quality of output from the printer and to assist in troubleshooting image quality problem see Test 8 in the Diagnostic Test Menu Map on page 3 5 Each area of the test print is used for a image quality parameter The following pages explain each of the areas and the image quality parameters Follow these guidelines when generating the test print m Use supported paper from a fresh unopened ream m Print five copies of the test print m Discar
73. ay 2 Cassette PL 2 2 Tray 3 Cassette PL 2 3 Duplex Assembly Chapter 8 2 Parts List Serial Number Format Changes to Xerox products are made to accommodate improved components as they become available It is important when ordering parts to include the following information m Component s part number m Product type or model number m Serial Number of the printer The serial number is found on a label located on the frame of the printer Front Cover must be opened to locate the Serial Number The nine digit serial number has the following format PPPRSSSSS um PPP Three digit alphanumeric product code a R Single digit numeric revision digit 0 9 To be rolled when a major product change occurs and initiated with a change request Product Code Product MLB 3600 B 110 V Engine MKA 3600V B 220 V Engine MHB 3600 N 110 V Engine MHX 3600V N 220 V Engine Mass Production Units MP Build PPP1SSSSS SSSSS Five digit numeric serial number based on the following table Product Starting Serial Number Ending Serial Number 3600 B 110 V Engine 804501 836500 3600V B 220 V Engine 836501 843500 3600 N 110 V Engine 843501 908500 3600V_N 220 V Engine 908501 995500 Example MLB1804599 Xerox Serial Number MLB Product Code for the Phaser 3600 configuration B 110V printer 1 Revision Level 804599 Serial Number for 3600 B Serial Number Format Phaser 3600 Printer Ser
74. ce Parts Disassembly Transfer Roller PL 1 1 7 Phaser 3600 Printer Service Manual Caution Do not touch the surface of the Transfer Roller 1 Open the Top Cover page 7 10 2 Remove the Print Cartridge and protect it from exposure to light 3 Locate the cap on the left side of the Transfer Roller 4 Use small needlenose pliers to depress one end of the cap and remove from the roller 5 Pull the tab of the bearing clips on both ends of the Transfer Roller toward you to release roller tension 6 Slide the roller slightly to the right so the end of the shaft clears the lip on the printer case and lift the Transfer Roller and the Bearing Clips from the printer Caution Be careful not to drop the separate springs copper contact and plastic parts into the chassis Holder MTS Sont Transfer Roller s3600 055 7 43 Service Parts Disassembly Exit Roller PL 1 3 6 1 Remove the Right Cover page 7 6 2 Remove the Left Cover page 7 7 3 Remove the Top Cover page 7 10 4 Remove the locking bearings from both ends of the shaft o Caution When you remove the Exit Rollers do not lose the springs Exit Roller Rack Exit Roller rel ae eso e Sofa KAN LR s3600 057 Exit Gear PL 1 3 9 1 Remove the bearing in order to remove the Exit Gear Bearing Exit Gear 3600 058 7 44 Phaser 3600 Printer Service Manual Service
75. cement Note After reinstalling the SMPS board make sure the actuator from the chassis can move freely into the Paper Tray Empty Sensor 7 75 Phaser 3600 Printer Service Manual Service Parts Disassembly Switched Mode Power Supply PL 1 1 29 2 Remove the Print Cartridge Remove Tray 2 and Tray 3 if installed Remove the Right Cover page 7 6 Remove the Rear Cover page 7 8 Remove the Registration Assembly page 7 41 Turn the printer upside down so that you are viewing the bottom of the chassis Remove the rear Cross Bar secured by 2 screws Remove the Tray 2 No Paper Actuator for better access 9 Remove the left and right Duplex Unit Guides o0 BR wn o N s3600 072 10 Remove 5 screws from the SMPS Power Supply Board 11 Remove one grounding screw from the rear of the power supply 12 Remove the SMPS Power Supply Board from the printer Caution Since the fuser wire is hardwired to the SMPS Power Supply Board disconnect the wire from the fuser side 7 76 Phaser 3600 Printer Service Manual Service Parts Disassembly 3600 073 7 77 Phaser 3600 Printer Service Manual Service Parts Disassembly 7 78 Phaser 3600 Printer Service Manual Parts List In this chapter Serial Number Format Using the Parts List PL 1 1 Main Assembly PL 1 2 Cover Assembly PL 1 3 Frame Assembly 1 of 2 PL 1 3 Frame Assembly 2 of 2 PL 1 4 Fuser Assembly PL 2 1 Tr
76. ces Main Board PL1 1 19 Sensor to Main Board Wiring Diagram m Tray Full Actuator PL 1 3 8 on page 9 14 Tray Full Sensor PL1 3 95 Main Drive Joint Board and Optional Tray Wiring Diagram on page 9 15 Step Actions and Questions Yes No 1 Check the Tray Full Sensor and Replace the Go to Step 2 actuator for obvious damage actuator Is the actuator damaged page 7 45 2 Use diagnostics to test the Tray Full Replace the Main Replace the Tray Sensor Board Full Sensor Does the sensor operate correctly page 7 39 page 7 23 3 22 Phaser 3600 Printer Service Manual General Troubleshooting In this chapter m Servicing Instructions m Preventive Maintenance Procedure m Control Panel Troubleshooting m Power Supply Troubleshooting Chapter General Troubleshooting Servicing Instructions 4 2 The service flowchart is an overview of the path a service technician should take using this manual to service the print engine and options Step 1 Identify the Problem 1 Verify the problem reported and check for any error codes and write them down 2 Print normal customer prints and service test prints and look for any of the following a any image quality problems in the test prints b any mechanical or electrical abnormalities present c any unusual noise or smell coming from the printer 3 View the fault and jam histories and look at the total print coun
77. che rne eL bez a dene i E dar Ieri Tas e er oes d ni e EN vii Regulatory Information eero 20 6 esie elu RR RR Rer ev vr deu aw ra E RR g ix Manual Organization girs acs os ies oreste A SR xi 1 General Information Printer Configurations x usce ss da rire a a ueri eiu 1 2 Printer Options and Supplies 1 2 Consumable and Service Part Life Expectancy 1 3 PantS Of the Printer tee PEU ee awe ee hee bl redu a trate a arg ace Berat d Bewerten o 1 4 FROME VIGW caia oeste es ios Ven AE IMS D T IUD M pie 1 4 ENES HIER 1 4 Control Pelos ee oot MERS add Caos ties bed eae bius ice TAE RA ai dee 1 5 MENU MAD ELT 1 5 Error and Warning Messages 1 5 Printer Specifications 1 6 Printer Location and Clearance 1 6 Printer Physical Specifications 1 7 Functional Specifications 1 7 Electrical Specifications 1 9 Environmental Specification 1 9 Media and Tray Specifications
78. connector from the right tab of the Thermistor Phaser 3600 Printer Service Manual 7 61 Service Parts Disassembly 5 Remove two screws 8mm securing the Fuser connector to the Fuser Assembly __ NN MH WE tg hu A s3600 119 6 Disconnect the center Thermistor plug from the Fuser Connector s3600 117 7 62 Phaser 3600 Printer Service Manual Service Parts Disassembly 7 Loosen but do not remove two screws 6mm securing the Heat Roller retaining plates on each side of the Heat Roller s3600 127 Phaser 3600 Printer Service Manual 7 63 Service Parts Disassembly 8 Pull the retaining plates away from roller and lift the roller free from the assembly Note Make sure you do not lose any of the Heat Roller claws s3600 125 9 Remove the bushing and rubber sleeve from the left side of the roller EN s3600 121 7 64 Phaser 3600 Printer Service Manual Service Parts Disassembly 10 From the right side of the roller remove the spring retaining clip securing the gear to the roller s3600 122 o Caution Be careful not to break the Dual lamp when removing the roller o Caution Be sure to seat the Heat Roller claws over the Heat Roller before securing the Heat Roller to the assembly s3600 126 Phaser 3600 Printer Service Manual 7 65 Service Parts Disassembly Dual
79. d the first two prints and retain the remaining prints for image quality analysis Deletions Inspect the test print for the presence of deletions or unprinted spots If these are found see Repeating Bands Lines Marks or Spots on page 5 22 5 4 Phaser 3600 Printer Service Manual Print Quality Troubleshooting Fusing Rub the image three times at the indicated points with a soft cloth or tissue The toner should not lift off of the surface of the print If the image smears or toner lifts off the image onto the cloth see Unfused Image on page 5 24 in We conduct many of 75 ever these mail s 5 coverage Would yo o your time to read d survey has been de time and effort T test pattern a qu envelope are enclo HHHH SCAN We conduct many of ever these mail s coverage Would yo your time to read survey has been de time and effort T test pattern a qu envelope are enclo s3600 080 Resolution Observe the three resolution check points on several test prints m Ensure that the 2 pixel horizontal vertical and diagonal lines are clear and continuous The diagonal lines might appear to be narrower than the others m Characters in the text paragraphs should be uniform and equal in density m The halftone patches should be uniform in appearance If the image does not meet the criteria see Light or Undertone Print on page 5 11 or Background Contamination on page 5 15 Phaser 3600 Printer Servic
80. dures to replace the part Step 5 Final Checkout 1 Test the printer to be sure you have corrected the initial problem and there are no additional problems present Phaser 3600 Printer Service Manual General Troubleshooting Preventive Maintenance Procedure Perform the following procedures whenever you check service or repair a printer Cleaning the printer as outlined in the following steps assures proper operation of the printer and reduces the probability of having to service the printer in the future The frequency of use and the type of paper a customer prints on determines how critical and how often cleaning the machine is necessary Record the number of sheets printed Recommended Tools Phaser 3600 Printer Service Manual m Toner vacuum cleaner m Clean water m Clean dry lint free cloth m Black light protective bag 4 3 General Troubleshooting Control Panel Troubleshooting The following procedures cover Control Panel and Start up problems with the printer when no specific error code or Control Panel message is displayed No Control Panel Display after Power Is Turned ON 1 Verify that power cord is securely plugged into both the printer and the grounded three prong AC outlet with the appropriate power available 2 Ensure that all covers are securely closed 3 Verify the Top Cover Print Cartridge and Fuser interlocks are functional 4 Verify voltages at the Main Board See Taking V
81. e Replace Print Cartridge Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References m Print Cartridge PL1 1 34 Toner Sensor Board PL1 3 47 2 a Main Board PL1 1 19 m Map 2 Main Board on page 9 5 Main Drive Joint Board and Optional Tray Wiring Diagram on page 9 15 Step Action and Questions Yes No 1 Open the top cover and ensure Complete Go to Step 2 that the Print Cartridge is properly seated Does the error clear after reseating the cartridge 2 Check the Print Cartridge for Go to Step 3 Replace Print damage Cartridge Does the cartridge contain toner and appear to be operating properly 3 Reseat all harness connections to Complete Go to Step 4 the Toner Sensor CRUM Board Does the error clear 4 Check continuity between the Replace the Toner Replace the Main Toner Sensor CRUM Board and Sensor Board Board page 7 39 CN7 on the Main Board page 7 24 Phaser 3600 Printer Service Manual Close Fuser Door Troubleshooting Reference Table Error Messages Applicable Parts Wiring and Plug Jack Map References Fuser Assembly PL1 4 1 m Main Board PL1 1 19 Switched Mode Power Supply SMPS PL1 1 29 2 a LSU and Main Motor to Main Board Wiring Diagram on page 9 16 m Map 2 Main Board on page 9 5 Map 3 SMPS Board on page 9 6 Step Action and Questions Yes No 1
82. e 7 10 2 Remove the 6 screws securing the LCD and control panel and remove from the top cover Note DO NOT remove the 3 screws securing the plastic portion of the LCD display 3600 074 Phaser 3600 Printer Service Manual 7 13 Service Parts Disassembly Tray 1 MPT Assembly Caution Tray 1 and the Knock Up Plate contain unsecured plastic parts that fall off and are easy to lose Also be careful in step 6 to not exert too much pressure or you can break the plastic tracks Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Open Tray 1 Unhook only the bottom of the 2 springs connecting the Knock Up Plate to the Pick Up Rack a ron Note DO NOT unhook the top portion of the springs from the Pick Up Rack s3600 032 6 To disengage the Knock Up Plate from the Tray 1 MPT Assembly flex the left and right tray links from the indented portion of the tracks 7 14 Phaser 3600 Printer Service Manual Service Parts Disassembly j s3600 033 7 Facing Tray 1 slide the tray to the left to release the 4 pivot points securing the Tray then remove the Tray 1 Assembly from the printer Replacement Note Follow these steps to ensure correct replacement of the tray To attach the Tray 1 MPT assembly to the Knock Up Plate 1 Attach the left and right plas
83. e Exit Go to Step 3 Use service diagnostics to test the Roller page 7 44 main drive to exit Is the exit roller damaged or binding 3 Visually inspect the Fuser Remove Go to Step 4 Fuser rollers Is there paper wrapped around the obstruction and clean Fuser rollers 4 Is the Fuser Assembly operational Go to Step 5 Replace the Fuser Do the Fuser gears rotates when Assembly the Main motor is on page 7 54 5 Use the embedded diagnostics to Replace Main Replace the SMPS check the Exit Roller Board page 7 39 page 7 76 Are the rollers operational 3 15 Error Messages Jam At Rear Duplex Jam 1 Troubleshooting Reference Table Applicable Parts Transfer Roller PL1 1 7 Duplex Exit Sensor PL2 3 15 Duplex Roller PL2 3 4 Duplex Unit PL2 3 0 Wiring and Plug Jack Map References Main Drive Joint Board and Optional Tray Wiring Diagram on page 9 15 3 16 a Main Board PL1 1 19 Step Actions and Questions Yes No 1 Does paper jam after reversal Go to Step 2 Go to Step 3 but before reaching the Duplex Sensor 2 Replace Transfer Roller Shaft Replace Duplex Unit Complete Assembly page 7 43 page 7 37 Does problem recur 4 Inspect the Duplex Unit Is any Removeobstruction Go to Step 5 paper wrapped around the and clean rollers Duplex Rollers 5 Are the rollers damaged or Replace the Duplex
84. e Manual 5 5 Print Quality Troubleshooting We conduct many of a ever these mail s a coverage Would yo O your time to read x survey has been de time and effort T le test pattern a qu envelope are enclo HAHTHHTA SCAN We conduct many of ever these mail s coverage Would yo 2 your time to read survey has been de time and effort T test pattern a qu envelope are enclo 3 gt Registration and Skew Fold the paper from two consecutive test prints in half first side edge to side edge and then top edge to bottom edge Observe the fold lines with reference to the crosshairs of the printed target The fold line should be aligned perpendicular to the target crosshairs and should be within 2 0 mm of the target crosshairs each line on the target is 1 0 mm If the image does not meet the criteria see Skew on page 5 25 5 6 Phaser 3600 Printer Service Manual Print Quality Troubleshooting H H SCAN E 3600 083 PROCESS bnduct many of these mail et T pattern a qu bpe are enclo Fold Line 3600 082 Phaser 3600 Printer Service Manual 5 7 Print Quality Troubleshooting Skips or Smears Check the test print in the indicated areas for loss stretching or distortion of the image in bands across the process direction that make the image seem distorted blurred or compressed If these faults are observed see Horizontal Band Voids or Streaks on page 5 27
85. e life 2 Enhanced mode Used for printing on plain paper with an addressable resolution of 1200 x 1200 dpi Phaser 3600 Printer Service Manual 2 3 Theory of Operation Printer Paper Path Paper Path Components The diagram below shows the paper path and identifies the major components of the printer The simplex paper path is shown in red and the duplex path is shown in light red Imaging Drum OPC Exit Roller Heat Roller Registration Sensor Exit Duplex Roller Idler Fuser Exit Roller Fuser Exit Sensor Feed 2 Idler Pressure Roller Feed 2 Roller Transfer Retard Roller Roller Feed 1 Roller Duplex Tray 2 Rollers Pick Roller Duplex Sensor Retard Roller Tray 3 No Paper Sensor Taya Feed haller Tray 2 No Paper Sensor Tray 3 Pick Roller 3600 085 Media that meets printer specifications can be fed from Tray1 MPT and Tray 2 or the Optional Tray 3 If you use thick paper with a weight of more than 105 gsm 60 lbs you must insert the paper into Tray 1 MPT and select the paper type Paper will exit the printer to the face down top tray A door at the rear of the printer provides access for jam clearance All major components of the printer are explained in greater detail under Printer Controls on page 2 10 2 4 Phaser 3600 Printer Service Manual Theory of Operation Duplex Paper Path When 2 sided printing is selected side two is printed first the image being printed is the f
86. e lists normal display T1 Psize1 Sen Sensor before touching the sensor and the Low High second value lists normal display aftertouching the sensor T1 PSize2 The first value lists normal display T1 Psize2 Sen Sensor before touching the sensor and the Low High second value lists normal display after touching the sensor T2 PSize0 The first value lists normal display T2 Psize0 Sen Sensor before touching the sensor and the Low High second value lists normal display aftertouching the sensor T2 PSize1 The first value lists normal display T2 Psize1 Sen Sensor before touching the sensor and the Low High second value lists normal display aftertouching the sensor 3 7 Error Messages 3 8 Diagnostic Menu Map Options Main Menu Sub Menu Description Function Control Panel Display Sensor T2 PSize2 The first value lists normal display T2 Psize2 Sen Status cont Sensor before touching the sensor and the second value lists normal display aftertouching the sensor Low High T3 PSize0 The first value lists normal display T3 Psize0 Sen Sensor before touching the sensor and the Low High second value lists normal display aftertouching the sensor T3 PSize1 The first value lists normal display T3 Psize1 Sen Sensor before touching the sensor and the Low High second value lists normal display aftertouching
87. e the Right Cover page 7 6 2 Disconnect the Developer Drive Assembly from the connector CN21 on the Main Board 3 Remove 4 screws securing the assembly to the printer lt EN Replacement Note B LT Po D 7 A RN o V RN 6 0 s3600 063 Reassemble the 4 screws in order of the numbers etched in the metal plates of the Developer Drive Assembly 7 51 Service Parts Disassembly Joint Board PL 1 3 61 1 Remove the Right Cover page 7 6 2 Disconnect all connectors to the Joint Board 3 Remove 1 screw securing the Joint Board to the chassis and remove gt s3600 064 Replacement Note Be sure to insert the board in the securing slot before re installing the board Secure with the single screw 7 52 Phaser 3600 Printer Service Manual Service Parts Disassembly Paper Size Sensor PL 1 3 14 Note If Tray 2 or the optional Tray 3 Feeder is installed they must be removed before performing this procedure Remove the Print Cartridge Remove the Left Cover page 7 7 Disconnect connector PSIZE from the Paper Size Sensor Genily turn the printer upside down AR ND Note The Paper Size Sensor can be removed and replaced without removing the rear crossbar However to provide improved access remove the crossbar screw above the Paper Size Sensor and loosen the screw on the other side
88. e trays Does the error still occur 13 Replace the Tray 2 Feed Roller Replace the Complete page 7 30 Retard Does the error still occur Assembly page 7 19 5 26 Phaser 3600 Printer Service Manual Horizontal Band Voids or Streaks Print Quality Troubleshooting Areas of the image are extremely light or missing entirely The missing areas form wide bands covering a wide area horizontally and perpendicular to the paper feed direction Initial Actions m Check the paper transfer path m Ensure there are no debris on the transfer path Troubleshooting Reference Table Applicable Parts Example Print Registration Assembly PL1 1 12 Transfer Roller PL1 1 7 Laser Scan Unit PL1 1 15 m Print Cartridge PL1 1 34 arj Horizontal Band Void or Streaks Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Print a demo page Go to step 3 Go to step 2 Does the error still occur when printing 2 Print a customer application page Go to step 3 Complete Does the error still occur 3 Check the document path Remove the Go to step 4 Are there any debris on the paper debris path 4 Check for band s regular intervals Refer to Go to step 5 Are there any bands on the page page 5 4 5 Check the Print Cartridge for damage Replace the Go to step 6 Is the Print Cartridge damaged Print Cartridge 6 Check the paper condition Go to
89. ect position Phaser 3600 Printer Service Manual 5 25 Print Quality Troubleshooting Troubleshooting Procedure Table continued Step Action and Questions Yes No 4 Check the Print Cartridge for correct Go to step 5 Complete installation Reseat the Print Cartridge Does the error still occur 5 Check the Separator Pad Assembly Remove the Go to step 6 Is there damage or debris on the debris or replace Separator Pad the Separator Pad Assembly page 7 20 6 Check for a skewed tray reseat the paper Go to step 7 Is the skewed paper fed from Tray 1 and go to step 7 MPT 7 Checkthe Tray 1 MPT Side Guides Go to step 8 Complete Reset the Paper Guides Does the error still occur 8 Replace the Tray 1 MPT Feed Roller Go to step 9 Complete page 7 14 Does the error still occur 9 Check the Registration Assembly and Replace the Complete Transfer Roller for correct installation Registration Reseat the Transfer Roller page 7 43 assembly Does the error still occur page 7 41 then go to step 10 10 Check the skewed mode through the Go to step 11 Go to step 12 Duplex Unit Is the skewed paper fed the from the Duplex 11 Check the Duplex Unit for correct Go to step 12 Complete installation Reseat the Duplex Roller page 7 47 Does the error still occur 12 Check additional paper trays for Go to step 13 Complete correct installation Reseat th
90. ecuring the solenoid to the printer Remove the solenoid assembly o0 BR ND Note There is a resistor attached by the upper right hand screw When reassembling the printer ensure the resistor is in place D E PL AER SIDA SC CA ES AE s3600 056 7 48 Phaser 3600 Printer Service Manual Frame Assembly Service Parts Disassembly Feed Idle Unit PL 1 3 50 Phaser 3600 Printer Service Manual a LON Remove the Tray 1 MPT Assembly page 7 14 Remove the Retard Assembly page 7 19 Remove the Tray 1 Separator Holder Pad Assembly page 7 20 Remove 4 screws 2 for each of the Feed Idle Units Remove each Feed Idle Unit t 3600 061 7 49 Service Parts Disassembly Pre transfer Lamp PTL Board PL 1 3 71 Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Remove the Registration Assembly page 7 41 Disconnect the wiring harness CN22 from the Main Board Remove 1 screw and take out the PTL board O OO wn PTL Upper Terminal PTL PBA lt d FX E Y a E Jeo e INES e APO BE RE NY A N s fi T BY p 07 GN Wy d Jr 3600 062 7 50 Phaser 3600 Printer Service Manual Service Parts Disassembly Developer Drive Assembly PL 1 1 17 Phaser 3600 Printer Service Manual 1 Remov
91. ength for the weight of the printer 596 mm 24 6 in 1255 6 mm he 49 2 in 320 mm 12 6 in ee 482 6 mm 18 8 in CA s3600 003 Phaser 3600 Printer Service Manual Printer Physical Specifications Physical Dimensions and Weight General Information Item Specification Packaging Packing Dimension w o 518 566 568mm Dimension option tray 20 4 22 3 22 4 W D H Net Dimension w o Option 396 453 353mm Net Dimension Tray 15 6 17 8 13 9 DM Net Dimension with Option 396 453 501mm Tray 15 6 17 8 19 7 Toner Dimension Toner 314x 225 x 116 mm QUOI Toner Packing 368 x 286 x 169 mm Weight SET with 10K toner 17 30kg 38 14Ib cartridge SET w o toner cartridge 15 46kg 34 061b Consumable toner cartridge 10K 1 85kg 4 08lbs 20K 2 06kg 4 54 Ibs Set Consumables 19 15 kg 42 21b with 10K toner cart Packing We ight 22 46kg 49 501b Functional Specifications Phaser 3600 Printer Service Manual Print Operability Characteristic Specification Printing process Non Impact Electrophotography Color medium Monochrome Resolution Addressability True 600 x 600 dpi Addressable 1200 x 1200 dpi Operating Modes Standby Mode Print engine capable of making prints in less than 9 seconds Sleep Low Power Power Saver Mode 31 seconds from completion of a print Continuous Operating Printing
92. er disassembly 7 7 light or undertone defects 5 11 Locator Maps Map 1 LSU and Fuser 9 4 Map 2 Main Board 9 5 Map 3 SMPS Board 9 6 Map 4 HVPS Board 9 7 LSU and Fuser locator map 9 4 LSU and Main Motor to Main Board Wiring Diagram 9 16 Main Assembly parts list 8 7 view of parts 8 6 Main Board disassembly 7 39 theory 2 6 Main Drive disassembly 7 38 Solenoid disassembly 7 40 theory 2 5 to Joint Board and Optional Tray Wiring Diagram 9 15 maintenance preventive 6 2 tools 6 2 map column 9 2 Menu map 3 3 Microswitches 2 14 Motor Drive Assemblies 2 7 Motor tests 3 8 O OPC drum 2 7 optional trays 2 9 Outbin Full Assembly Actuator disassembly 7 45 Outbin Full Sensor disassembly 7 46 theory 2 16 output capacity tray 1 10 P P J designators 9 2 Paper feed sequence 2 5 paper path 2 4 paper path sensors 2 15 Paper Size Sensor 2 16 Paper Size Sensor disassembly 7 53 Paper Tray Assembly Paper Pick up Process 2 7 Paper Tray Empty Actuator disassembly 7 23 Paper Tray Empty Sensor 2 15 Paper Tray Empty Sensor disassembly 7 22 Parts list using 8 4 Photo sensors 2 13 Physical Specifications 1 7 Pick Up Assembly Pick Roller and Shaft disassembly 7 25 Pick Roller disassembly 7 28 Pick Up Gear disassembly 7 34 Pick Up Rack disassembly 7 18 Pick Up Roller 2 5 Plug Jack Designation diagrams 9 2 locator table 9 3 notation 8 4 Pre transfer Lamp disassembly 7
93. er Drive Assembly PL 1 1 17 22 7 51 Joint Board PE 1 3 61 toss sr od Adda ener ra ade eked 7 52 Paper Size Sensor PL 1 3 14 d nere nee EP o Eo BR hake a eed 7 53 Fuser Assembly 1 3 80 7 54 Fuser Interlock Switch PL 1 8 77 esses csse oh prb ne apa HEX Es 1 55 Fuser Exit Sensor PL 1 3 76 1 56 Fuser Thermostat PL daa om m bd E te dd o ea 1 57 Fuser Thermistor PL 1 4 40 oooooocccccoccocc IRI e 1 58 Heat Roller PL 1 4 53 and Bushing PL 1 4 44 2 7 60 Dual lamp PL 1 4 56 44444448 eee 7 66 Pressure Roller PL 1 4 66 and Bushing PL 1 4 50 7 67 Laser Scan Unit PL 1 1 15 44 4444 ETE A E E eds 7 70 LSU Lower Cover PL 1 348 1 oec eese br bb eed a died ada db HER 7 72 Left Side Cooling Supply Fan and Duct PL 1 1 31 2 7 73 Cover Open Board and Sensor PL 1 3 47 7 74 Power Supplies hr ar A tata GONE dto ia 7 75 High Voltage Power Supply HVPS PL 1 1 29 1 7 15 Switched Mode Power Supply PL 1 1 29 2 7 16 8 Parts List Serial
94. error message will display on the Control Panel The signal from the Fuser Exit Sensor is also used to control paper feed to the Duplex Unit for duplex print jobs Cover Open Interlock Switch The Cover Open Interlock Switch detects whether the top cover is open or closed When the top cover is open the Close Top Cover message displays on the Control Panel Duplex Sensor The Duplex Unit slides into the rear of the printer above Tray 2 The Main Board senses the presence of the Duplex Unit and paper in the Duplex unit through the Duplex connector As paper leaves the Fuser Assembly and is picked up by the Exit Rollers the drive direction is reversed to send the paper into the Duplex Unit As the paper leaves the Duplex Unit it activates the Duplex Sensor within the unit This activates the Feed Roller to position the paper for printing on the second side of the paper 2 16 Phaser 3600 Printer Service Manual Power Supplies Theory of Operation High Voltage Power Supply HVPS Phaser 3600 Printer Service Manual The HVPS section generates and supplies the following voltages m Transfer Voltage m Charge Voltage m Bias Voltage m Supply Voltage The Bias Supply and Charge voltages are used by the Print Cartridge The power distribution section receives AC voltage and creates the required DC outputs 3 3 VDC 5 VDC and 24 VDC to power the printer components It also supplies AC voltage to the Fuser Assembly
95. eshooting Step Actions and Questions Yes No 6 Check the paper condition Go to step 7 Replace the Is the paper dry recommended type paper and loaded in the correct position 7 Check the Transfer Roller Replace the Go to step 8 Are there any damages on the roller Transfer Roller surface page 7 43 8 Check the Registration Assembly for Complete Go to step 9 correct installation Reseat the assembly page 7 41 Does the image quality improve 9 Check for debris in the laser beam Remove the Go to step 10 path between the Laser Scan Unitand debris the Registration Assembly Is there any debris 10 Does the image quality improve Complete Replace the Laser Scan Unit page 7 70 5 23 Print Quality Troubleshooting Unfused Image The toner image is not completely fused to the paper The image easily rubs off Initial Actions m Check the paper transfer path m Ensure there are no debris on the transfer path Troubleshooting Reference Table Applicable Parts Example Print m Print Cartridge PL1 1 34 m Fuser Assembly PL1 4 1 Unfused Image A Warning Ensure to wait for the Fuser to cool down before starting the procedure Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Print a demo page Go to step 2 Complete Does the error still occur when printing 2 Verify the media type selection Go to step 3 Select the cor
96. f 1 Silver colored tapping 2 Screw thread is coarse plastic D EE Coarse compared to metal screw G 3 Screw tip is thin Plastic Parts etc Self 1 Black colored tapping 21 coarse 2 Screw thread is coarse plastic with 7 3 compared to metal screw flange 3 Screw has a flange Plastic DN Parts etc 4 Screw tip is thin Sheet Metal 1 Silver colored silver 2 Diameter is uniform Sheet Parts etc Metal Sheet Metal 1 Silver colored with flange 2 Screw has a flange 3 Diameter is uniform Sheet Parts etc Metal Caution Use care when installing self tapping screws in plastic To properly start the screw in plastic turn the screw counter clockwise in the hole until you feel the screw engage the threads then tighten as usual Failure to properly align or over tighten the screw can result in damage to previously tapped threads Always use the correct type and size screw Using the wrong screw can damage tapped holes Do not use excessive force to remove or install either a screw or a printer part Note Unless specifically noted in the text all screws listed in the disassembly chapter for the Phaser 3600 are 10mm self tapping screws Phaser 3600 Printer Service Manual Service Parts Disassembly Notations in the Disassembly Text m The notation item X points to a numbered callout in the illustration corresponding to the disassembly procedure being performed m The n
97. face from end to end axially as it rotates The beams are turned on to print a pixel and off when no printing is required The negative charge on the drum surface is reduced to approximately 250 VDC at each point where the energized laser beam strikes to form an invisible electrostatic latent image on the drum surface Development Negatively charged toner particles from the toner hopper are applied to the supply roller and are then applied to the developer roller in a even layer controlled by the metering blade The developer roller turns against the drum and the toner particles are attracted to the relatively positive latent image The toner forms a visible image on the drum surface Pre Clean The pre transfer Lamp exposes the developed surface of the drum lowering the surface potential and thereby providing enhanced transfer efficiency Transfer The finished toner image on the drum is transferred onto the print media using the voltage supplied by the Transfer Roller The conductive Transfer Roller receives a high positive voltage approximately 1000 VDC from the HVPS that puts it at a higher potential than the drum Since the Transfer Roller is located behind the print media the toner image is attracted to the high potential and deposits on the surface of the print media Fixing The finished toner image is impermanent and easily smeared To fix the image the print media goes through the Fuser where it passes between a pressure roller
98. ge for damages Replace the Go to step 4 Is the Print Cartridge damaged Print Cartridge Phaser 3600 Printer Service Manual 5 9 Print Quality Troubleshooting 5 10 Troubleshooting Procedure Table continued Step Actions and Questions Yes No 4 Check the Registration Assembly Is there any damage to the Registration Assembly Replace the Go to step 5 Registration Assembly page 7 41 Check the Transfer Roller for correct installation Reseat the Transfer Roller page 7 43 Does the image quality improve Complete Go to step 6 Check the laser beam path Is there any debris between the Laser Scan Unit and Transfer Roller Remove any Go to step 7 debris Check the wiring harness connector between the Laser Scan Unit and the Main Board Are the connectors securely connected Go to step 8 Recomnect the connectors then go to step 8 Check the Main Board for correct installation Reseat the Main Board page 7 39 Does the image quality improve Complete Go to step 9 Check the HVPS for correct installation Reseat the HVPS Board page 7 75 Does the image quality improve Complete Go to step 10 10 Replace the Laser Scan Unit page 7 70 Does the image quality improve Complete Replace the Main Board page 7 39 Phaser 3600 Printer Service Manual Light or Undertone Print The image density is too light in a
99. he Main Board will shut down the machine the control panel LED will blink red and a Jam error message will display on the control panel 2 15 Theory of Operation Secondly the signal generated by the sensor tells the Main Board that the paper is almost at the transfer area and it is time to start the xerographic process It is important that the leading edge of the paper enters the transfer area at the same time as the leading edge of the developed image on the drum Paper Size Sensor The Paper Size Sensor detects the presence of paper and monitors a paper size plate consisting of three sensitive metal tabs in the paper path Depending on the size of the paper one or more of these tabs will send a signal to the Main Board with the information needed to determine the paper size For information regarding the paper size combinations see Paper Size Control on page 2 10 Outbin Tray Full Sensor The Outbin Tray Full Sensor detects when the output bin is full and can no longer accept more paper from the exit section of the paper path When the Main Board detects this sensor it sends an Output Bin Full message to the control panel Fuser Exit Sensor The Fuser Exit Sensor monitors paper exit and detects the Jam at Exit error if the paper takes too long getting to the sensor or it stays at the sensor too long At this point the Main Board will shut down the printer the Control Panel LED will blink red and a Jam at Exit
100. he Main Drive Assembly page 7 38 Remove the locking bearing on the front of the shaft by rotating it in the direction of the arrows shown below i m CY pin tun 3600 095 7 25 Service Parts Disassembly 8 Remove 1 screw on the right end of the shaft securing the bracket Gear Assembly remove the bracket with the bearing s3600 041 9 Remove the right side gear from the shaft Phaser 3600 Printer Service Manual 7 26 Service Parts Disassembly 10 Lift the latch on the idle cam and slide the shaft to the right through the cam to free it from the printer 0 AD E M ge J A p Z 4 A gt X g EE L P Ze Se gt s3600 042 Phaser 3600 Printer Service Manual 7 27 Service Parts Disassembly Tray 1 MPT Pick Roller Only PL 1 3 2 4 Note If you are only removing the Pick Roller and not the shaft it may be necessary to rotate the shaft release the solenoid and then rotate the shaft gear clockwise to position the roller properly Caution Do not break the pick shaft by trying to force the Pick Roller off 1 Slide the idle gears outward Release the locking tab on the Pick Roller Assembly and slide the roller to the right iN L Ds PME a rt buc c Mc Idle 53600 043 7 28 Phaser 3600 Printer Service Manual Service Parts Disassembly Tray 1 MPT Solenoid PL 1 1 26 1 Remove the Right Cover page 7 6
101. he machine is and how often it is necessary Record the number of sheets printed Recommended Tools General Cleaning 6 2 Toner vacuum cleaner Clean water Clean dry lint free cloth Black light protective bag Perform the following general cleaning steps as indicated by the printer s operating environment Caution Never apply alcohol or other chemicals to any parts of the printer Never use a damp cloth to clean up toner If you remove the Print Cartridges place them in a light protective bag or otherwise protect them as exposure to light can quickly degrade performance and result in early failure 1 Record number of sheets printed 2 Print several sheets of paper to check for problems or defects 3 Turn the printer power Off and disconnect the power cord 4 Remove the Transfer Unit Fuser Print Cartridges Duplex Unit if installed and Side Covers before cleaning 5 Remove the Rear Cover and clean the Rear Cover Fan to remove excess dust 6 Remove the Top Cover and clean the Main Fan to remove excess dust 7 Ensure that all cover vents are clean and free of obstructions 8 Remove any debris or foreign objects from the Fuser Transfer Unit Print Cartridges Duplex Unit and inside of the printer 9 Remove and clean the paper trays 10 Clean all rubber rollers with a lint free cloth slightly dampened with cold water Phaser 3600 Printer Service Manual Cleaning and Maintenance Cleaning the Lase
102. her dangerous for the consumer nor for the environment To ensure compliance with European Union regulations use shielded interface cables A full declaration of conformity defining the relevant directives and referenced standards can be obtained from your Xerox Limited representative Phaser 3600 Printer Service Manual Manual Organization Phaser 3600 Printer Service Manual The Phaser 3600 Printer Service Manual is the primary document used for repairing maintaining and troubleshooting the printer Use this manual as your primary resource for understanding the operational characteristics of the printer and all available options This manual describes specifications theory and the diagnosis and repair of problems occurring in the print engine and attached options Also included are detailed replacement procedures parts lists and wiring diagrams The Phaser 3600 Printer Service Manual contains these chapters Introductory Safety and Regulatory Information This section contains important safety information and regulatory requirements Chapter 1 General Information This chapter contains an overview of the printer s operation configuration specifications and consumables Chapter 2 Theory of Operation This chapter contains detailed functional information on the printer components Chapter 3 Error Messages This chapter provides detailed troubleshooting procedures for error messages generated by resident diagnostics
103. hich can be determined by turning the equipment Off and On the user is encouraged to try to correct the interference by one or more of the following measures m Reorient or relocate the receiver device being interfered with m Increase the separation between the printer and the receiver m Connect the equipment into an outlet on a circuit different from that which the receiver is connected m Consult the dealer or an experienced radio television technician for help Any changes or modifications not expressly approved by Xerox could void the user s authority to operate the equipment To ensure compliance with Part 15 of the FCC rules use shielded interface cables Canada Regulations Phaser 3600 Printer Service Manual This Class B digital apparatus complies with Canadian ICES 003 Cet appareil num rique de la classe B est conforme la norme NMB 003 du Canada European Union The CE mark applied to this product symbolizes Xerox s C declaration of conformity with the following applicable Directives of the European Union as of the dates indicated December 12 2006 Council Directive 2006 95 EC as amended Approximation of the laws of the member states related to low voltage equipment December 15 2004 Council Directive 2004 108 EC as amended Approximation of the laws of the member states related to electromagnetic compability This product if used properly in accordance with the user s instructions is neit
104. ht Cover page 7 6 2 Remove the Left Cover page 7 7 3 Remove the Top Cover page 7 10 4 Remove the Tray 1 MPT Assembly page 7 14 5 Remove the Inner Cover page 7 16 6 Remove 2 screws securing the Pick Up Rack and remove the rack Caution Do not remove or lose the springs 72 Y uw LOS S NESSUN N s3600 036 g V ME if e Ey LA en EL G EE Replacement Note When reinstalling be sure to secure the Pick up Rack in the boss on each side of the rack Phaser 3600 Printer Service Manual 7 18 Service Parts Disassembly Retard Assembly PL 1 3 49 1 Remove Tray 1 MPT Assembly page 7 14 2 Remove the Inner Cover page 7 16 3 Remove the Tray 1 Pick Up rack page 7 18 4 Squeeze the lock as shown below and slide the Retard Assembly off of the Retard Roller s3600 037 Replacement Note When reassembling insert the Retard Roller over the left end of the retard shaft until the roller snaps in place s3600 009 Phaser 3600 Printer Service Manual 7 19 Service Parts Disassembly Tray 1 MPT Separator Pad Assembly PL 1 3 4 1 Remove the Tray 1 MPT Assembly page 7 14 2 Remove the Retard Assembly page 7 19 3 Loosen the wire harness from the plastic wire holder and disconnect the connector CN 1 from the Separator Pad Assembly Do not use a needlenose set of pliers to loosen the connector
105. ies The Motor Drive Assemblies include the Main Motor and the Developing Motor Under control of the Main Board the Main Motor Drive is a power delivery unit Through a series of gears it supplies the power to the paper feed components the fusing unit and the distributing unit For the duplex process the Main Motor energizes a solenoid to change paper direction By gearing the main motor drives the rollers such as Feed Roller developing roller fuser roller and Exit Roller In addition a step motor controls the acceleration of the drive gearing The Developing motor also drives gears that in turn drive components used in the image development process Feed Assembly Process and Components Phaser 3600 Printer Service Manual The Feed assembly process and components consists of 1 Separation process Separates the paper from the friction pad mounted to the center of the cassette and applies a Retard Roller which uses a spring clutch A separate Feed Roller then uses an electronic clutch to control driving power 2 Center Loading Process A center loading method applies friction pad separation which means that a software process first detects paper even though there is a paper sensor After the initial detection the Paper Size Sensor determines paper size see Paper Size Sensor on page 2 16 Both the side guide and the rear guide can be adjusted for various types of papers from A5 to legal size paper The process also incl
106. ing PL 1 1 21 0 0 cc cece eee tenet eens 7 34 Tray 2 Feed Roller PL1 3 59 5 os c02saceieeeetaiw ane din di delta oP add edb iv etude mde Res 7 35 Tray 2 Pick Roller PL1 3 59 2 7 35 Tray 2 PL2 1 0 and Optional Tray 3 PL2 2 0 Replacement 7 36 Duplex Unit PE2 3 0 1 3 A ds Siete PR a cree a O E eae oka ml Ra REP not 7 37 Main Drive and Registration Assemblies 7 38 Main Drive Assembly PL 1 1 18 7 38 Main Board PL 1 1 19 e echt ti eoe ba ii 7 39 Main Solenoid PET ii a ex bb O a RO RO ees 7 40 Registration Assembly PL 1 1 12 2 7 41 Transfer Roller PE 1 1 7 cocoa a la his 7 43 Exit Roller PLA isa a sibs A ia 7 44 Exit Gear PL TES 9 riada ato da ha bee aac are egw a A dis Se a 7 44 Outbin Full Actuator PL1 3 8 cat e Ren ERE A 7 45 Outbin Full Sensor PL1 3 21 7 46 Duplex Roller PL icon eh un et Re ED eee ec d 7 47 ExitiSolenioid PL dico cad a at Da deer he ob ee Ae raa 7 48 Frame Assembly ss aaa a a ch ade BA dd Ad ud 1 49 Feed Idle Unit PL 1 3 50 i ui cache pe trt aime b leks Lehane Boas eb Rt a 7 49 Pre transfer Lamp PTL Board PL 1 3 71 2 1 50 Develop
107. iption Part Number 36 LEVER AUTO RELEASE L 37 TUBE SMALL 38 TUBE MIDDLE 39 RING E 40 THERMISTOR 130N01462 41 TUBE LARGE 42 SPRING ETC LOCK 43 LEVER AUTO RELEASE R 44 BUSHING HEAT_ROLLER 013N13883 48 BEARING BALL 49 CAP FUSER LOCK 50 BUSHING PRESSURE_ROLLER 013N 13884 52 HOLDER PR SHAFT 53 HEAT ROLLER 022N02351 54 BRACKET DRAWER 55 MEC BRUSH ANTISTATIC 56 LAMP DUAL 266 110V 122N00277 LAMP DUAL 266 220V 122N00278 57 GROUND HR LAMP 58 SPRING CS 59 COVER FUSER LO LAMP 60 BRACKET LAMP LEFT 61 CAP ACTUATOR 63 SPRING ETC GUIDE 64 FELT CLEAN TONER 65 GUIDE REAR LAMP 66 PRESSURE ROLLER 022N02352 Phaser 3600 Printer Service Manual Parts List Phaser 3600 Printer Service Manual 8 23 Parts List PL 2 1 Tray 2 Cassette s3600 016 8 24 Phaser 3600 Printer Service Manual PL 2 1 Tray 2 Assembly Parts List Table Parts List Item No Description Part Number 0 ELA UNIT CASSETTE 109R00756 1 FRAME M CASSETTE 2 GUIDE M HANDLE 3 INDICATOR EMPTY 4 PLATE P KNOCK UP 5 SPRING PLAT K UP 6 GEAR PINION 7 CAP M GUIDE SIDE L 8 GUIDE P SIDE L 9 GUIDE M SIDE LOCK 10 GUIDE P SIDE R 11 GUIDE M REAR 12 GUIDE P REAR PAPER 13 SPRING ETC GUIDE PAPER 14 GUIDE M LOCK 15 GUIDE M REAR 16 GUIDE M EXTENTION 17 BRACKET P EXTENTION 18 GUIDE M PAPER 19 HOLDER M PAD HOUSING 20 MEA UNIT
108. ire harness It indicates that connector Jack 1 is attached to one end of the wire harness and connector J2 is attached to the other end that is plugged into P2 Only parts showing part numbers are available for support Parts not showing part numbers are available on the parent assembly Identifier Meaning C C ring E E ring KL K clip S Screw 6 4 Phaser 3600 Printer Service Manual Parts List Phaser 3600 Printer Service Manual 8 5 Parts List PL 1 1 Main Assembly s3600 011 Phaser 3600 Printer Service Manual 8 6 PL 1 1 Main Assembly Parts List Table Phaser 3600 Printer Service Manual Parts List ID No Name Description Part Number 1 ELA UNIT FRAME BASE 2 ELA HOU BASE HOUSING 3 MEA UNIT KNOCK UP MP Tray 1 Knock Up Plate 050N00475 3 1 PLATE M KNOCK UP MP 3 2 MPR PAD KNOCK UP MP 3 3 PMO SIDE GUIDE MP R 3 4 PMO SIDE GUIDE MP L 3 5 GEAR PINION 3 6 SHAFT REINFORCEMENT 4 MEA UNIT COVER MP XRX Transfer Roller 002N02410 4 1 COVER M MP XRX 4 2 TRAY M EXTND MP 5 TRAY M LINK MP L 012N00521 6 TRAY M LINK MP R 012N00522 7 ROLLER TRANSFER 022N02353 8 ELA UNIT HOLDER TR R 030N00560 8 1 PMO BUSHING TR 8 2 SPRING ETC TR R HAWK 8 3 PMO TRANSFER HOLDER 8 4 IPR PLATE TR 9 ELA UNIT HOLDER TR L 019E63480 9 1 PMO BUSHING TR 9 2 SPRING ETC TR R HAWK 9 3 PMO TRANSFER
109. irst image After the first image prints the paper is reversed and is fed through the duplexer and back up to the feed roller with side one positioned for printing with the second image Paper Feed Sequence When the Main Board is ready to feed paper it energizes the paper feed solenoid The solenoid armature releases the clutch and the Pick Up Roller makes one revolution This drives the paper to the Feed Roller and the Retard Roller The Feed Roller and Retard Roller drive the paper to the Registration Assembly which in turn drives the paper towards the transfer area Before arriving at the transfer area the paper actuates the Feed Sensor Paper Transport The Registration Assembly continues to drive the paper into the transfer area where the image is transferred from the drum to the paper After the image transfers the paper continues to the Fuser Assembly for the fusing the process In the Fuser Assembly the Heat Roller is heated by a heat element and the paper passes in between the Heat Roller and the pressure roller where toner melts onto the paper to form a permanent image The temperature of the heat roller is monitored by a Thermistor that sends signals to the Main Board The Fuser Assembly drives the paper into the Exit Rollers which drive the paper into the output tray When printing the first side of a duplex print job the drive direction is reversed when the Exit Sensor is actuated Paper is then directed into the Duplex
110. is on the transfer path Troubleshooting Reference Table Applicable Parts Example Print Transfer Roller PL1 1 7 Registration Assembly PL1 1 12 m Print Cartridge PL1 1 34 Color Uneven or Wrong Process Direction Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Print a demo page Go to step 3 Go to step 2 Does the error still occur when printing 2 Print a customer application page Go to step 3 Complete Does the error still occur 3 Is the original document normal Go to step 4 Replace the original document 4 Check the paper condition Go to step 5 Replace the Is the paper dry recommended type paper and loaded in the correct position 5 Check the Print Cartridge for damages Replace the Go to step 6 Is the Print Cartridge damaged Print Cartridge 5 18 Phaser 3600 Printer Service Manual Phaser 3600 Printer Service Manual Troubleshooting Procedure Table continued Print Quality Troubleshooting Step Actions and Questions Yes No 6 Check the Registration Assembly Replace the Go to step 7 Is there any damage to the Registration Registration Assembly Assembly page 7 41 7 Check the Transfer Roller for correct Complete Replace the installation Reseat the Transfer Roller Transfer Unit page 7 43 page 7 43 Does the image quality improve 5 19 Print Quality Troubleshooting Random Spot
111. k and Wiring Diagrams Main Drive Joint Board and Optional Tray Wiring Diagram Main Board CN20 Developer Motor nDEV_MOT_READY DRV_MOT_CLK nDEV_MOT_ON DEV_MOT_DIR RARE m amp ABO N CN21 PTL1 PTL2 5VDC PTL_ON KK CN23 P J5 43 3VDC AC EXIT_SENS GND Y UL AA TE Exit Sensor Y LLL Joint Board 24VDC A CN24 424VDC pur MAIN CLUTCH MP CLUTCH REGI CLUTCH MP_EMPTY ra 3 8VDC ES CASSETTE DETECT GND 2 TEMP 1 ae Main Solenoid MP Solenoid Tray 1 MPT Paper Empty CNT Sensor 3 3VDC SIGNAL GND m a w Qo o 10 O1 WN m RO O o do N 24VDC savocl CN N a CN7 24VDC 18 Optional 3 3VDC 17 Tray 3 Board SCF EMPTY 16 SCF RXD 15 SCF DETECT SCF TXD 13 GND GND GND GND GND VI CANDOR WD N A VIN vaki AE UIUIUIUIUIUIUIUIUIUIL ND C0 BR O1 s3600 021 Phaser 3600Printer Service Manual 9 15 Plug Jack and Wiring Diagrams LSU and M
112. lamp PL 1 4 56 A Warning Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1 Remove the Fuser Assembly from the Printer page 7 54 2 Remove the Heat Roller and Bushing page 7 60 3 Slide the Dual lamp free from the Heat Roller s3600 120 Caution Do not touch the lamps when re installing Fingerprints can cause the lamps to burn out prematurely 7 66 Phaser 3600 Printer Service Manual Service Parts Disassembly Pressure Roller PL 1 4 66 and Bushing PL 1 4 50 A Warning Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1 Remove the Fuser Assembly from the Printer page 7 54 2 Remove two screws from the Fuser assembly see inset below s3600 114 Phaser 3600 Printer Service Manual 7 67 Service Parts Disassembly 3 Unfold the Fuser Assembly to expose the Heat Roller and the Pressure Roller s3600 124 4 Facing the Fuser Connector disconnect the single wire connector from the right tab of the Thermistor 5 Remove two screws 8mm securing the Fuser connector to the Fuser Assembly 6 Remove one screw from each end of the Pressure Roller s3600 128 Phaser 3600 Printer Service Manual 7 68 Service Parts Disassembly Sy le 7 Slide the retaining plate and bushing off of each end of the Pressure Roller 8 Lift the Pressure Roller free from the assembly s3600 130 Replacement Note Slide the retaining plates
113. list If you continually press this control the menu items will wrap OK Executes the highlighted menu item Menu Map The Menu Map is a visual representation of the Control Panel settings and information pages All Menu Map settings are documented in the User Guide Error and Warning Messages When there is a problem with the printer the Control Panel LED 3 blinks red for an error and a warning An error or warning message is displayed in the Alphanumeric Display 5 Phaser 3600 Printer Service Manual 1 5 General Information Printer Specifications Printer Location and Clearance Place the printer in a dust free area where the temperature range is 50 degrees F to 89 degrees F 10 degrees C to 32 degrees C and the relative humidity range is between 20 to 80 1 6 Place the printer in an area where there is adequate space for ventilation operation and servicing See the clearance graphic below Do not block or cover the slots and openings on the printer The printer can overheat without adequate ventilation For altitudes under 2 050 meters 6 726 feet use the Low Altitude setting For altitudes over 2 050 meters 6 726 feet use the High Altitude setting Do not place the printer near a heat source Do not place the printer in direct sunlight Do not place the printer in line with the cold air flow from an air conditioning system Place the printer on a level solid surface with adequate str
114. listed in the second column 3 Use the coordinates to locate the connection indicated on the map with its P J designation number Phaser 3600Printer Service Manual Plug Jack and Wiring Diagrams Plug Jack and Connector Locators and Maps Printer Plug Jack Connector Designators Phaser 3600Printer Service Manual Print Engine Plug Jack Designator Table Map P J Coordinates Remarks 1 P J1 H 143 Connects the Laser Scan Unit to CN10 of the Main Board 2 CN3 J 139 Connects the Ethernet to the Main Board 2 CN4 1 134 Connects the USB to the Main Board 2 CN6 H 134 Connects the Serial port to the Main Board 2 P J9 F 134 Connects Main Board to the Thermistor 2 P J11 E 134 Connects the main board to the Duplex Solenoid 2 P J12 D 134 Connects the Main Board to the 1st RAM DIMM 2 P J14 F 142 Connects the Main Board to the 2nd RAM DIMM 2 P J16 C 134 Connects the Main Board to the Control Panel 2 P J17 C 138 Connects the Main Board to the Duplex Board 2 P J18 C 139 Connects the Main Board to the Main Motor 2 P J19 C 136 Connects the Main Board to CONA of the SMPS Board 2 P J20 B 135 Connects the Main Board to the Developer Motor 2 P J21 B 136 Connects the Main Board to the PTL Board 2 P J22 B 137 Connects the Main Board to CON3 of the SMPS Board 2 P J23 B 139 Connects the Main Board to P J5 of the Exit Sensor 2 P J24 B 140 Con
115. ll colors Initial Actions Phaser 3600 Printer Service Manual m Check the paper path for any debris m Check the Control Panel settings for proper print settings Troubleshooting Reference Table Print Quality Troubleshooting Applicable Parts Example Print Transfer Roller PL1 1 7 m Laser Scan Unit PL1 1 15 m Print Cartridge PL1 1 34 um HVPS PL1 1 29 m Main Board PL1 1 19 Light or Undertone Print Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Print a demo page Go to step 3 Go to step 2 Does the error still occur when printing 2 Print a customer application page Go to step 3 Complete Does the error still occur 3 Check the paper condition Go to step 4 Replace the Is the paper dry recommended type paper and loaded in the correct position 4 Check the Print Cartridge for damages Replace the Go to step 5 Is the Print Cartridge damaged Print Cartridge 5 Check the Transfer Roller for correct Complete Go to step 6 installation Reseat the Transfer Roller page 7 43 Does the image quality improve 6 Replace the Main Board page 7 39 Complete Go to Step 7 Does the image quality improve 5 11 Print Quality Troubleshooting Troubleshooting Procedure Table continued Step Actions and Questions Yes No 7 Check the laser beam path Remove the Go to step 8 Is there any debris between the Laser deb
116. ne bla Bde ele prada 7 10 Access Door PE 1 2 LT erba ar o taa RES 1 12 Control Panel PLV2 9 v0 cack s eee Pese Pesce bibend e rex bt en b ER nd 1 13 Tray 1 MPT ASSembly 00 e RII hh ra 7 14 Inner Cover PL 1 2 5 c2taawed ket RR ERRPURERSRMRERR MAI iaa bea deb e a A 7 16 Tray 1 MPT Knock Up Plate Only PL 1 1 3 7 17 Tray 1 MPT Pick Up Rack PL 1 3 2 2 0 ccc cece tenn teen ene ee ees 7 18 Retard Assembly PL 1 3 49 220 7 19 Tray 1 MPT Separator Pad Assembly PL 1 3 4 7 20 Tray 1 MPT Feed Sensor PL1 3 97 7 21 Paper Tray Empty Sensor PL1 3 95 7 22 Paper Tray Empty Actuator PL1 3 58 7 23 Sub Toner Low Sensor Board PL1 3 47 7 24 Pick Roller and Shaft PL 1 3 2 5 7 25 Tray 1 MPT Pick Roller Only PL 1 3 2 4 7 28 Tray 1 MPT Solenoid PL 1 1 26 1 29 Phaser 3600 Color Laser Printer Service Manual 3 Tray 2 Pick Up Assembly and Rollers 7 30 Pick Up Gear and Bear
117. nects the Main Board to CN12 of the Joint Board 2 P J25 B 141 Connects the Main Board to he Optional Tray 3 2 P J26 D 134 Connects the Main Board to the Rear Fan 3 P J1 A 140 Connects the SMPS Board to the AC inlet 3 P J2 A 141 Connects the SMPS Board to the Fuser 3 P J3 D 141 Connects the SMPS Board to CN23 of the Main Board 3 P JA J 141 Connects the SMPS Board to CN20 of the Main Board 3 P J5 H 141 Connects the SMPS Board to the Jam Cover Switch 3 P J6 J 140 Connects the SMPS Board to CN1 of the HVPS Board 4 P J1 J 134 Connects the HVPS Board to CONG of the SMPS Board 4 P J2 K 136 Connects the HVPS Board to CN2 of the Toner Sensor Board 4 P J8 J 139 Connects the HVPS Board to the Feed Sensor 4 MP J2 J 140 Connects the HVPS Board to the Tray Empty Sensor 9 3 Plug Jack and Wiring Diagrams Map 1 LSU and Fuser s3600 101 9 4 Phaser 3600Printer Service Manual Plug Jack and Wiring Diagrams Map 2 Main Board Pafeofofo e ro s xfo CN26 CN9 CN6 CN16 a CN8 CN4 134 CN20 SE A E O o 135 CN21 o 9 CNi9 T y ER 136 i o 7 LL O cN22 11 L 137 WO E CN2 mm C17 1l z m 138 O o l eme O SEN e gl rr ik CN23 7 fo 140 CN24 Al O 141 Y cas A gt 142 Elan i CN14 E
118. nge Open the Top Cover for access Remove the Print Cartridge and protect it from light exposure Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the 2 screws located on the front of the Top Cover en the rear right side of the printer remove 1 screw securing the Top over oc BR wn s3600 031 7 Release 3 tabs one on the left one on the right and one on the rear of the Top Cover Replacement Note You may need to open the Rear Cover slightly before reinstalling the Top Cover 7 10 Phaser 3600 Printer Service Manual Service Parts Disassembly s3600 010 8 Disconnect the Control Panel wiring harness CN17 from the Main Board Replacement Note Note the position of the wiring harness and ferrite coil for reassembly 7 11 Phaser 3600 Printer Service Manual Service Parts Disassembly Access Door PL 1 2 1 1 Note Since the top cover is being redesigned the following instructions will change Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Remove the 2 screws and stoppers from the Access Door Remove the Access Door from the Top Cover by flexing the 2 tabs c BR ND s3600 104 7 12 Phaser 3600 Printer Service Manual Service Parts Disassembly Control Panel PL 1 2 9 1 Remove the Top Cover pag
119. oids Diagnostics also contain built in test prints cleaning procedures printer status and some NVRAM access Service diagnostics are to be executed through the control panel by a certified service technician only Service Diagnostics Menu Map Entering Service Diagnostics D pd SY 3600 113 1 Turn the printer power OFF 2 While holding down the OK button 1 turn the printer back ON 2 Note Refer to the Diagnostic Test Menu Map on page 3 5 to see the description of all component tests Phaser 3600 Printer Service Manual 3 3 Error Messages Service Diagnostic Control Panel Button Descriptions 1 Cancel Button 2 Return Button 3 On line Data Error LED 4 Menu Button 5 Status Error Messages and Menus 6 Up Arrow Button 7 OK Button 8 Down Arrow Button s3600 002 The alphanumeric display provides status messages and control panel menus Diagnostic Control Panel Buttons Button Function BACK Returns to the prior higher level menu structure if available Stops the actively running test CANCEL Terminates the current test MENU Cycles through all of the top level menu items UP Scrolls up one menu item within a menu list This control does not wrap Used to increment values in tests requiring user input DOWN Scrolls up one menu item within a menu list This control does not wrap Used to increment values in
120. oltage Measurements on page 4 5 5 Replace the Power Supply Board Replace the Main Board 7 Replace the Control Panel o Control Panel LED is On Control Panel Display Is Blank 1 Remove and reseat the Control Panel wiring to the Main Board 2 Replace the Control Panel 3 Replace the Main Board 4 4 Phaser 3600 Printer Service Manual General Troubleshooting Power Supply Troubleshooting 1 Check the voltage at the AC wall outlet there should be approximately 110 VAC or 220 VAC if the printer is a 220 V model atthe AC wall outlet 2 Check the power cord for defects damage or a loose connection Check the AC switch harness for continuity 4 Verify the Power Supply is operating correctly Taking Voltage Measurements Phaser 3600 Printer Service Manual To locate connectors or test points refer to Printer Plug Jack Connector Designators on page 9 3 for more information Unless otherwise specified the following voltage tolerances are used within this section Stated Measured 3 3 VDC 3 135 to 43 465 VDC 5 0 VDC 4 75 to 45 25 VDC 24 0 VDC 21 6 to 26 4 VDC 0 0 VDC Less than 0 5 VDC 4 5 General Troubleshooting 4 6 Phaser 3600 Printer Service Manual Print Quality Troubleshooting In this chapter m Print Quality Problems Overview m Repeating Defects m Control Panel Internal Test Print m Image Quality Troubleshooting Chapter 5 Print Quality Tro
121. onverter The Fuser Assembly contains the entire Fuser Subsystem and is a field replaceable unit The Fuser Assembly contains the following components m Heat Element and Heat Roller Two quartz lamps operate as the heating elements which generate the heat inside the Heat Roller The Heat Roller melts the toner so it adheres to the paper m Pressure Roller Provides pressure on the opposite side of the print media so the Heat Roller can embed the melted toner in the media m Thermistor Monitors the surface temperature of the Heat Roller This information is used to control the heat lamp and thus keep the Heat Roller at the correct temperature m Thermostat Prevents overheat damage when unexpected system faults occur Phaser 3600 Printer Service Manual Theory of Operation Duplex and Tray Assemblies Duplex Assembly The Optional Duplex Assembly automatically prints on both sides of a sheet of paper With the Duplex Assembly the printer can print A4 sized paper up to 26 inches per minute IPM and letter sized paper up to 27 IPM The duplexer also supports the Oficio and Folio paper sizes The components of the Duplex unit include a paper transfer function paper guide function jam removing function paper sensing function and main board supporting function You can remove a jam at the front of the assembly by merely opening up the cassette and paper guide To remove a jam in a rear part of the assembly merely open the rear c
122. otation PLX X X indicates that this component is listed in the Parts List m Bold arrows in an illustration show direction of movement when removing or replacing a component Standard Orientation of the Printer When needed the orientation of the printer is called out in the procedure for locating printer parts Refer to the printer orientation graphic for locating the right left front and back sides of the printer s3600 008 Phaser 3600 Printer Service Manual 7 5 Service Parts Disassembly Covers and Control Panel Right Cover PL 1 2 3 1 Turn OFF the Printer Power Switch and unplug the power cord 2 Remove the Duplex Unit page 7 37 3 Remove the 2 rear screws securing the Right Cover to the rear of the printer s3600 027 4 Remove the right side access cover 5 To remove from the printer slide the Right Cover towards the rear of the printer to release the 3 tabs on the top of the cover and 3 hooks on the bottom of the cover Replacement Note When reinstalling the cover insert the 3 bottom hooks first then slide the cover from the rear to the front Make sure the cover is securely behind the 3 tabs 7 6 Phaser 3600 Printer Service Manual Service Parts Disassembly Left Cover PL 1 2 2 Disconnect the power cord Remove the Duplex Unit page 7 37 Open the Rear Cover for access to the top rear screw Remove the 2 rear screws of the cover Slide
123. ove 5 13 Print Quality Troubleshooting 5 14 Troubleshooting Procedure Table continued Step Actions and Questions Yes No 6 Check the wiring and connectors Go to step 7 Reconnect the between the Laser Scan Unit and the connectors Main Board then go to step Are the connectors securely 7 connected 7 Replace the Laser Scan Unit Complete Go to step 8 page 7 70 Does the image quality improve 8 Check the Main Board for correct Complete Go to step 9 installation Reseat the Main Board page 7 39 Does the image quality improve 9 Check the HVPS for correct Complete Go to step 10 installation Reseat the HVPS Board page 7 75 Does the image quality improve 10 Replace the Print Cartridge Complete Replace the Does the image quality improve Main Board page 7 39 Phaser 3600 Printer Service Manual Print Quality Troubleshooting Background Contamination There is toner contamination on all or most of the page The contamination appears as a very light gray dusting Initial Actions m Check the paper transfer path m Ensure there are no debris on the transfer path m Clean the Pre transfer Lamp PTL Troubleshooting Reference Table Applicable Parts Example Print Transfer Roller PL1 1 7 m Registration Assembly PL1 1 12 m Print Cartridge PL1 1 34 HVPS PL1 1 29 Background Contamination Troubleshooting Procedure Table
124. over Tray 2 and Optional Tray 3 Assemblies Phaser 3600 Printer Service Manual You can increase the paper handling capacity of the printer by installing Tray 2 or an optional Tray 3 Each tray holds 500 sheets of paper Cassette is same size as the Tray1 MPT Each tray includes a separate driving mechanism with the following features m Feeding Method Cassette Type m Feeding Standard Center Loading m Feeding Capacity Cassette 500 Sheets 75g 20lb Paper Standard m Paper Detecting Sensor Photo Sensor m Paper Size Sensor Yes 2 9 Theory of Operation Printer Controls Paper Size Control The paper size selection for Tray 2 and Tray 3 is set by moving the paper guide in the tray This in turn sets the plastic fingers on the side of the paper tray to a specific postion The position of the fingers activates the correct combination of the three paper size switches located in each paper tray slot for the selected paper size Additionally the back of the tray must be pulled down in order to select the two largest sizes US Folio and Legal Not all sizes can be used in both trays See Media and Tray Specifications on page 10 for a complete listing of the media types for each tray Additional media types can be used in Tray 1 MPT After inserting the media in Tray 1 use the Control Panel controls to select the media type Paper Size Switch Paper Size SW1 Sw2 SW3 LEGA
125. r Motor direction or stop On Off Phaser 3600 Printer Service Manual Diagnostic Menu Map Options Error Messages Main Menu Sub Menu Description Function Control Panel Display Motors T3 Feed The motor will run on the forward T3 Feed Motor Cont Motor direction or stop On 0ff T4 Feed The motor will run on the forward T4 Feed Motor Motor direction or stop On Off Fans Fuser Fan The fan will run or stop Fuser Fan Test 3 On Off Fuser Fan Check whether the fan is in the Fuser Fan Rdy Rdy locked state Ready Not Ready SMPS Fan The fan will run or stop SMPS Fan On Off SMPS Fan Check whether the fan is in the SMPS Fan Rdy Rdy locked state Ready Not Ready Duplex Fan The fan will run or stop Duplex Fan On Off Clutches T1 P up The clutch will run or stop T1 P up Clutch Solenoids Clutch On Off Test 4 T2 P up The clutch will run or stop T2 P up Clutch Clutch On Off T3 P up The clutch will run or stop T3 P up Clutch Clutch On Off T4 P up The clutch will run or stop T4 P up Clutch Clutch On Off Bypass The clutch will run or stop Bypass Clutch Clutch On Off Duplex Sol The solenoid will run or stop Duplex Sol On Off Fuser Ctrl Fuser Bias The bias will have the previously Fuser Bias Test 5 saved value On Off Temp The fuser unit will control the power Temp Control Control for fixing
126. r Scan Unit Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Remove the cover frame exit cover to expose the Laser Scan Unit window 5 Use a dry lint free cloth to wipe any dust off of the window AO NN pee PS NS s3600 091 Cleaning the Print Cartridge Caution Do not expose the Print Cartridge to light for more than 5 minutes Cover the Print Cartridge to avoid damage 1 Open the Top Cover 2 Remove the Print Cartridge 3 Use a dry lint free cloth to wipe any dust and or spilled toner from the Print Cartridge area Remove any paper debris from the area Phaser 3600 Printer Service Manual 6 3 Cleaning and Maintenance Control Panel Maintenance Cleaning the Drum To clean the Drum from the Control Panel 1 Turn on the printer and wait for the Ready display on the Control Panel 2 Press Menu gt System Setup gt Maintenance gt Clean Drum 3 Select Print Yes Note A test page will print notifying you that the Clean Drum cycle has successfully completed Cleaning the Fuser To clean the Fuser from the Control Panel 1 Turn on the printer and wait for the Ready display on the Control Panel 2 Press Menu gt System Setup gt Maintenance gt Clean Fuser 3 Select Print Yes Note A test page will print notifying you that the Clean Fuser cycle has successfully completed 6 4 Phaser 3600 Printer Service Manual ser
127. r you clean the product Electrostatic Discharge Precautions Some semiconductor components and the respective sub assemblies that contain them are vulnerable to damage by Electrostatic Discharge ESD These components include Integrated Circuits ICs Large Scale Integrated circuits LSIs field effect transistors and other semiconductor chip components The following techniques will reduce the occurrence of component damage caused by static electricity Be sure the power is Off to the chassis or circuit board and observe all other safety precautions vi Immediately before handling any semiconductor components assemblies drain the electrostatic charge from your body This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source Wearing a wrist strap will also prevent accumulation of additional bodily static charges Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock After removing a static sensitive assembly from its anti static bag place it on a grounded conductive surface If the anti static bag is conductive you may ground the bag and use it as a conductive surface Do not use freon propelled chemicals These can generate electrical charges sufficient to damage some devices Do not remove a replacement component or electrical sub assembly from its protective package until you are ready to install it
128. recautions Power Source For 115 VAC printers do not apply more than 127 volts RMS between the supply conductors or between either supply conductor and ground For 230 VAC printers do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground Use only the specified power cord and connector This manual assumes that the reader is a qualified service technician Plug the three wire power cord with grounding prong into a grounded AC outlet only If necessary contact a licensed electrician to install a properly grounded outlet If the product loses its ground connection contact with conductive parts may cause an electrical shock A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation Disconnecting Power A Phaser 3600 Printer Service Manual Warning Turning the power Off using the power switch does not completely de energize the printer You must also disconnect the power cord from the printer s Alternating Current AC inlet Disconnect the power cord by pulling the plug not the cord Disconnect the power cord in the following cases m ifthe power cord or plug is frayed or otherwise damaged m if any liquid or foreign material is spilled into the product m ifthe printer is exposed to any excess moisture m ifthe printer is dropped or damaged m if you suspect that the product needs servicing or repair m wheneve
129. rect media 3 Check the paper condition Go to step 4 Replace the Is the paper dry recommended type paper and loaded in the correct position 4 Check the Print Cartridge for damages Go to step 5 Replace the Is the Print Cartridge damaged Print Cartridge 5 24 Phaser 3600 Printer Service Manual Troubleshooting Procedure Table continued Print Quality Troubleshooting Step Actions and Questions Yes No 5 Check the Fuser for correct Complete Replace the installation Reseat the Fuser Fuser page 7 54 page 7 54 Does the image quality improve Skew The printed image is not parallel with both sides of the paper Initial Actions m Check the paper transfer path m Ensure there are no debris on the transfer path Troubleshooting Reference Table Applicable Notes Example Print Retard Assembly PL1 3 49 m Tray 1 MPT Assembly PL1 2 35 Separator Pad Assembly PL1 3 4 Feed Idle Unit PL1 3 50 Registration Assembly PL1 1 12 Duplex Unit PL2 3 0 Skew 2 Troubleshooting Procedure Table Step Action and Questions Yes No 1 Print a demo page Go to step 3 Go to step 2 Does the error still occur when printing 2 Print a customer application page Go to step 3 Complete Does the error still occur 3 Check the paper condition Go to step 4 Replace the Is the paper dry recommended type paper and loaded in the corr
130. rews 4 on the Main Board and 2 on the outside chassis to the parallel connector securing the Main Board to the printer 4 Position the retainers on the parallel port connector straight out from the connector for removal 5 Move the board toward the front of the printer so the connectors clear the bracket and remove the Main Board to the right s3600 051 Phaser 3600 Printer Service Manual 7 39 Service Parts Disassembly Main Solenoid PL 1 1 25 1 Remove the Right Cover page 7 6 2 Disconnect the connector CN10 from the Joint Board to the Main Solenoid 3 Remove 1 screw securing the Main Solenoid and remove from the chassis HT s3600 052 7 40 Phaser 3600 Printer Service Manual Service Parts Disassembly Registration Assembly PL 1 1 12 Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Locate the Gear Cap on the right side of the Registration Assembly Lift up on the tab to release and remove the Gear Cap from the assembly O1 BR ND Gear Cap s3600 053 6 Remove the 4 screws securing the Registration Assembly to the printer 7 Remove the Registration Assembly from the printer Phaser 3600 Printer Service Manual 7 41 Service Parts Disassembly s3600 054 UR IWS A S OA Phaser 3600 Printer Service Manual 7 42 Servi
131. ris then go Scan Unit and Transfer Roller to step 5 8 Replace the Laser Scan Unit Complete Go to step 9 page 7 70 Does the image quality improve 9 Check the HVPS for correct Complete Replace the installation Reseat the HVPS Board HVPS Board Does the image quality improve page 7 39 5 12 Phaser 3600 Printer Service Manual Black Print Initial Actions Phaser 3600 Printer Service Manual The entire image is black m Check the paper transfer path Troubleshooting Reference Table Print Quality Troubleshooting m Ensure there is no debris on the transfer path Applicable Parts Example Print Transfer Roller PL1 1 7 m Laser Scan Unit PL1 1 15 m Print Cartridge PL1 1 34 um HVPS PL1 1 29 a Main Board PL1 1 19 Black Print Troubleshooting Procedure Table Actions and Questions Yes No Print a demo page Go to step 3 Go to step 2 Does the error still occur when printing Print a customer application page Go to step 3 Complete Does the error still occur Check the paper condition Go to step 4 Replace the Is the paper dry recommended type paper and loaded in the correct position Check the Print Cartridge for damages Replace the Go to step 5 Is the Print Cartridge damaged Print Cartridge Check the Transfer Roller for correct Complete Go to step 6 installation Reseat the Transfer Roller page 7 43 Does the image quality impr
132. rrents Warning Labels Read and obey all posted warning labels Throughout the printer warning labels are displayed on potentially dangerous components As you service the printer check to make certain that all warning labels remain in place Safety Interlocks Make sure all covers are in place and all Interlock Switches are functioning correctly after you have completed a printer service call If you bypass an Interlock Switch during a service call use extreme caution when working on or around the printer Class 1 Laser Product The Phaser 3600 is certified to comply with Laser Product Performance Standards set by the U S Department of Health and Human Services as a Class 1 Laser Product This means that this product does not emit hazardous laser radiation which is possible only because the laser beam is totally enclosed during all modes of customer operation When servicing the printer or laser unit follow the procedures specified in this manual and there will be no hazards from the laser Phaser 3600 Printer Service Manual vii Servicing Electrical Components Before starting any service procedure switch the printer power Off and unplug the power cord from the wall outlet If you must service the printer with power applied be aware of the potential for electrical shock A Warning Do not touch any electrical component unless you are instructed to do so by a service procedure Servicing Mechanical Components When
133. rtical Optional Tray 3 2 0 mm 0 08 Simplex amp Horizontal 25mm Duplex amp Horizontal 2 5 mm 0 10 Simplex amp Vertical 0 1 0 1 3 0 mm 0 12 Duplex amp Vertical Phaser 3600 Printer Service Manual Electrical Specifications General Information Power Rating and Line Voltages Characteristic Specification Primary line voltages 110 127 V Printer 100 135 V 13 amp circuit 220 240 V Printer 180 264 V 7 8 amp circuit Primary line voltage frequency range 100 135 V Printer 50 60 Hz 3 Hz 220 240 V Printer 50 60 Hz 3 Hz Power consumption Printing 550 Watts average Sleep under 10 Watts Environmental Specification Operating Environment Characteristic Specification Optimal Temperature 10 30 degrees C 50 60 degrees F Optimal Humidity 20 80 Relative Humidity Altitude Operating Low Altitude Setting High Altitude Setting Transportation 0 2 500 meters 8 200 ft 0 2 050 meters 6 726 ft 2 050 2 500 meters 6 726 8 200 ft 0 6 092 meters 20 000 ft Acoustic Noise Idle Printing 35 0db or less 49 0db or less Acoustic Characteristic Mode Specification Printing Simplex from Tray1 Less than 56 0 dBA Simplex from MP Less than 56 0 dBA Simplex from SCF Less than 59 0 dBA Duplex from Tray1 Less than 59 0 dB
134. s Spots of toner are randomly scattered across the page Initial Actions m Check the paper transfer path m Ensure there are no debris on the transfer path Troubleshooting Reference Table Applicable Parts Example Print a Transfer Roller PL1 1 7 m Print Cartridge PL1 1 34 m Fuser PL1 4 1 Random Spots A Warning Ensure to wait for the Fuser to cool down before starting the procedure Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Print a demo page Go to step 3 Go to step 2 Does the error still occur when printing 2 Print a customer application page Go to step 3 Complete Does the error still occur 3 Check for any debris on the document Remove the Go to step 4 glass and the CVT window debris Are there any debris 4 Check for spot s regular intervals Go to step 5 Complete Are there any spots on the page 5 20 Phaser 3600 Printer Service Manual Print Quality Troubleshooting Troubleshooting Procedure Table continued Step Actions and Questions Yes No 5 Check the Print Cartridge for damages Replace the Go to step 6 Is the Print Cartridge damaged Print Cartridge 6 Check the Transfer Roller for correct Complete Go to step 7 installation Reseat the Transfer Roller page 7 43 Does the image quality improve 7 Check the Fuser for correct Complete Replace the installation Reseat the Fuser Fuser
135. servicing mechanical components within the printer manually rotate the Drive Assemblies Rollers and Gears A Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running Servicing Fuser Components A Warning This printer uses heat to fuse the toner image to paper The Fuser is VERY HOT Turn the printer power Off and wait at least 5 minutes for the Fuser to cool before attempting to service the Fuser or adjacent components viii Phaser 3600 Printer Service Manual Regulatory Information Xerox has tested this product to electromagnetic emission and immunity standards These standards are designed to mitigate interference caused or received by this product in a typical office environment United States FCC Regulations This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the Federal Communications Commission FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy If it is not installed and used in accordance with these instructions it may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception w
136. step 7 Replace the Is the paper dry recommended type paper and loaded in the correct position Phaser 3600 Printer Service Manual 5 27 Print Quality Troubleshooting Troubleshooting Procedure Table continued Step Actions and Questions Yes No 7 Check the Registration Assembly Replace the Go to step 8 Is there any damage to the Registration Registration Assembly Assembly page 7 41 8 Check the Transfer Roller for correct Complete Go to step 9 installation Reseat the Transfer Roller page 7 43 Does the image quality improve 9 Check for debris in the laser beam Remove the Go to step 10 path between the Laser Scan Unitand debris the Registration Assembly Is there any debris 10 Does the image quality improve Complete Replace the Laser Scan Unit page 7 70 5 28 Phaser 3600 Printer Service Manual Cleaning and Maintenance m Service Maintenance Procedure m General Cleaning Chapter 6 Cleaning and Maintenance Service Maintenance Procedure Perform the following procedures whenever you check service or repair a printer Cleaning the printer as outlined in the following steps assures proper operation of the printer and reduces the probability of having to service the printer in the future The frequency of use Average Monthly Print Volume AMPV type of media printed on and operating environment are factors in determining how critical cleaning t
137. stic Menu Map Options Error Messages Main Menu Sub Menu Description Function Control Panel Display Sensor Outbin The first value lists normal display Outbin Sensor Status cont Sensor before touching the sensor and the Normal Full second value lists normal display aftertouching the sensor Bypass The first value lists normal display Bypass Empty Empty before touching the sensor and the Empty Present second value lists normal display aftertouching the sensor T1 Paper The first value lists normal display T1 Paper Empty Empty before touching the sensor and the Empty Present second value lists normal display aftertouching the sensor T2 Paper The first value lists normal display T2 Paper Empty Empty before touching the sensor and the Empty Present second value lists normal display aftertouching the sensor T3 Paper The first value lists normal display T3 Paper Empty Empty before touching the sensor and the Empty Present second value lists normal display aftertouching the sensor T4 Paper The first value lists normal display T4 Paper Empty Empty before touching the sensor and the Empty Present second value lists normal display aftertouching the sensor T1 PSize0 The first value lists normal display T1 Psize0 Sen Sensor before touching the sensor and the Low High second value lists normal display aftertouching the sensor T1 PSize1 The first valu
138. t 1 Remove the defective Duplex Unit 2 Remove the new Duplex Unit from its plastic packaging and reinsert in the same slot s3600 089 Phaser 3600 Printer Service Manual 7 87 Service Parts Disassembly Main Drive and Registration Assemblies Main Drive Assembly PL 1 1 18 Caution When removing screw 3 in step 3 make sure you do not bend or break the wire connected to the varistor Also screw 4 has a grounding strap that must be replaced during reassembly 1 Remove the Right Cover page 7 6 2 Disconnect the CN1 cable on the Main Drive assembly The other end is attached to the Main Board at CN19 DC Motor 3 Remove all 6 screws in order The screw numbers are labeled on the main assembly plate 4 Remove the Main Drive Assembly Caution Be careful not to reposition the gears s3600 050 7 38 Phaser 3600 Printer Service Manual Service Parts Disassembly Replacement Procedure When reassembling 1 Line up the metal shaft of the main drive assembly to the correct hole 2 f necessary lubricate the gears with Xerox Plastislip grease lubricant PN 043E00550 3 Install screws in order on the etched plate when replacing the Main Drive 1 Caution Be careful not to bend the Varistor on screw 3 Main Board PL 1 1 19 1 Remove the Right Cover page 7 6 2 Disconnect all connectors from the Main Board 3 Remove the 6 sc
139. t for the printer 4 Verify the AC input power supply is within proper specifications by measuring the voltage at the electric outlet while the printer is running Step 2 Inspect and Clean the Printer 1 Switch OFF printer power and disconnect the AC power cord from the wall outlet 2 Verify the power cord is free from damage or short circuit and is connected properly 3 Remove the Print Cartridge and protect it from light then inspect the printer interior and remove any foreign matter obstructions or loose toner 4 Inspect the interior of the printer for damaged wires loose connections toner leakage and damaged or obviously worn parts 5 Do not use solvents or chemical cleaners to clean the printer interior 6 Do not use any type of oil or lubricant on printer parts 7 Use only an approved toner vacuum 8 Clean all rubber rollers with a lint free cloth dampened slightly with cold water 9 Replace any service items that have reached their 150 000 end of life Step 3 Find the Cause of the Problem 1 Use the Repair Analysis Procedures to find the cause of the problem 2 Use Diagnostics to check printer and optional components 3 Use the Wiring Diagrams to locate test points 4 Take voltage readings at various test points as instructed in the appropriate troubleshooting procedure Step 4 Correct the Problem 1 Use the Parts List to locate a part number 2 Use the Repair and Adjustments Proce
140. tection result is low the heater lamp is turned ON The fuser control circuit keeps the Fuser temperature at 185 C during printing and at 145 C during standby m When the power voltage for the printer is too high or too low the Fuser is stopped to protect the Fuser m When the AC voltage is not applied to the Fuser control circuit the fuser will not work and a Fuser Low Heat Error will occur m When the temperature of the Fuser is too high an Engine Overheat error occurs if the cooling operation is insufficient Error Description Error Message Open Heat Error When warming up the Fuser has been Fuser Failure lower than 60 degrees C for over 35 seconds Low Heat Error Stand by Engine Low Heat Error Lower than 130 degrees C for over 10 seconds m Printing m Up to 2 consecutive pages Lower than 155 degrees C for over 7 seconds From 3 consecutive pages Lower than 25 degrees C than the fixed fusing temperature over 7 seconds Over Heat Error Temperature is higher than 230 degrees Engine Over Heat C over 10 seconds Error 2 12 Phaser 3600 Printer Service Manual Sensor Functions Sensor Types Theory of Operation The types of sensors used vary with function In general there are three types in use Photo Sensors Phaser 3600 Printer Service Manual Two types of photo sensors are used photo reflective and photo receptive Photo reflective sensors use light reflected back from
141. ter you have switched OFF printer power for the Fuser to cool before you work on or around the Fuser Phaser 3600 Printer Service Manual Phaser 3600 Printer Service Manual Service Parts Disassembly 5 Tray 2 can interfere with the removal of many printer parts Remove Tray 2 before further disassembly Note Part names that appear in the disassembly procedures may not exactly match the names that appear in the Parts List For example a part called the Registration Transport Assembly may appear on the Parts List as Assembly Transport Regi Caution Many parts are secured by plastic tabs DO NOT over flex or force these parts Do not over torque the screws threaded into plastic parts Always use the correct type and size screw Using the wrong screw can damage tapped holes Do not use excessive force to either remove or install either a screw or a printer part A spring hook is required for removal and replacement of the various springs in the printer Springs can be damaged using pliers or other tools for this task Warning Unplug the AC power cord from the wall outlet before removing any printer part 7 3 Service Parts Disassembly 7 4 Fastener Types The following table lists the primary types of Posi Drive screws used to assemble the printer The procedures provide dimensional specifications for screws being removed Posi Drive Screw Types used in the Printer Type Application Shape Characteristics Sel
142. tests requiring user input OK Enters the highlighted menu Executes the current test item Used to select the value entered by the user 3 4 Phaser 3600 Printer Service Manual Error Messages Diagnostic Test Menu Map Note For definitions of Acronyms and Abbreviations listed in the Diagnostic Menu Map below refer to the Appendix page A 2 Diagnostic Menu Map Options Main Menu Sub Menu Description Function Control Panel Display Cover Status Top Cover If the cover is opened Open Top Cover Test 0 message will be displayed and if Closed Open not Closed displayed Tray 1 If the Tray is opened Open Tray 1 Cassette Cassette message will be displayed and if T1 thru T3 not Closed displayed refer to Tray 1 thru Tray3 respectfully T4 is not supported Tray 2 If the Tray is opened Open Tray 2 Cassette Cassette message will be displayed and if not Closed displayed Tray 3 If the Tray is opened Open Tray 3 Cassette Cassette message will be displayed and if not Closed displayed Fuser Door If the Door is opened Open Fuser Door message will be displayed and if not Closed displayed Closed Open Phaser 3600 Printer Service Manual 3 5 Error Messages 3 6 Diagnostic Menu Map Options Main Menu Sub Menu Description Function Control Panel Display Sensor Registration The first value lists normal
143. the Retard Roller to remove the roller 13 Remove 4 screws securing the Pick Up Assembly and maneuver the pick assembly out of the printer 14 Remove the Front Bottom Cross Bar secured by 2 screws and the ground strap Phaser 3600 Printer Service Manual 7 31 Service Parts Disassembly amp 3600 047 Replacement Note When you are replacing the Cross Bar place the ground strap between the bar and the printer before you insert the screw Note Remove a small support metal bracket and screw separately from the main feeder assembly while removing the 4 securing screws Also remove a rubber spacing block held in place by the metal support bracket 7 32 Phaser 3600 Printer Service Manual Service Parts Disassembly s3600 088 15 Release the plastic tab on the actuator that is mounted on the metal plate Once the screw is out just lift it free from the boss 16 Remove the 4 screws securing the pick assembly and maneuver the pick assembly out of the printer A NS y Na ey BDD Y o Y e S z CEJ M ILL N s3600 048 Phaser 3600 Printer Service Manual 7 33 Service Parts Disassembly Pick Up Gear and Bearing PL 1 1 21 1 Perform all steps for removing the Tray 2 Pick Up Assembly and Rollers page 7 30 2 Remove the pick up gear 3 Remove the locking bearing
144. tic tray links to the top portion of the Knock Up plate 2 Attach the bottom portion of the Knock Up Plate to the plastic mounting links on the chassis 3 Slide the assembly onto the four pivot points 4 Insert the top portion of the secured tray links through the Knock Up Plate indentations on the track Phaser 3600 Printer Service Manual 7 15 Service Parts Disassembly Inner Cover PL 1 2 5 1 Remove the Top Cover page 7 10 2 Remove the Tray 1 MPT Assembly page 7 14 3 Open or remove Tray 2 for better access 4 Remove 2 screws securing the Inner Cover to the printer frame 5 Remove the Inner Cover 3600 034 7 16 Phaser 3600 Printer Service Manual Service Parts Disassembly Tray 1 MPT Knock Up Plate Only PL 1 1 3 1 Follow the first three steps for removing the Tray 1 MPT Assembly page 7 14 2 Rotate the tray links down slightly until they come free from the printer Note The tray links are marked L for the left and R for the right 3 To free the Knock Up Plate carefully spread the slotted hinge piece to release the post then remove the Knock Up Plate Note Tray 1 and the Knock up Plate contain unsecured plastic parts that fall off and are easy to lose Knock Up Plate Assembly x Tray Link 53600 035 Phaser 3600 Printer Service Manual 7 17 Service Parts Disassembly Tray 1 MPT Pick Up Rack PL 1 3 2 1 Remove the Rig
145. tion have replaceable part numbers The text topics following the illustration describe those sensors that have associated part numbers Sub Toner Low Board Output Tray Full Sensor and Sensor Fuser Exit Sensor Fuser Interlock Switch A Cover Open Interlock Switch Paper Size Sensor E A dp Y Duplex Sensor jj a kay Paper Tray pa Empty Sensor me 71 wim Paper Empty Sensor Tray 1 MPT A M A s 9 Feed Feed Sensor gt nue ii sem LR Tray 3 Feed Sensor Tray 2 Paper Empty Sensor Tray 3 Paper Empty Sensor s3600 086 Paper Tray Empty Sensor Media supply is monitored by the Paper Tray Empty Sensor When any paper tray runs out of paper the sensor will send a signal to the Main Board the control panel LED will blink red and the message will display on the control panel identifying which tray No Paper in Tray 2 3 is empty Tray 1 MPT Paper Empty Sensor The Tray 1 MPT paper empty sensors monitors paper from Tray 1 If Tray 1 is selected and no paper is available a message appears on the control panel If there is no paper in Tray 2 or Tray 3 and the printer is in auto select mode the printer will look for paper in all the trays and report No Paper in Tray 1 Tray 1 MPT Feed Sensor Phaser 3600 Printer Service Manual The Tray 1 MPT Feed Sensor has two purposes First it monitors paper movement If the paper takes too long getting to the sensor or it stays at the sensor location too long t
146. ual Service Parts Disassembly Paper Tray Empty Actuator PL1 3 58 The Paper Tray Actuator passes through the Paper Tray Empty Sensor which is soldered in the Switched Mode Power Supply SMPS 1 Remove the Tray 1 MPT Assembly page 7 14 2 Locate the Paper Tray Empty Actuator on the opposite side of the SMPS board and chassis 3 Depress the elongated portion of the actuator slightly to release then remove the actuator from the chassis slot i s3600 088 Phaser 3600 Printer Service Manual 7 23 Service Parts Disassembly Sub Toner Low Sensor Board PL1 3 47 1 Remove the Right Cover page 7 6 2 Remove the Left Cover page 7 7 3 Remove the Top Cover page 7 10 4 Remove the Laser Scan Unit page 7 70 5 Remove the LSU Lower Cover page 7 72 6 Disconnect all connectors running to the Toner Sensor Board 7 Remove 2 screws securing the Toner Sensor Board to the LSU cover 8 Release the 2 locking tabs to remove the board v 2335 Springs B Fr yr EST ee Cx E 4 s3600 069 7 24 Phaser 3600 Printer Service Manual Service Parts Disassembly Pick Roller and Sha t PL 1 3 2 5 Phaser 3600 Printer Service Manual o0 BB OD Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Remove the Tray 1 MPT Assembly page 7 14 Remove the Inner Cover page 7 16 Remove t
147. ubleshooting Print Quality Problems Overview 5 2 Image quality defects can be attributed to printer components consumables media internal software external software applications and environmental conditions To successfully troubleshoot image quality problems as many variables as possible must be eliminated The following guidelines should be used before troubleshooting an image quality problem m Use an unopened ream of approved media for evaluating image quality problems See the approved media list Media and Tray Specifications on page 1 10 for media that has been tested and approved for use with the Phaser 3600 Laser Printer m Print atest page to see if the image quality problem still exists See Test 8 in the Diagnostic Test Menu Map on page 3 5 m When analyzing a image quality defect first determine if the defect is repeating or random Repeating defects can often be associated with a particular component m Inspect the surfaces of all rollers in the paper path for obvious defects Phaser 3600 Printer Service Manual Repeating Defects Print Quality Troubleshooting Some image quality problems can be associated with specific assemblies the most common problems and the associated assemblies are listed below Also see the specific image quality troubleshooting procedure for more information Print Cartridge m Streaks m FineLines m Banding in Process Direction m Uneven Density m Voids m Repe
148. udes a paper arranging function and a display function displays the amount of paper remaining In the front side of the tray there is a paper level indicator 3 Paper Pick up Process Functions include a paper pickup function paper feeding function and the removal of electronic static 2 7 Theory of Operation 2 8 4 Miscellaneous Paper Functions A paper arrangement function uses a stopper roller and a weight without an electric actuator It also includes an additional paper separating function a driving control function and a multi feeding prevention function The Feed Roller transfers paper along the paper path and is also part of jam detection Transfer Roller Assembly Fuser Assembly The transfer subsystem consists of the Pre transfer Lamp PTL and the Transfer Roller The PTL exposes the drum surface after the latent image has been developed to lower surface potential of the drum This provides enhanced transfer efficiency The Transfer Roller provides a high positive potential on the back of the print media This potential attracts the negatively charged toner image from the drum and deposits it on the surface of the print media The transfer voltage is controlled by PWM Pulse Width Modulation When the paper enters the Transfer Roller the resistance value of the Transfer Roller will change due to the surrounding temperature of the printer If the temperature changes a new voltage level is created through an AD c
149. ustomer Replaceable Unit Meter Memory CST Cassette CUPS Common Unix Printing System dB Decibel DC Direct Current is type of power for printer components Machine converts AC power from power source to DC power Ref 2 Phaser 3600 Printer Service Manual Phaser 3600 Printer Service Manual Reference Acronym Description DCU Diagnostic Control Unit DDR2 DIMM Double Data Rate Dual In Line Memory Module DEVE Developer DHCP Dynamic Host Configuration Protocol DIMM Dual In line Memory Module DPI Dot Per Inch DRV Drive DUP Duplex Duplex 2 sided printing EC European Community ECM Error Correction Mode EEA European Economic Area EEC European Economic Community EEPROM Electrically Erasable Programmable Read Only Memory EOM End of Message ESA Electric Static Attachment ESD Electrostatic Discharge A transfer of charge between bodies at different electrostactic potential FCC Federal Communications Commission FDR Feeder FE Field Engineer FPOT First Print Output Time FR FRNT Front FRU Field Replaceable Unit F W Firmware GB Giga Byte GDI Graphics Device Interface GND Ground HARN Harness HCF High Capacity Feeder HDD Hard Disk Drive HOU Housing HUM Humidity HVPS High Voltage Power Supply Hz Hertz cycles per second IC Integrated Circuit IDT Intermediate Drum Transfer Ref 3 Reference Ref 4
150. vice Manual Parts List Serial Number Label Location The location of the Serial Number Label appears to the right of Tray 1 MPT output bin XEROX Xerox Corporation gt s3600 110 Phaser 3600 Printer Service Manual 8 3 Parts List Using the Parts List 1 No The callout number from the exploded part diagram 2 Part Number The material part number used to order specific parts 3 Qty This number represents the parts per printer not the number of parts supplied in the actual part order 4 Name Description Details the name of the part to be ordered and the number of parts supplied per order 5 Parts identified throughout this manual are referenced PL For example PL 3 1 10 means the part is item 10 of Parts List 3 1 6 Ablack triangle preceding a number followed by a parenthetical statement in an illustrated parts list means the item is a parent assembly made up of the individual parts called out in parentheses 7 The notation with X Y following a part name indicates an assembly that is made up of components X through Y For example 1 with 2 4 means part 1 consists of part 2 part 3 and part 4 8 An asterisk following a part name indicates the page contains a note about this part 9 The notation NS next to a part indicates that particular part is not spared but contained in a kit or major assembly The notation J1 lt gt J2 and P2 is attached to a w
151. vice Parts Disassembly In this chapter Service Overview General Notes on Disassembly Covers and Control Panel Tray 1 MPT Assembly Tray 2 PL2 1 0 and Optional Tray 3 PL2 2 0 Replacement Duplex Unit PL2 3 0 Main Drive and Registration Assemblies Frame Assembly Fuser Assembly 1 3 80 Laser Scan Unit PL 1 1 15 Power Supplies Chapter Service Parts Disassembly Service Overview This section contains the removal and replacement procedures for selected parts of the printer according to the Service Parts List Not all Replacement Procedures are included in this Service Manual In most cases to reinstall a part simply reverse the Removal Procedure shown In some instances the Replacement Procedure is included because it may contain special steps For specific assemblies and parts see Parts List on page 8 1 General Notes on Disassembly 7 2 Preparation Before you begin any Removal and Replacement Procedure 1 Switch OFF the printer power and disconnect the power cord from the wall outlet 2 Remove the Print Cartridge and protect it from exposure to light by covering it with a light proof bag or by placing it in a light tight container 3 Disconnect all computer interface cables from the printer 4 Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards AN Warning Remove the Fuser Assembly or wait at least 5 minutes af
152. ween parts with harness or wires attached with signal name contents CLUTCH ON L 24V Function Logic 1 Denotes the function and logic value of the signal to operate the function Low L High H The given voltage is for signal in high status The arrow indicates the direction of signal EXIT SENSED L 3 3VDC lt lt Function Logic 2 Denotes the function and logic value of the signal when the function is operated Low L High H The given voltage is for signal in high status The arrow indicates the direction of signal Connection of Wires Denotes a connection between wires m Solenoid Clutch Denotes a Clutch or Solenoid 0 Motor Denotes a Motor Phaser 3600Printer Service Manual 9 9 Plug Jack and Wiring Diagrams Symbol Description C Optic Sensor Denotes a Photo Sensor A LED Denotes an LED Safety Interlock Switch Denotes a Safety Interlock Switch o o On Off Switch Denotes an On Off Switch single pole single throw switch q Temperature Switch Denotes an On Off Switch Temperature normally close SS A NPN Phototransistor Denotes an NPN Photo transistor Interconnection Represents an interconnection between parts using wiring harness or wire Interconnection Differing Represents an interconnection which differs according to the specifications 9 10 Phaser 36
153. with bushings onto the Roller and seat into the plastic retainers before securing the two end screws Phaser 3600 Printer Service Manual 7 69 Service Parts Disassembly Laser Scan Unit PL 1 1 15 1 Remove the Right Cover page 7 6 2 Remove the Left Cover page 7 7 3 Remove the Top Cover page 7 10 4 Remove the cover frame exit cover s3600 091 5 Disconnect the LSU cable connector from CN10 on the Main Board 6 Remove the 3 screws 8mm securing the LSU to the chassis and remove the LSU from the printer 7 70 Phaser 3600 Printer Service Manual Service Parts Disassembly W yt TA S OT Br AS 4 3600 066 Replacement Note The screws are numbered and need to be replaced and tightened in the correct order Phaser 3600 Printer Service Manual 7 71 Service Parts Disassembly LSU Lower Cover PL 1 3 48 Remove 1 screw securing the fan duct Remove the fan and duct to access the screws in the next step Remove 3 screws 12mm securing the LSU Cover Disconnect all the connectors running to the LSU Cover Lift the cover free from the chassis a ron s3600 067 7 72 Phaser 3600 Printer Service Manual Service Parts Disassembly Left Side Cooling Supply Fan and Duct PL 1 1 31 Remove the Right Cover page 7 6 Remove the Left Cover page 7 7 Remove the Top Cover page 7 10 Remove the Laser Scan Unit page 7 70

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