Xerox Phaser 3020, Service Manual

Page 1: ...Xerox Phaser 3020 Service Manual 702P02829 June 2014 Initial Issue ...

Page 2: ......

Page 3: ...rd party provided service While Xerox has tried to make the documentation accurate Xerox will have no liability arising out of any inaccuracies or omissions WARNING This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions documentation may cause inter ference to radio communications It has been tested and found to comply...

Page 4: ...June 2014 2 Xerox Phaser 3020 Printer Service Manual Initial Issue ...

Page 5: ...cumentation iii How to Use this Manual iv Service Safety Summary v Reference Symbology vi Voltage Specifications vii Health and Safety Incident Reporting viii Regulatory Specifications ix Translation of Warnings x Tag Usage xi Phaser 3020 Overview xii Additional Product Safety Information xii ...

Page 6: ...June 2014 ii Xerox Phaser 3020 Printer Service Manual Introduction ...

Page 7: ...stments This section contains the Adjustment and Repair procedures Repairs include procedures for removal and replacement of parts which have the following special conditions When there is a personnel or machine safety issue When removal or replacement cannot be determined from the exploded view of the Parts List When there is a cleaning or a lubricating activity associated with the procedure When...

Page 8: ...or other reference is unique amongst different configu rations of the machine the appropriate configuration designator is indicated Any artwork is also specific NOTE This manual services all configurations of the machine Ignore references to options not installed on the machine Warnings Cautions and Notes WARNING A warning is used whenever an operating or maintenance procedure practice condi tion ...

Page 9: ...e for details Maintenance Safety Do not attempt any maintenance procedure that is not specifically described in the docu mentation supplied with the printer Do not use aerosol cleaners The use of supplies that are not approved may cause poor performance and could create a hazardous condition Do not burn any consumables or routine maintenance items For information on Xerox supplies recycling progra...

Page 10: ...en the machine is closed and operat ing Use caution when reaching in the machine ESD Certain components in this product are susceptible to damage from Electrostatic Discharge Observe all ESD procedures to avoid component damage The following reference symbols are used throughout the Xerox Phaser 3020 Service Man ual 1 Flag This symbol indicates a reference point into a circuit diagram from a RAP 2...

Page 11: ...eferenced in a diagnostic procedure Table 2 DC Voltage Measurements in RAPs The RAPs have been designed so that when it is required to use the DMM to measure a DC voltage the first test point listed is the location for the red meter lead and the second test point is the location for the black meter lead For example the following statement may be found in a RAP There is 5 VDC from TP7 to TP68 In th...

Page 12: ... American North and Latin American South Phone Xerox EH S at 1 800 828 6571 Electronic mail Xerox EH S at USA XEROX EHS xerox com Fax Xerox EH S at 1 585 216 8817 intelnet 8 219 68817 For incidents in Europe and Developing Markets East Middle East Africa India China and Hong Kong Phone Xerox EH S at 44 0 1707 353434 intelnet 8 668 3434 Electronic mail Xerox EH S at EH S Europe xerox com Fax Xerox ...

Page 13: ...he equipment Off and On the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiver Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced radio television technician for help Any c...

Page 14: ...ando elimine el módulo Consulte el GP 16 El módulo es pesado WARNING Follow the service procedure exactly as written Use of controls or adjustments other than those specified in this manual may result in an exposure to invisible laser radia tion During servicing the invisible laser radiation can cause eye damage if looked at directly DANGER Les procédures de dépannage doivent être suivies à la let...

Page 15: ...Komponenten anderer Hersteller setzt möglicherweise das Sicherheitszertifikat außer Kraft AVISO Utilice solo los materiales y componentes Xerox Este producto dispone de un certificado de seguridad si se utilizan los materiales y componentes Xerox Este certifi cado de seguridad no será válido si se utilizan materiales y componentes que no sean de Xerox WARNING Do not touch the fuser while it is hot...

Page 16: ...uchez pas les zones apposées d une étiquette lorsque la machine est en cours de fonctionnement afin d éviter de vous blesser les doigts avec les bords coupants du papier AVVERTENZA Non toccare le aree con etichette quando la macchina è in funzione I bordi taglienti della carta potrebbero causare lesioni alle mani VORSICHT Mit Aufklebern gekennzeichnete Bereiche während des Betriebs des Geräts nich...

Page 17: ...l Service Call Procedures 1 Service Call Procedures Call Flow Service Call Overview 1 3 Safety Precautions 1 3 SCP 01 Introduction to Service Call Procedures 1 4 SCP 02 Initial Actions 1 4 SCP 03 Corrective Actions 1 5 SCP 04 Final Actions 1 5 HFSI s 1 6 ...

Page 18: ...June 2014 1 2 Xerox Phaser 3020 Printer Service Manual Service Call Procedures ...

Page 19: ...ting procedure 4 Correct the problem Use the Parts List to locate part numbers Use the Repair Procedures to replace parts 5 Final Actions Test the printer to verify that the problem has been corrected and that there are no additional problems Diagnostic Mode The Xerox Phaser 3020 printer has built in diagnostics to test components display status and some NVM access The diagnostic tests are accesse...

Page 20: ...urpose of the Initial Actions is to help organize the service call Customer input machine observations and print samples are all used to gather information about the condition of the system Gather a list of symptoms error codes or other information concerning the problem that the customer may provide This information may help identify and correct intermittent or unusual problems During each servic...

Page 21: ... associated fault codes that have the same or nearly the same times tamp as the primary fault code Troubleshoot fault codes with the lowest chain number first 2 If the problem is IQ related refer to Section 3 Image Quality Entry RAP 3 When the primary problem is resolved proceed to Final Actions SCP 04 Final Actions Purpose Final Actions verify total operation of the machine ensures that the HSFI ...

Page 22: ...Log Book operator tracking sheet Service Maintenance Inter vals If necessary and if the customer agrees clean replace any secondary HFSI s that are due or may cause a return service call Be sure to continually update and review the Printer Service Log and Customer Maintenance Log for all maintenance actions to avoid any unnecessary actions that increase customer equipment down times service time a...

Page 23: ...idge Near End of Life Fault 2 6 09 350 Print Cartridge End of Life Fault 2 6 09 450 Print Cartridge At End of Life Fault 2 7 09 550 Print Cartridge Undetected Fault 2 7 09 800 Incompatible Print Cartridge Fault 2 8 10 100 Fuser Temperature Open Fault 2 8 10 200 300 Fuser Under Over Temperature Fault 2 9 17 100 IP Conflict Error Fault 2 10 17 310 Communication Error Main PWB to Wireless PWB Fault 2...

Page 24: ...June 2014 2 2 Xerox Phaser 3020 Printer Service Manual Status Indicator RAPs ...

Page 25: ...rive Motor is not working correctly BSD Reference 6 1 Laser ROS Procedure WARNING Do not perform repair activities with the power on or electrical power supplied to the machine The machine could activate and cause serious personal injury when the power is on or electrical power is supplied DANGER Ne pas effectuer de dépannage avec le contact principal activé ou avec l ali mentation électrique appl...

Page 26: ...t no paper is loaded in the tray Clear any jammed sheets Refer to Section 7 Trou bleshooting in the Xerox Phaser 3020 User Guide for detailed instructions on clearing paper jams Procedure Check the Feed and Width Sensor actuators for damage or binding The actuators moves freely and are undamaged Y N Replace the Feed or Width Sensor Actuator PL 3 3 Enter Diagnostic EDC Mode Select DC330 Component C...

Page 27: ...Paper Feed Sensor The signal changes Y N Check that the connection is secure and no contamination or damage is present Check that there is no damage or contamination on any connectors from the Feed Sensor to the LVPS HVPS PWB Repair as necessary Replace the Paper Feed Sensor REP 1 2 PL 3 3 Perform SCP Final Actions If the problem is intermittent recheck the cables and look for a cable that is bind...

Page 28: ...tridge 2 Check the remaining life of the Print Cartridge 3 If the Print Cartridge has reached end of life switch Off the power and replace the Print Cartridge 09 350 Print Cartridge End of Life Fault The Print Cartridge has reached end of life BSD Reference None Procedure 1 Check the remaining life of the Print Cartridge by using one of the methods listed below Print a Supplies Information Report ...

Page 29: ...ftware is unable to detect the Print Cartridge BSD Reference None Initial Actions Ensure that the Print Cartridge has been installed and the cover is fully closed and latched Procedure 1 Switch Off the power 2 Remove the Print cartridge Rotate the cartridge five to six rotations to distribute the toner evenly 3 Check the CRUM contact area for contamination and clean if necessary 4 Reinstall the Pr...

Page 30: ...fuser components operate at hot temperatures and can produce serious personal injury if touched DANGER Ne pas manipuler les éléments du four avant de les laisser refroidir Certains éléments du four fonctionnent à des températures très élevées et peuvent causer de graves blessures s ils sont touchés AVVERTENZA Non maneggiare i componenti del fusore finché non sono raffreddati Alcuni di questi compo...

Page 31: ... personal injury if touched DANGER Ne pas manipuler les éléments du four avant de les laisser refroidir Certains éléments du four fonctionnent à des températures très élevées et peuvent causer de graves blessures s ils sont touchés AVVERTENZA Non maneggiare i componenti del fusore finché non sono raffreddati Alcuni di questi componenti funzionano ad alte temperature e possono provocare gravi ferit...

Page 32: ...DHCP or BOOTP reboot the machine to receive a new IP address 17 310 Communication Error Main PWB to Wireless PWB Fault The machine software has detected a communication error between the Main PWB and the Wireless PWB BSD Reference None Initial Actions Switch Off the power then switch On the power Check the machine network and data configuration settings Procedure 1 Ensure that the connectors are f...

Page 33: ...ing a machine communica tion error BSD Reference None Procedure 1 Switch Off the power then switch On the power 2 Check BOOTP and network configuration 17 800 810 DHCP Error Fault The machine displays the error message DHCP or BOOTP causing a machine communica tion error BSD Reference None Procedure 1 Switch Off the power then switch On the power 2 Check DHCP and network configuration ...

Page 34: ...cator RAPs 17 910 Firmware Upgrade Fault The firmware upgrade aborted due to an invalid file BSD Reference None Initial Actions 1 Check the USB connection 2 Verify that the correct firmware file is being used Procedure Cycle the machine power and repeat upgrade procedure GP 5 ...

Page 35: ...ack Line and Band RAP 3 4 IQ2 Vertical White Line and Band RAP 3 4 IQ3 Horizontal Black Bands RAP 3 5 IQ4 Spots RAP 3 5 IQ5 Low Image Density RAP 3 6 IQ6 Black or Dark Image RAP 3 6 IQ7 Uneven Density RAP 3 7 IQ8 Background RAP 3 8 IQ9 Residual Image Ghosting RAP 3 9 IQ10 Blank Page RAP 3 9 IQ11 Partial Image Deletions RAP 3 10 ...

Page 36: ...June 2014 3 2 Xerox Phaser 3020 Printer Service Manual Image Quality ...

Page 37: ...etzungen oder Stromschlägen führen AVISO No realice reparaciones con la máquina encendida o conectada a la corriente Algunos componentes de la máquina contienen voltajes eléctricos peligrosos que pueden producir una descarga eléctrica y causar daños graves Defects Associated with Specific Components To aid with diagnosis the list below outlines image defects associated with specific compo nents lL...

Page 38: ...Figure 1 Black lines and bands IQ2 Vertical White Line and Band RAP Thin white vertical lines or white vertical bands occur in the printed image Initial Actions Clean the surface of the LSU window with a clean cotton swab and recommended cleaner IPA Procedure From the Control Panel check the life of the Print Cartridge The Print Cartridge has reached end of life Y N Switch Off the power Replace th...

Page 39: ...ure 1 Horizontal black bands IQ4 Spots RAP Random or periodic dark areas in the low density areas of a print or voids in the dark areas of a print Figure 1 Initial Actions Ensure that the Imaging Unit is firmly seated Procedure Check the Transfer Roller for wear damage and remaining life The Transfer Roller is OK Y N Replace the Transfer Roller REP 1 13 PL 3 1 Clean the voltage terminals for the P...

Page 40: ...mentation électrique appliquée à la machine Certains éléments de la machine compor tent des tensions électriques dangereuses qui peuvent causer un choc électrique et de graves blessures AVVERTENZA Non effettuare alcuna riparazione con l alimentazione elettrica inserita Alcuni componenti contengono corrente ad alta tensione che può provocare forti scosse e gravi ferite VORSICHT Es dürfen erst Repar...

Page 41: ...lectrique et de graves blessures AVVERTENZA Non effettuare alcuna riparazione con l alimentazione elettrica inserita Alcuni componenti contengono corrente ad alta tensione che può provocare forti scosse e gravi ferite VORSICHT Es dürfen erst Reparaturarbeiten durchgeführt werden wenn das Gerät aus geschaltet ist oder der Netzstecker nicht mehr mit der Stromquelle verbunden ist Ein ige Komponenten ...

Page 42: ...k that the paper meets specifications Refer to Section 6 for product specifications Check the supplies life of the Print Cartridge refer to GP 2 Machine Status and Reports Replace the Print Cartridge if it has reached end of life Procedure Switch off the power Clean the contacts on the Print Cartridge and the LVPS HVPS PWB Switch on the power and make a test print The test print looks OK Y N Repla...

Page 43: ...PS PWB REP 1 5 PL 3 1 Figure 1 Ghost Image IQ10 Blank Page RAP The entire image area is blank Figure 1 Initial Actions Replace any components at end of life Procedure Switch Off the power Check the space between the LSU and the Print Cartridge for a blockage remove any debris or blockage Clean the contacts on the Print Cartridge and the LVPS HVPS PWB Switch on the power and make a test print The p...

Page 44: ...rtridge side to side for 5 to 6 full rotations to redistribute the toner Reinstall the Print Cartridge and print 10 test copies The problem continues Y N Go to SCP 04 Final Actions Switch Off the Power Check the Transfer Roller for the following Wear or damage The left and right tension springs for damage Be sure all parts are installed correctly The Transfer Roller is OK Y N Replace the Transfer ...

Page 45: ...June 2014 3 11 Xerox Phaser 3020 Printer Service Manual IQ11 Image Quality Figure 1 Image Deletions ...

Page 46: ...June 2014 3 12 Xerox Phaser 3020 Printer Service Manual IQ11 Image Quality ...

Page 47: ...S HVPS PWB 4 6 REP 1 6 Main PWB 4 7 REP 1 7 Control Panel PWB 4 9 REP 1 8 WNPC WiFi PWB 4 10 REP 1 9 Left Frame and Drive Motor 4 11 REP 1 10 LSU 4 13 REP 1 11 Feed Rolls and Retard Pad 4 15 REP 1 12 Feed Sensors PWB and Actuators 4 18 REP 1 13 Transfer Roll 4 19 REP 1 14 Fuser Module 4 20 REP 1 15 LSU Cables 4 22 REP 1 16 Feed Clutch 4 23 REP 1 17 Paper Drive Roll and Drive Gear 4 24 REP 1 18 Pap...

Page 48: ...June 2014 4 2 Xerox Phaser 3020 Printer Service Manual Repairs ...

Page 49: ...used to hold the PWB to the frame Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame Install the components in the reverse of removal REP 1 2 Left and Right Side Covers Parts List on PL 1 1 Removal 1 Switch Off the Printer and disconnect the Power Cord 2 The side covers are held in place with Plastic Latches release them carefully to avoid break...

Page 50: ...n PL 1 1 Removal 1 Switch Off the Printer and disconnect the Power Cord 2 Remove the Left and Right Side Covers REP 1 2 3 Remove the Rear Cover Screws 2 and the cover Figure 1 Figure 1 Rear Cover Screws Replacement Important If the Rear Cover is being replaced remove the Data Plate Label from the old Rear Cover and install it onto the new Rear Cover Figure 1 NOTE Tapered Plastic Screws and Round M...

Page 51: ...ing replaced remove the Tag Matrix from the old cover and install it on to the new Cover Figure 1 Figure 1 Jam Clearance Cover Support Arms and Pivots Top View Top Cover Removal 1 Remove the Left and Right Side Covers REP 1 2 2 Remove the Rear Cover REP 1 3 3 Remove the Front Cover REP 1 1 4 Remove the Jam Clearance Cover 5 Disconnect the Control Panel PWB connector from the Main PWB Figure 2 6 Re...

Page 52: ...orrente ad alta tensione che può provocare forti scosse e gravi ferite VORSICHT Es dürfen erst Reparaturarbeiten durchgeführt werden wenn das Gerät aus geschaltet ist oder der Netzstecker nicht mehr mit der Stromquelle verbunden ist Ein ige Komponenten des Gerätes sind stromführend und können daher zu ernsthaften Verletzungen oder Stromschlägen führen AVISO No realice reparaciones con la máquina e...

Page 53: ...es tensions électriques dangereuses qui peuvent causer un choc électrique et de graves blessures AVVERTENZA Non effettuare alcuna riparazione con l alimentazione elettrica inserita Alcuni componenti contengono corrente ad alta tensione che può provocare forti scosse e gravi ferite VORSICHT Es dürfen erst Reparaturarbeiten durchgeführt werden wenn das Gerät aus geschaltet ist oder der Netzstecker n...

Page 54: ...the machine 2 Connect the PWS to the printer via USB connection 3 Run the USB Serial Number Writing Tool application Download the USB Serial Number writing application to the PWS from the GSN website GP 9 a Double click the executable file and follow the steps listed in the USB Serial applica tion window to write the machine serial number to the new Main PWB Figure 2 NOTE Select the Check USB butt...

Page 55: ...and remove the Top Cover Figure 1 Figure 1 Control Panel PWB Connector 4 Remove the Control Panel PWB from the underside of the Top Cover Figure 2 a Remove the screw 1 b Release the latches and remove the PWB Figure 2 Control Panel PWB Bottom View Replacement NOTE Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the frame Make sure that the Plastic Screws go into plastic...

Page 56: ...gure 1 Figure 1 LVPS HVPS PWB Connector 4 Remove the WLNPC WiFi PWB Figure 2 a Disconnect the connector on the WNPC WiFi PWB b Remove the screw 1 and the WNPC WiFi PWB Figure 2 WLAN WiFi PWB Replacement NOTE Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the frame Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame In...

Page 57: ... Remove the Print Cartridge 3 Remove the following covers a Left and Right Side Covers REP 1 2 b Rear Cover REP 1 3 c Front Cover REP 1 1 d Top Cover REP 1 4 4 Disconnect the Drive Motor connector Figure 1 Figure 1 Drive Motor Connector Front View 5 Remove the Fuser Module REP 1 14 6 Remove the Main Drive Unit 4 screws Figure 2 Figure 2 Main Drive Unit Removal Left View Connector Screws ...

Page 58: ...o the frame Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame Install the components in the reverse of removal NOTE The Frame is flexible and can be bowed out if the screws are not tightened in the cor rect order Reinstall the Frame as follows so it seats flush against the printer internal modules 1 Align the Left Frame on to the internal modul...

Page 59: ...grave pericolo di scossa elettrica e serie ferite VORSICHT Beim Ersetzen der Lasereinheit LSU ROS und beim Umgang mit Hoch spannungsleitern ist äußerste Vorsicht geboten Die Lasereinheit muss durch Berühren des Hochspannungsleiters mit dem Gehäuse des Geräts entladen werden Nach Betrieb der Lasereinheit ROS bleibt immer eine Hochspannungsladung zurück welche ein hohes Elektroschockrisiko darstellt...

Page 60: ...Screws Top View 6 Remove the screws 3 and the LSU Figure 3 Figure 3 LSU Removal Top View Replacement NOTE Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the frame Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame Install the components in the reverse of removal Screws Screw ...

Page 61: ...and Right Side Covers REP 1 2 b Rear Cover REP 1 3 c Front Cover REP 1 1 d Top Cover REP 1 4 4 Perform the following Figure 1 a Disconnect the Drive Motor connector 1 b Remove the inside LSU cover screws 2 Figure 1 Motor Connector and LSU Cover Screws Front View 5 Remove the top LSU Cover screws 2 and the cover Figure 2 Figure 2 LSU Cover Top Screws Top View 6 Remove the Feed Rolls Assembly screws...

Page 62: ...y up to release the locating pins from the frame b Move the Feed Roll assembly up to the right and remove it Figure 4 Feed Rolls Assembly Removal Top View 8 Remove the Retard Pad Figure 5 Be careful not to lose the Retard Pad Spring a From the rear of the printer release the Pivot Latches 2 b Move the Retard Pad into the printer to remove it Screwdriver Access Holes Front View Bottom View ...

Page 63: ... go into plastic components and Machine Screws go into the metal frame Install the components in the reverse of removal When replacing the Retard Pad make sure the Spring is positioned on the locating post on the frame Figure 5 When replacing the Feed Rolls Assembly make sure the Locating Pins are positioned in the frame holes before installing the screws 2 Figure 6 Figure 6 Feed Rolls Assembly Lo...

Page 64: ...cutout for reinstallation a Unlatch and remove the actuator 5 Removing the Width Actuator Figure 2 Note the location of the Spring in the frame cutout for reinstallation a Unlatch and remove the actuator Figure 2 Sensor Actuators and Springs Rear View Replacement NOTE Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the frame Make sure that the Plastic Screws go into pla...

Page 65: ...Cord 2 Remove the Print Cartridge 3 Remove the Fuser Module REP 1 14 4 From the rear of the printer using a small screwdriver release the latches 2 and push the Transfer Roll Bushing into the printer Figure 1 Figure 1 Transfer Roll Bushing Latches Rear View 5 Lift the Transfer Roll out of the printer Figure 2 Figure 2 Transfer Roll Removal Top View Latches Transfer Roll ...

Page 66: ...t ist oder der Netzstecker nicht mehr mit der Stromquelle verbunden ist Ein ige Komponenten des Gerätes sind stromführend und können daher zu ernsthaften Verletzungen oder Stromschlägen führen AVISO No realice reparaciones con la máquina encendida o conectada a la corriente Algunos componentes de la máquina contienen voltajes eléctricos peligrosos que pueden producir una descarga eléctrica y causa...

Page 67: ...igure 1 Fuser Connector and Wire Guides NOTE The top right viewed from the rear Tapered Plastic Screw is different than the other plastic screws in the printer make sure it is installed in the correct location during replacement 5 Remove the screws 3 Figure 2 Figure 2 Fuser Screws Top View Connector Wire Guides Screws ...

Page 68: ...rame NOTE The top right Tapered Plastic Screw viewed from the rear is different than the other plastic screws in the printer make sure it is installed in the correct location during replacement refer to Figure 2 Install the components in the reverse of removal REP 1 15 LSU Cables Parts List on PL 3 6 Removal 1 Switch Off the Printer and unplug the Power Cord 2 Remove the following covers a Left an...

Page 69: ...old the PWB to the frame Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame Install the components in the reverse of removal REP 1 16 Feed Clutch Parts List on PL 3 3 Removal 1 Switch Off the Printer and unplug the Power Cord 2 Remove the following covers a Left and Right Side Covers REP 1 2 b Rear Cover REP 1 3 c Front Cover REP 1 1 d Top Cover...

Page 70: ...Machine Screws go into the metal frame Install the components in the reverse of removal NOTE Make sure the Feed Drive Shaft engages the Feed Roll Assembly REP 1 17 Paper Drive Roll and Drive Gear Parts List on PL 3 3 Removal 1 Switch Off the Printer and unplug the Power Cord 2 Remove the following covers a Left and Right Side Covers REP 1 2 b Rear Cover REP 1 3 NOTE When removing the Main Drive Un...

Page 71: ... Drive Roll Gear and remove it Figure 2 Figure 2 Paper Drive Roll Gear Left View 5 Remove the Feed Sensor Actuator Figure 3 Note the location of the Spring in the frame cutout for reinstallation a Unlatch and remove the actuator Figure 3 Feed Sensor Actuator Rear View Gear Spring Latch Feed Sensor Actuator ...

Page 72: ...astic Screws go into plastic components and Machine Screws go into the metal frame NOTE Make sure that the Actuator Spring is location in frame cutout Figure 3 NOTE When replacing the Main Drive Unit the drive gears may need to be rotated to align them with the other drives Install the components in the reverse of removal REP 1 18 Paper Tray Parts List on PL 3 1 Removal 1 Switch Off the Printer an...

Page 73: ...per Tray from the Right Frame Figure 2 Paper Tray Removal Front View Replacement NOTE Tapered Plastic Screws and Round Machine Screws are used to hold the PWB to the frame Make sure that the Plastic Screws go into plastic components and Machine Screws go into the metal frame Install the components in the reverse of removal NOTE Make sure the Locating Pins and Tabs on the Paper Tray align with the ...

Page 74: ...June 2014 4 28 Xerox Phaser 3020 Printer Service Manual REP 1 18 Repairs ...

Page 75: ... Cover 5 4 Frame PL 3 1 Frame 5 5 Fuser PL 3 2 Fuser 5 6 Paper Path Frame PL 3 3 Paper Path Frame 5 7 Main Left Frame PL 3 4 Main Left Frame 5 8 Main Frame Right PL 3 5 Main Frame Right 5 9 Middle And Bottom Frame PL 3 6 Paper Tray And LSU Frame 5 10 Feed Idle Frame PL 3 7 Paper Feed Assembly 5 11 Part Number Index 5 12 ...

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Page 77: ...ver 4 Frame PL3 1 5 002N03170 Rear Cover 002N03171 Rear Cover Black 6 Main PWB Insulator 7 140N63720 Main PWB 3020 BI DMO E Russia Middle East South Africa Argentina Peru 140N63721 Main PWB 3020 BI Chile 140N63719 Main PWB 3020 BI NA DMO W 8 Wireless Cover 9 140N63727 WNPC WIFI PWB 10 002N03183 Right Cover 002N03184 Right Cover Black 11 002N03178 Paper Support 002N03179 Paper Support Black 12 Fron...

Page 78: ... 2 1 Top Cover Item Part Description 1 Dust Cover 2 Stacking Guides 3 Output Support 4 Inner Output Support 5 Shaft Holder 6 Jam Clearance Cover 7 Trim Strip 8 Top Cover 9 WPS Key 10 140N63725 Control Panel PWB 11 002N03159 Top Cover Assembly 002N03160 Top Cover Assembly Black ...

Page 79: ... 1 Paper Tray PL 3 6 2 LSU Frame PL 3 6 3 Main Frame Left PL 3 4 4 Paper Feed Assembly PL 3 7 5 Paper Path Frame PL 3 3 6 022N02794 Transfer Roller 7 Fuser Module PL 3 2 8 LSU Cover 9 Main Frame Right PL 3 5 10 HVPS Insulator 11 HVPS Contact 12 105N02303 LVPS HVPS 220V 105N02302 LVPS HVPS 110V 13 Input Guide ...

Page 80: ... Lower Fuser 10 Fuser Cover 11 126N00432 Fuser Module Assembly 110V 126N00433 Fuser Module Assembly 220V 12 Exit Shaft 13 Rubber Rolls 14 Exit Roller 15 Holder 16 Exit Roller 17 Spring 18 Bracket 19 Bushing 20 Pressure Roll 21 Bracket 22 Frame 23 Fuser Gear Stopper 24 Jam Lever 25 Lamp Cover 26 Fuser Gear 27 Heat Roll 28 Guide 29 Spring 30 Thermostat 31 Thermistor 32 Fuser Cover 33 Bushing 34 Fuse...

Page 81: ...1759 Paper Feed Sensor PWB 2 120N00546 Feed Sensor Actuator 3 Spring 4 120N00547 Width Sensor Actuator 5 Spring 6 022N02798 Paper Drive Roll 7 Plate 8 Ground 9 Ground Clip 10 Paper Path Guide 11 Feed Roll Shaft 12 121N01246 Feed Clutch 13 007N01801 Feed Gear 14 Bushing 15 Spring 16 Bushing 17 001N00547 Retard Pad 18 Path Frame ...

Page 82: ... 4 Parts Lists PL 3 4 Main Left Frame Item Part Description 1 Left Frame 2 Feed Drive Gear 3 RDCN OPC Gear 4 Out Drive Gear 5 RDCN Drive Gear 6 Drive In Gear 7 Fuser Drive Gear 8 RDCN Fuser Gear 9 RDCN A Gear 10 Drive Motor 11 001N00548 Left Main Frame Assembly ...

Page 83: ... Printer Service Manual PL 3 5 Parts Lists PL 3 5 Main Frame Right Item Part Description 1 Right Frame 2 CRUM Contact 3 Spring 4 Ground Clip 5 Washer 6 Tap Screw 7 CRUM Cover 8 Right Print Cartridge Guide 9 Right Main Frame Items 1 8 ...

Page 84: ...arts Lists PL 3 6 Paper Tray And LSU Frame Item Part Description 1 001N00549 Paper Tray 2 LSU Frame 3 Right Guide 4 Left Guide 5 Rubber Friction Pad 6 Bottom Plate 7 Pinion Gear 8 Sponge Damper 9 062N00293 LSU 10 Motor Cover 11 LSU Frame 12 117N01970 LSU Flat Cable ...

Page 85: ...ller 3 Spring 4 Guide Plate 5 Latch 6 Paper Stopper 7 130N01757 Feed Rolls Assembly 8 Latch 9 Damper Sponge 10 Feed Rolls Housing 11 Feed Rolls Shaft 12 Shaft Holder 13 Bushing 14 Spring 15 Collar 16 Joint Gear 17 Pick Up Clutch 18 Bushing 19 Pick Up Roller 20 Plain Washer 21 Bushing 22 Sleeve 23 Spring 24 Pick Up Gear 25 Feed Gear 26 Drive shaft Roller ...

Page 86: ...PL 1 1 002N03165 PL 1 1 002N03166 PL 1 1 002N03170 PL 1 1 002N03171 PL 1 1 002N03178 PL 1 1 002N03179 PL 1 1 002N03183 PL 1 1 002N03184 PL 1 1 007N01801 PL 3 3 022N02794 PL 3 1 022N02798 PL 3 3 062N00293 PL 3 6 105N02302 PL 3 1 105N02303 PL 3 1 117N01970 PL 3 6 120N00546 PL 3 3 120N00547 PL 3 3 121N01246 PL 3 3 126N00432 PL 3 2 126N00433 PL 3 2 130N01757 PL 3 7 130N01759 PL 3 3 140N63719 PL 1 1 14...

Page 87: ...pecifications 6 7 General Procedures and Information GP 1 Diagnostics Entry and Exit 6 11 GP 2 Machine Reports 6 11 GP 3 Machine Firmware Version 6 12 GP 4 Machine Settings 6 12 GP 5 Altitude Adjustment 6 13 GP 6 Firmware Upgrade 6 13 GP 7 Usage of the Electrostatic Discharge ESD Field Service Kit 6 14 GP 8 Software ServiceTools 6 15 Diagnostics Diagnostic EDC Mode 6 17 Machine Reports 6 17 Glossa...

Page 88: ...June 2014 6 2 Xerox Phaser 3020 Printer Service Manual General Procedures and Information ...

Page 89: ...20 printer produces high quality prints from electronic documents with speeds of up to 21 ppm and an effective output resolution of up to 1200 x 1200 dpi System Overview This section provides illustrations of the following systems Paper Path Figure 1 System Layout Figure 2 Print Process Figure 3 Laser Scanner Unit LSU Figure 4 Drives Figure 5 Toner System Figure 6 ...

Page 90: ...erview General Procedures and Information Paper Path The following diagrams display the path that the paper follows during the printing process Figure 1 Paper Path System Layout The figures below illustrates the mechanical parts of the printer Figure 2 System Layout ...

Page 91: ... Figure 3 presents a general layout of the fusing and printing components used in the print pro cess Figure 3 Print Process Laser Scanner Unit LSU The Scanner Unit receives image data from the HVPS PWB and scans the surface of the pho toreceptor drum OPC with a laser to create a latent image Figure 4 Laser Scanner Unit ...

Page 92: ... Main BLDC Motor Registration and Pick up Clutches along with various gears for the Drum Cartridge OPC Fuser Pick up Registration Feed and Exit Rollers Toner System The Phaser 3020 printer uses a integrated toner system The toner cartridge photoreceptor and developer units are contained within the Print Cartridge Figure 5 Integrated Toner System ...

Page 93: ...nd Software Item Specification Processor 600 MHz Memory 128 MB Printer Languages GDI Fonts Windows Print Driver Default Driver SPL Install SPL Supporting OS Windows XP 32 64bits Windows Vista 32 64bits Windows 2003 32 64bits Windows 2008 32 64bits c7 32 64bits Windows 2008 R2 64bits Windows 7 8 32 64bits Linux RedHat Enterprise Linux 5 6 Fedora 11 19 SuSE Linux 10 0 11 32 bit Open SuSE 11 0 11 1 1...

Page 94: ...1 in Letter A4 A5 Executive ISO B5 JIS B5 Oficio Folio Envelope No 10 Monarch DL C5 Custom Media Type Plain Heavy weight Light weight Cotton Colored Pre printed Recycled Envelope Label Cardstock Bond Archive Media Weight 16 to 43 lb 60 to 163 gsm Sensing NA Optional Cassette Tray NA Output Tray Stacking Capacity Face down 100 Sheets 20 lb 80 gsm Output Tray Full Sensing NA Duplex Supporting Yes Ma...

Page 95: ...e Yield See Note Print Cartridge 1500 Images Table 6 Reliability and Service Item Specification Printing Volume SET AMPV 75 Pages MPBF 10 000 Pages MTTR 30 Minutes SET Life Cycle 30 000 Pages or 5 Years whichever comes first Table 7 Environment Item Specification Operating Environment Temperature 50 90 F 10C to 32C Humidity 10 80 Acoustic Noise Level Sound Power Pressure Print Less Than 50 dB Stan...

Page 96: ...June 2014 6 10 Xerox Phaser 3020 Printer Service Manual Product Specifications General Procedures and Information ...

Page 97: ...ubleshooting problems Procedure To access machine reports follow the steps below From the Control Panel 1 To print a Configuration Report press and hold the WPS button for approximately 10 seconds The green LED light flashes goes solid then flashes again Release button to print report 2 To print the Supplies Information and Usage Counter Reports press and hold the WPS button for approximately 15 s...

Page 98: ...rinter Manager to launch the CentreWare Internet Services CWIS application 2 Log into CWIS enter user name admin and password 1111 3 Select the Support Tab The Firmware version is listed next to the Main Controller Board GP 4 Machine Settings Purpose Use this procedure to provide information on how to configure machine settings Procedure From Easy Print Manger 1 Connect to the Phaser 3020 Print vi...

Page 99: ...Connect a USB cable from the PWS to the USB port on the printer 2 Confirm that the printer is the Ready status 3 Drag the SWUPGRADE_ON prn file and drop it onto usblist2 exe This file enables firm ware upgrade on the device 4 Drag and drop the firmware file onto usblist2 exe The firmware update will start automat ically 5 The Printer will reboot when the upgrade is complete Upgrading the Firmware ...

Page 100: ... power cords 2 Assemble the kit a Place the static dissipative work surface mat on a flat surface in close proximity to the machine or the component b Connect the snap end of the green grounding cord to the snap on the static dissipa tive work surface mat Connect the male end plug to the frame c Connect the small snap end of the blue cord to the top snap on the green grounding cord d Connect the s...

Page 101: ...ry 7387 https www xrxgsn com secure main pl catid 13991 Software_tools zip 2 Download the Software_tools zip file onto the PWS 3 Open the zip folder and extract the tool files 4 The WorkCentre 3020 uses the following tools SWUPGRADE_ON prn to enable the machine to accept software downloads usblist2 exe to download software via USB connection USB Serial Number Writing Tool to write the machine seri...

Page 102: ...June 2014 6 16 Xerox Phaser 3020 Printer Service Manual GP 8 General Procedures and Information ...

Page 103: ...he following sub menus DC330 Comp Ctrl Select the Enter button to confirm menu selections and run diagnostics tests Select the Upper Level button to stop tests Select the Exit button to exit EDC mode Machine Reports Refer to Section 1 of the Phaser 3020 User Guide for information regarding Control Panel Functions including Demo Page Supplies Info and Event Log Configuration Reports LED Status Disp...

Page 104: ...June 2014 6 18 Xerox Phaser 3020 Printer Service Manual Diagnostic EDC Mode General Procedures and Information ...

Page 105: ...t A private computer network that uses internet protocol technology to share information operational systems or computing services within an organization IP address Internet Protocol Address A unique number that devices use to iden tify and communicate with each other over a network utilizing the IP standard IPP The Internet Printing Protocol A standard protocol that can be used locally or over th...

Page 106: ...June 2014 6 20 Xerox Phaser 3020 Printer Service Manual Glossary General Procedures and Information ...

Page 107: ...cumentation the service documentation takes precedence CHAIN 1 POWER 1 1 AC LOW VOLTAGE and HIGH VOLTAGE POWER INTERLOCKS CHAIN 3 COMMUNICATIONS 3 1 PRINTER COMMUNICATIONS CHAIN 4 MAIN DRIVE 4 1 MAIN DRIVE CHAIN 6 LSU 6 1 LSU CHAIN 7 PAPER FEED AND REGISTRATION 7 1 PAPER FEED AND REGISTRATION CHAIN 9 XEROGRAPHICS 9 1 PRINT MODULE CHAIN 10 FUSING 10 1 FUSING Prepared by Content Development and Lang...

Page 108: ...Xerox Phaser 3020 Printer Service Manual June 2014 BSDs THIS PAGE INTENTIONALLY BLANK ...

Page 109: ...DC POWER GENERATION 5VDC 24VDC J2 DC COM DC COM 14 13 DC COM 19 17 15 11 DC COM 12 J1 P1 24 VDC Off Sleep Mode 24 VDC 7 8 DC COM 2 4 6 24 VDC 24 VDC 24 VDC 10 DC COM DC COM DC COM DC COM DC COM 5 VDC 5 VDC 24 VDC 5 VDC 3 3 VDC POWER GENERATION 3 3 VDC FRONT COVER INTERLOCK SWITCH SQQ 3 3 VDC 3 16 P4 J4 18 5 COVER CLOSED H 3 3 VDC 7 14 3 3 VDC 3 3 VDC 3 3 VDC 9 J4 P4 24 VDC Off Sleep Mode ...

Page 110: ...8 DC COM 3 3 VDC 11 1 3 9 3 3 VDC 3 3 VDC DC COM DC COM 2 10 8 4 WITH WIRELESS MODEM PL 2 1 CONTROL PANEL PWB DC COM 3 3 VDC 1 P2 J2 9 3 7 DC COM 3 3 VDC 8 2 READY LED POWER KEY TONER LED 8 2 9 1 DC COM 3 3 VDC 4 6 ERROR LED 5 5 POWER LED 6 4 WPS KEY WPS LED 7 3 9 3 DC COM 2 10 DC COM DC COM DC COM 3 3 VDC 3 3 VDC DC COM DEBUG 1 J1 2 3 4 3 3 VDC WIDTH SENSOR FEED SENSOR SIGNAL SIGNAL SIGNAL SIGNAL...

Page 111: ... 2014 Xerox Phaser 3020 Printer Service Manual BSDs A B C D E F G H J 1 2 3 4 5 6 4 1 MAIN DRIVE PL 1 1 MAIN PWB PL 3 4 DRIVE MOTOR 4 PHASE A PHASE B PHASE C PHASE D 3 MOT 2 24 VDC MOTOR DRIVER 1 J7 P7 7 3 ...

Page 112: ...LSU 7 4 PL 1 1 MAIN PWB PL 3 1 LSU LSU MOTOR 5 4 MOTOR ENABLED CLOCK 3 1 6 READY POWER 9 LSU ON 10 7 DC COM DC COM DC COM 11 6 V1 DN V1 DP 12 13 5 4 DC COM DC COM DC COM LSU 1 9 8 DC COM DC COM DC COM 14 3 3 3 VDC 16 1 SYNC SIGNAL 15 2 24 VDC 2 24 VDC 24 VDC 5 1 J6 P6 2 4 3 8 3 3 VDC 3 3 VDC ...

Page 113: ...J 1 2 3 4 5 6 PL 1 1 MAIN PWB DC COM 24 VDC 1 J8 P8 2 FEED CLUTCH ON L 24 VDC PL 3 3 FEED CLUTCH DC COM 3 3 VDC 3 3 VDC 3 3 VDC 3 3 VDC 3 2 5 1 SENSOR CN PAPER AT FEED SENSOR L 3 3 VDC PAPER AT REG SENSOR L 3 3 VDC DC COM 3 3 VDC 3 3 VDC PL 3 3 FEED SENSOR PWB 3 1 2 CN1 4 5 WIDTH SENSOR FEED SENSOR 4 7 5 ...

Page 114: ...CS PL 1 1 MAIN PWB PRINT MODULE 11 J4 P4 12 10 CRUM SIGNAL CRUM SIGNAL DEVELOPER ENABLED 13 TRANSFER ON 15 CHARGE ON 19 CHARGE ENABLED 20 DEVELOPER ON 17 1 3 4 2 CRUM TRANSFER ROLL CHARGE SUPPLY ROLL DEVELOPER ROLL PR DRUM 1 J11 P11 3 4 2 3 3 VDC DC COM 3 VDC DC COM DEVELOPER AC DEVELOPER DC 18 TRANSFER ENABLED 9 8 6 2 1 4 3 ...

Page 115: ...R PL 1 1 MAIN PWB 2 Fuser Temperature Signal OVERTEMPERATURE THERMOSTAT FUSER THERMISTOR RT10 001 PL 3 1 LVPS HVPS PWB T1 T2 HEAT LAMP 3 3 VDC ACH ACN 1 P4 J4 20 CN CN 5 16 Enable Fuser Relay Fuser Relay On 3 3 VDC PL 3 2 FUSER MODULE Heat Lamp On ACH PL 3 2 FUSER MODULE L CN1 CN N 1 CN FUSER 7 7 ...

Page 116: ... 2014 Xerox Corporation All rights reserved Xerox and the sphere of connectivity design are trademarks of Xerox Corporation in the US and or other countries ...