Training (Mecha) [ML-5510N/ ML-5510ND/ML-6510ND ML-5512ND/ML-6512ND Product Development Group 2 Samsung IT Solutions Business Jan. 14. 2011

Contents Process Installation of Option Disassembly Fault Diagnosis Troubleshooting Contents

Convert to Bit Map image Restore to original image I. Process 1. Process Original Image Convert to Printing Language DRIVER Electronic Signal Convert to Bit Map image Restore to original image LSU Charge Exposure Developing Fusing Transfer

I. Process 2. Paper Path System Layout LSU Toner DRUM Fuser Simplex Path Duplex Path Manual

I. Process 3. Deve Process Developing Method : 2-component Magnetic Brush Polymerase Toner Remained toner sensor : N/A Life: 80K Distinguish cartridges : by CRUM ID 1 OPC (Light-Sensitive Device) 2 Mag Roller 3 Supply Roller 7 4 4 Charge Roller 2 5 1 3 5 Cleaning Blade 6 6 Turbine Roller (Collecting waste toner) 7 2’nd Blade

I. Process 4. Toner Life: 10K (CRU 20K/30K) Developing Method : 2-component Magnetic Brush OPC Cleaning : Collect residue toner with cleaning blade Distinguish TONER CARTRIDGE : by CRUM ID

I. Process 5. Feeding Unit (Cassette) Feeding Method : Cassette Loading Basis : Center Loading Capacity : 520sheets (80g/㎡) Paper Sensing : Empty Sensor Paper-Size Sensor : Tact S/W (A4, Letter, A5, B5, State., Folio, Legal, Custom)

I. Process 5. Feeding Unit (Cassette) Retard Roller & Knock-up Lifting method - Improved multi-feeding and Jam issues - Easier Service : Simple Exchange of Pickup & Retard Roller Supporting Media - Weight : 60 ~ 163 g/㎡ - Size : Letter, Legal, Oficio, Folio, A4, JIS B5, ISO B5, Executive, A5, Statement, A6, Cardstock, Postcard, Custom[98.6x148.5mm(3.88"x5.85“)~216x356mm(8.5”x14")] - Support Special Paper : Envelope 50sheets (Monarch, No.10, DL, C5, C6, No.9)

I. Process 5. Feeding Unit (MP) Feeding Method : AUTO-COMPENSATOR PICK-UP Structure Loading Basis : Center Loading Capacity : 100sheets (80g/㎡) Paper Sensing : Empty Sensor Paper-Size Sensor : N/A

I. Process 5. Feeding Unit (MP) Retard Roller & Swing Type(ADF) - Improved multi-feeding and Jam issues - Easier Service : Simple Exchange of Retard Roller Supporting Media - Weight : 60 ~ 220 g/㎡ - Size : Letter, Legal, Oficio, Folio, A4, JIS B5, ISO B5, Executive, A5, Statement, A6, Cardstock, Postcard, Custom[76 x 127mm (3.0" x 5.0") ~ 216 x 356mm (8.5" x 14")] Pickup Forward Swing Type Retard

I. Process 6. Drive Supply power through Gears Supply power to OPC/DEVE/Feeding/Fuser part with 4 BLDC motors Supply power to Exit/Duplex/Release Pressure(Fuser) with 3 Step motors Operate 1 DC motor In Toner-supplying mode Improve the image quality by operating separated drive for each OPC/DEVE/Feeding/Fuser part BLDC MOTOR (FUSER) STEP MOTOR (EXIT) BLDC MOTOR (FEED) BLDC MOTOR (DEVE) BLDC MOTOR (OPC) STEP MOTOR (DUPLEX) STEP MOTOR (FUSER Release)

I. Process Error Phenomenon 7. LSU Consisted of LD(Laser Diode) and Polygon Motor Control Error Polygon Motor Error Hsync Error Phenomenon Unstable rotating of Polygon Motor No Hsync signal generated, Despite the stable rotation of Polygon Motor.

I. Process 8. Fuser Life : More than 150,000sheets Halogen Lamp : Adjust the fusing temperature by heating Heat Roller : Teflon Coating Pressure Roller : Silicon 1 PR System Thermistor : Temperature Sensor Thermostat : Heat Cut-off Sensor Halogen Lamp Fuser unit

I. Process 8. Fuser Assembling Guide : Push the unit inside until 4 points (marked in red below) touch Frame and tighten Screws

I. Process Error Phenomenon 8. Fuser Consisted of Heat Lamp, Heat Roller, Pressure Roller , Thermistor, Thermostat Error Open Heat Error Low Heat Error Phenomenon Center temperature stays lower than 90℃ for 20 secs from Warm-up. Side temperature stays lower than 70℃ for 20 secs from Warm-up. Center temperature stays lower than 50℃ for 10 secs from Warm-up, and lower than 80℃ for 18 secs. Warm-up : After reaching 90℃, Center temperature stays lower than motor-start temperature for longer than 20 secs. Finishing Warm-up, Center temperature stays 15ADC lower than target for longer than 10 secs. Stand-by : 35ADC lower than target for longer than 10 secs. (Center) 60ADC lower than target for longer than 10 secs. (Side) Printing : 27ADC lower than setting for longer than 7 secs. (Center) 40ADC lower than setting for longer than 7 secs. (Side) Over Heat Error Warm-up : Over 220℃ for 20 secs or over 230℃ for 3 secs.(Center / Side) Stand-by : Over 220℃ for 20 secs or over 230℃ for 3 secs.(Center / Side) Over the initial setting Center temperature of each environment for 3 mins.(Center / Side) Printing : Over 220℃ for 20 secs or over 230℃ for 3 secs.(Center / Side) Power Save : Over 220℃ for 20 secs or over 230℃ for 3 secs.(Center / Side)

I. Process 9. Duplex Feeding Method : 2 FEED-ROLLER + 1 TIMING BELT Loading Basis : Side feeding Media Weight : 60~120g/m2 Media Size : A4, Ltr, Legal, Folio, Oficio Significant point : Paper size set-up available (A4/LTR)

I. Process 10. Exit Exit Method : Non-Contact Roller (Paper goes out in waved form) Capacity : 500sheets (80g/m2) Paper Sensing : Paper Full Sensor Paper FULL Sensor Paper Out in Wave

[1]MAIN(SMPS) FAN (left) I. Process 11. Fan Harrier has Fans in 4 places to control temperature of inside the Printer/LSU/SMPS/FDB/Print-out papers. [2]LSU FAN (right) 1) Function of FAN [1] Main(SMPS) FAN : blow-in, Feedback signal (Error displays on UI, when problem occurs.) -. Blow the external cold air into Fuser, Developer and SMPS in order to cool down SMPS and to prevent the heat of Fuser from affecting Developer. [2] LSU FAN : blow-out, Feedback signal -. Blow the internal warmed air out of the printer. [3] REAR FAN : blow-out, Feedback signal -. Let out the heat of Fuser, and cool down the papers printed-out and prevent steam. [4] FDB FAN : blow-out, No Feedback signal (No error shows on UI when problem occurs.) -. Let out the heat of FDB. 2) Operation of FAN [1] In ready mode -. Every Fan is off when the internal temperature is lower than 50℃. -. When internal temperature is over 50℃ right after printing job, MAIN(SMPS) Fan operates until the temperature gets lower than 50℃. [2] During warm-up or printing -. Every Fan operates. [3]FDB FAN (right) [4]REAR-FAN (rear) [1]MAIN(SMPS) FAN (left) Location of Fans [1] Main(SMPS) FAN – Left side of Printer [2] LSU FAN – Right side of Printer [3] FDB FAN – Right side of Printer [4] REAR FAN – Rear side of Printer

I. Process 12. CRU/FRU Information 1) Toner Feature Item ML-551x & ML-651x series Model name Remark Toner(Black) -Initial: average output 10K MLT-D309S -High Yield: average output 30K MLT-D309L Imaging Unit Initial : 80K MLT-R309 Evaluating Criteria ISO/IEC 19752 Test Page Print-out - Key CRUM type Life detect By Dot Count 2) Reliability and Life Item ML-551x series ML-651x series Recommended Monthly Print Volume 6,000 sheets/month 7,000 sheets/month Maximum Monthly Print Volume 275,000 sheets/month MPBF 87,500 sheets 125,000 sheets MTBF 12 months MTTR 30 min. SET life 1,000,000 sheets or 5 years (whichever comes first)

I. Process 12. CRU/FRU Information 3) FRU (ML-PMK65K) Item Part Code Life Q’ty Remark Fuser Unit JC91-01014A (110V) JC91-01014B (220V) Approx. 150,000 Pages 1ea Transfer roller JC93-00267B 100,000 Pages Pick-up Roller Forward Roller JC97-02259A 200,000 Pages 6ea Retard Roller ※ Clean inside machine (paper dust or toner powder) after replace the consumable parts.

I. Process 13. Option Information Item SPEC MODEL REMARK Memory 512MB ME-MEM170 Optional Tray 520 Sheets @80gr ML-S6510A High Capacity Feeder 2,000 Sheets @80gr ML-H6510A Multi bin Mailbox 4 bin, 400 Sheets @80gr ML-MBT65 Finisher (Stacker & Stapler) 500 Sheets @80gr ML-OCT65 Duplex Unit Harrier ML-U5510A HDD(Hard Disk Drive) 80GB ML-HDK465 Wireless LAN IEEE 802.11 b/g/n ML-NWA65L Parallel Option IEEE 1284 Parallel ML-PAR100

II. Installation of Option 1. SCF/HCF & STAND

II. Installation of Option 2. Mail Box/Finisher Mail Box Finisher

II. Installation of Option 3. Duplex (“N” Model)

II. Installation of Option 4. Memory/Wireless/HDD Memory Wireless HDD

II. Installation of Option 5. Maintenance Kit

III. Disassembly Purpose Ⅰ. Learn how to disassemble printer Ⅱ. Understand the function of each part Ⅲ. Understand the basic structure of main parts

III. Disassembly Open Top Cover and remove Toner, Imaging Unit. 1. Cover Unit Open Top Cover and remove Toner, Imaging Unit. Open WTB Cover and remove WTB. Remove Screws following the order below.

III. Disassembly 1. Cover Unit ※ Open the rear cover about 30 degrees (because of D-cut direction) and then lift up the right side of rear cover.

III. Disassembly 1. Cover Unit

III. Disassembly Remove Cover Rear. Remove Duplex Unit. 2. Fuser Unit Remove Cover Rear. Remove Duplex Unit. Loosen Screws a little with things like coins, then remove Screws by hand.

III. Disassembly Remove Cover Right. 3. Main PBA & Engine PBA Remove Cover Right. Remove connector from Main PBA & Engine PBA. Remove Screws following the order below, then remove PBA. Main PBA Engine PBA ※ It would be more easy unplug all harness connectors before unfasten screws.

III. Disassembly Remove Cover Right. Remove Engine PBA. 4. Main Drive Unit Remove Cover Right. Remove Engine PBA. Remove 5 Screws and remove Main Drive unit.

III. Disassembly Remove Cover Right. Remove Engine PBA. 5. Feed Drive Unit Remove Cover Right. Remove Engine PBA. Remove 2 clutches like below picture. Remove 5 Screws and remove Main Drive Unit. Remove Feed Drive Unit and Clutch. ※ Be careful the direction of bracket-clutch during assemble.

III. Disassembly Remove Cover Right. 6. Fuser Drive Unit Remove Cover Right. Remove 2 Screws and remove Main PBA Unit from Frame. ※ Spring

III. Disassembly Remove Cover Right and Engine PBA. 7. Duplex & Lift Drive Unit Remove Cover Right and Engine PBA. Remove Duplex & Lift Motor.

III. Disassembly 8. Fuser Release Drive Unit Remove Cover Left and Cover Rear.(Duplex Unit, as well) Remove 3 Screws and remove Fuser Release Motor. ※ Open the Cover-WTB(①) and then remove the Cover-Left(②).

III. Disassembly Remove Cover Right and Main PBA. 9. Fuser Drive Board (FDB Unit) Remove Cover Right and Main PBA.

III. Disassembly Remove Cover Right. 10. LSU Fan Remove Cover Right. Remove 1 Screw and remove LSU Fan. ※ Be careful the FAN direction (Blow-out)

III. Disassembly Remove Cover Top. (Refer to ‘12. Exit unit’ section) 11. LSU Unit Remove Cover Top. (Refer to ‘12. Exit unit’ section) Remove Harness Cable. Remove 4 Screws (M4*L10). ※ Screw Type: M4*L10

III. Disassembly Remove every Cover. 12. Exit Unit Remove every Cover. Remove the Exit unit following the order below.

III. Disassembly Remove Cover Left. Follow below pictures. 13. Housing Terminal & WTB Frame & Main Fan Remove Cover Left. Follow below pictures. WTB Frame Main Fan Housing Terminal ※ Be careful the FAN direction (Blow-In)

III. Disassembly Remove every Cover. 14. SMPS & HVPS PBA Remove every Cover. Remove Fuser unit, and remove SMPS & HVPS Unit following below.

III. Disassembly 14. SMPS & HVPS PBA

III. Disassembly Remove Cover Left. 15. 3*5 Belt Remove Cover Left. Remove the Belt following the order below. 1 2 ※ Push to the left(①) and lift up(②).

III. Disassembly Open Cover Top. 16. Transfer Roller Open Cover Top. Unlock the Locking of Holder, and take off Roller. ※ Caution for contamination of Transfer Roller. (Oil, Duty, Moisture, etc.)

III. Disassembly Remove Cover Right and then remove the regi clutch. 17. Registration Unit Remove Cover Right and then remove the regi clutch. Unfasten 4 screws and lift up registration unit. ※ Caution Actuators.

III. Disassembly Remove the actuator cover. Disassemble the actuators. 18. Actuator Regi & Feed Remove the actuator cover. Disassemble the actuators.

III. Disassembly Remove Cover Right. Remove 1 Screw and remove Sensor. 19. External Temperature Sensor Remove Cover Right. Remove 1 Screw and remove Sensor.

III. Disassembly Remove Cover-Right, Cover-Front. 20. MP Unit Remove Cover-Right, Cover-Front. Remove 4 Screws and pull out Harness, and remove MP Unit.

III. Disassembly Remove 1 Screw and take out Retard Roller Assembly. 21. MP Roller Remove 1 Screw and take out Retard Roller Assembly. Caution) Exchanging Retard roller, make sure the Spring is placed properly.

III. Disassembly Remove Cassette. 22. Pick up roller & Forward roller Remove Cassette. Push the Green Lever to Unlock the Roller. Move the Roller to the left, and remove it. ※ Lift span : 200,000 sheets

III. Disassembly Remove Cassette. 23. Retard roller (Cassette) Remove Cassette. Release the Locking on the both sides of Cap Retard. Move the Roller to the left, and remove it. ※ Lift span : 100,000 sheets

III. Disassembly Remove Cover Top. 24. OPE Board Remove Cover Top. Remove OPE PBA following the order below. 1. Remove 2 Screws and 2 Hinges. 2. Open the both hinges to remove OPE Cover. 3. Remove 3 Screws in OPE—LOWER COVER. 6. Pull out connector and release 2 hooks and remove LCD. 5. Pull out connectors of OPE HARNESS and remove 7 Screws. 4. Move OPE-LOWER COVER to the direction indicated below to remove it.

Can you disassemble and re-assemble Harrier? III. Disassembly Review Can you disassemble and re-assemble Harrier? (ML-551x/ML-651x Series)

IV. Fault Diagnosis Tech Mode & EDC Mode : Manu ( )→ # → 1934 → Manu( ) ☞ Main Motor : Tech Mode → EDC Mode → Test Routines → 100-Motor → Main BLDC → Status [off] , OK Key : Motor turn on/ Stop Key : Motor stop Level 1 Level 2 Level 3 Level 4 Detail Data Setup HDD Test HDD Format Yes/No Counter Reset Fuser Counter Clear After change the CRU, reset the counter Roller 류 Pick-up, Forward, Retard, Transfer Roller Toner low level 1-30% Select Toner Low level Paper Substitution On/Off Mismatch, On:A4/Ltr Report Configuration F/W Version and other information Supplies info CRU/FRU Counter Usage Counter Total Impressions Event Log Error Information Job Duty Report 1/2/3/4/5/Over 6 pages Job Count EDC Mode NVM Read Write MSOK NVM Initialize Initialize (Clear) Test Routines Motor Motor, Clutch, Sensor, MHV Bias, THV Bias, Transfer Bias, Fuser Heater, LSU, Toner, Inner Sensor, Outer Sensor Can check every part with EDC mode Ex) Feed Motor On/Off Exit Sensor status check LSU Fan turn on/off Clutch Sensor MHV Bias 외

IV. Fault Diagnosis Sensor(Actuator) Location & Function Simplex Path Duplex Path Manual No Actuator Function S1 Empty Sensor CST Paper Empty Check S2 Regi Sensor Paper Registration, Clutch On/Off S3 Feed Sensor Image Start(LSU Start) Jam 1 S4 Fuser Sensor Jam2 Check S5 Out bin Full Check the output tray full S6 MP Paper empty Check S7 CTD Sensor Image density control(EP) Actuator : Clean the window of CTD S8 Duplex Sensor Duplex Jam 1 Check

IV. Fault Diagnosis Roller Diameter & Period Name Diameter Band Period REGI ROLLER Ø 18.73 58.8 mm FEED ROLLER Ø 15.00 47.1 mm FORWARD ROLLER Ø 23.00 72.3 mm PICKUP ROLLER RETARD ROLLER MP PICK-UP HEAT ROLLER Ø 49.35 154.9 mm PRESSURE ROLLER Ø 50.00 157.0 mm DUPLEX ROLLER Ø 11.30 35.5 mm Transfer-Roller Ø 18.40 57.8 mm OPC Drum Transfer R Pickup HEAT R Pressure R Retard R Forward R MP Pickup Regi R Feed R Duplex R OPC Magnetic Roller Cleaning Roller Charge Roller Name　 Diameter Band Period OPC DRUM Ø 30.06 94.4 mm Cleaning Roller Ø 12.7 39.8 mm Charge Roller Ø 16.00 50.2 mm Magnetic -Roller Ø 25.0 78.5 mm

V. Trouble shooting (Paper Jams) 1. Jam0 (Jam in Tray1) ▪ Case 1. Paper can’t get out from feeding part. 2. It occurs when paper gets fed in the printer. Check List Check the Guide-rear Solution Adjust the proper Guide-Rear to the size of paper or change it. Check how much the surface of Pick up roller is contaminated Wipe it with wet smooth fabric(with water or IPA (Isopropyl alcohol). Check how much the surface of Retard Roller is contaminated Wipe it with wet smooth fabric ( NO CHEMICAL ON IT. Only water or IPA). If Retard roller is worn out badly, change it.

V. Trouble shooting (Paper Jams) 2. Jam1 (Registration Jam, Jam inside Machine) ▪ Case Paper stopped near Regi roller Paper stopped front or inside of fuser Check List Check the movement of Feed Actuator Solution Check Feed Actuator and change it. Check inside of Guide-Envelope and remove jammed paper. Check the movement of Exit Actuator Change Exit Actuator Check if there are any objects in the paper path Remove the objects

V. Trouble shooting (Paper Jams) 3. Jam2 (Jam in Exit Area) ▪ Case Tail edge of paper is jammed inside of fuser Lead edge of paper is jammed in the fuser Check List Check if there are any objects in the paper path Solution Remove the object Check the guide claw of fuser inside If spring is moved or deformed, it needs to be changed. H/R or P/R contaminated with residue toners Remove residue toners with gauze

V. Trouble shooting (Paper Jams) 4. Duplex Jam1 (Jam Top of Duplex) ▪ Case Duplex Print paper Jam Check List Check whether paper size of DUPLEX UNIT is set up as A4 or LTR Solution Set up the paper size of Duplex unit correctly Check the frame & roller of DUPLEX UNIT if they are contaminated with residue toners Remove residue toners

Paper in Duplex doesn’t reach the feed sensor in time V. Trouble shooting (Paper Jams) 5. Duplex Jam0 (Jam Bottom of Duplex) ▪ Case Paper in Duplex doesn’t reach the feed sensor in time Check List Check if there are any object on Guide-Paper or Burr Solution Remove the object & burr Check Feed & Regi Roller if they are contaminated or worn out Remove the contaminated part. Change the part if necessary

Paper doesn’t reach feed sensor from MP while feeding V. Trouble shooting (Paper Jams) 6. MP Jam0 Case Paper doesn’t reach feed sensor from MP while feeding Check List Check the condition of roller (contaminated?, worn out?) Solution Remove the contaminated part. Change the part if necessary Stopper is locked because paper is pushed too much. Re-install the Stopper so it doesn’t get pressed too much Guide-Side is too tight Adjust Guide-Side

Paper is jammed while feeding from SCF V. Trouble shooting (Paper Jams) 7. SCF Jam0 ▪ Case Paper is jammed while feeding from SCF Check List Check the Guide-rear Solution Adjust the proper Guide-Rear to the size of paper or change it. Check how much the surface of Pick up roller is contaminated Wipe it with wet smooth fabric(with water or IPA (Isopropyl alcohol). Check how much the surface of Retard Roller is contaminated Wipe it with wet smooth fabric ( NO CHEMICAL ON IT. Only water or IPA). If Retard gear is worn out badly, change it.

V. Trouble shooting (Paper Jams) 8. Mail Box Jam ▪ Case Paper is jammed from Mail Paper doesn’t enter the sensor in Mail Box in time Check List Check the location of paper jam by opening Mail Box Cover Solution Correct the actuator & diverter in Mail Box Check paper Curl If paper is curled too much, flip the paper to use Check whether paper is full (100pages) Reduce stacked paper if it is full

V. Trouble shooting (Paper Jams) 9. Finisher Jam ▪ Case Paper is jammed in finisher Paper doesn’t enter the sensor in finisher in time Paper is jammed during finisher stapler Check List Check the location of jam by opening finisher cover Check the paper Solution Check and re-assemble Actuator correctly Check paper Curl If paper is curled too much, flip the paper to use Check whether paper is full (500pages) Reduce the amount of paper if it is full

V. Trouble shooting (Paper Jams) 10. Multi-feeding Check List Solution Check how much the surface of Retard Roller is contaminated (Life cycle : 100,000 pages) Wipe it with wet smooth fabric ( NO CHEMICAL ON IT. Only water or IPA). If Retard gear is worn out badly, change it. Check the roughness of paper surface Use smooth paper surface ▪ Case Multiple paper were fed in once Check if many types of paper used together or paper is stacked overly disordered Using with same types of paper preferred Rearrange the paper so the stack is straightened.

Thank you !