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

2. Contents Process Installation of Option Disassembly Fault Diagnosis
Troubleshooting
Contents

3. 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

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

5. 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

6. 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

7. 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)

8. 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)

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

10. 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

11. 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)

12. 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.

13. 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

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

15. 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)

16. 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)

17. 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

18. [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

19. 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 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)

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

21. 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
ML-H6510A
Multi bin Mailbox
4 bin, 400
ML-MBT65
Finisher
(Stacker & Stapler)
500
ML-OCT65
Duplex Unit
Harrier
ML-U5510A
HDD(Hard Disk Drive)
80GB
ML-HDK465
Wireless LAN
IEEE b/g/n
ML-NWA65L
Parallel Option
IEEE 1284 Parallel
ML-PAR100

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

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

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

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

26. II. Installation of Option
5. Maintenance Kit

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

28. 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.

29. 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.

30. III. Disassembly
1. Cover Unit

31. 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.

32. 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.

33. 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.

34. 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.

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

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

37. 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).

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

39. 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)

40. 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

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

42. 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)

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

44. III. Disassembly
14. SMPS & HVPS PBA

45. 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).

46. 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.)

47. 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.

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

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

50. 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.

51. 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.

52. 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

53. 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

54. 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.

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

56. 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

57. 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

58. 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

59. 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.

60. 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

61. 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

62. 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

63. 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

64. 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

65. 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.

66. 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

67. 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

68. 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.

69. Thank you !