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Phaser Color Laser Printer
®
6250
Service
Manual
Phaser® 6250 Color Laser Printer
Service Manual
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: July, 2003 071-0869-00
Copyright
Copyright © 2003, Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the Copyright © 2003, Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States.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 of 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®, The Document Company®, the stylized X®, CentreWare®, Made For Each Other®, Phaser®, PhaserSMART®, and the TekColor® icon are registered trademarks of Xerox Corporation. infoSMARTTM, PhaserCalTM, PhaserMatchTM, PhaserPortTM, PhaserToolsTM, and the TekColorTM name are trademarks of Xerox Corporation. Adobe® Reader®, Illustrator®, PageMaker®, Photoshop®, PostScript®, ATM®, Adobe Garamond®, Birch®, Carta®, Mythos®, Quake®, and Tekton® are registered trademarks and Adobe JensonTM, Adobe Brilliant ScreensTM technology, and IntelliSelectTM are trademarks of Adobe Systems Incorporated or its subsidiaries which may be registered in certain jurisdictions. Apple®, LaserWriter®, LocalTalk®, Macintosh®, Mac® OS, AppleTalk®, TrueType2®, Apple Chancery®, Chicago®, Geneva®, Monaco®, and New York® are registered trademarks, and QuickDrawTM is a trademark of Apple Computer Incorporated. PCL® and HP-GL® are registered trademarks of Hewlett-Packard Corporation. Windows® and Windows NT® are registered trademarks of Microsoft Corporation. Novell®, NetWare®, NDPS®, NDS®, and Novell Directory Services® are registered trademarks, and IPXTM and Novell Distributed Print ServicesTM are trademarks of Novell, Incorporated. Sun® and Sun Microsystems® are registered trademarks of Sun Microsystems, Incorporated. SPARC® is a registered trademark of SPARC International, Incorporated. SPARCstationTM is a trademark of SPARC International, Incorporated, licensed exclusively to Sun Microsystems, Incorporated. SWOP® is a registered trademark of SWOP, Inc. UNIX® is a registered trademark in the US and other countries, licensed exclusively through X/Open Company Limited. This product uses code for SHA-1 written by John Halleck, which is being used with his permission. This product includes an implementation of LZW licensed under U.S. Patent 4,558,302. Other marks are trademarks or registered trademarks of the companies with which they are associated. PANTONE® Colors generated may not match PANTONE-identified standards. Consult current PANTONE Publications for accurate color. PANTONE® and other Pantone, Inc. trademarks are the property of Pantone, Inc. © Pantone, Inc., 2000.
As an Energy Star® 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.
Service Terms
Manual Terms
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 read NOTE, CAUTION, and WARNING statements.
Common Acronyms:
The following list defines the acronyms that may be fournd in this manual. ADC: Automatic Density Control BTR: Bias Transfer Roller CRUM: Customer Replaceable Unit Monitor CTD: Toner Density Control DRV: Motor Driver Board ESD: Electrostatic Discharge IDT: Intermediate Transfer Unit MCU: Engine Control Board NCS: Non-Contact Sensor PHD: Imaging Unit PL: Corresponds to the FRU Parts List. RMI: Routine Maintenance Item ROS: Laser Scanning Unit RTC: Charge Roller
Note A note indicates an operating or maintenance procedure, practice or condition that is neccessary 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.
Product Terms
Caution: A personal injury hazard exists that may not be apparent. For example, a panel may cover the hazardous area. Danger: A personal injury hazard exists in the area where you see the sign.
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Phaser 6250 Color Printer
Symbols Marked on the Product
DANGER high voltage.
Protective ground (earth) symbol.
Hot surface on or in the printer. Use caution to avoid personal injury.
0
The surface is hot while the printer is running. After turning off the power, wait 30 minutes.
30 min.
Avoid pinching fingers in the printer. Use caution to avoid personal injury.
Use caution (or draws attention to a particular component). Refer to the manual(s) for information.
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Power Safety Precautions
Power Source
For 110 VAC printers, do not apply more than 140 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 VAC printers, do not apply more than 264 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord. This manual assumes that the reader is a qualified service technician. Plug the three-wire power cord (with grounding prong) into a grounded AC outlet only. If necessary, contact a licensed electrician to install a properly grounded outlet. If the product loses its ground connection, contact with conductive parts may cause an electrical shock.
Disconnecting Power
Turning the power off using the On/Off switch does not completely de-engergize the printer. You must also disconnect the printer power cord from the AC outlet. Position the power cord so that it is easily accessible during servicing so that you may power down the printer during an emergency. Disconnect the power plug by pulling the plug, not the cord. Disconnect the power cord in the following cases:
if the power cord or plug is frayed or otherwise damaged, if any liquid or foreign material is spilled into the case, if the printer is exposed to any excess moisture, if the printer is dropped or damaged, if you suspect that the product needs servicing or repair, whenever you clean the product.
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Phaser 6250 Color Printer
Electrostatic Discharge (ESD) Precautions
Some semiconductor components , and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity. Be sure the power is off to the chassis or circuit board, and observe all other safety precautions.
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. 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 unpackaged 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 EPROM's carefully to avoid bending pins. Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCB's).
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Service Safety Summary
General Guidelines
For qualified service personnel only: Refer also to the preceding Power Safety Precautions. Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present. Use care when servicing with power: Dangerous voltages may exist at several points in this product. 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 currents. Power source: This product is intended to operate from a power source that will not apply more then 264 volts rms for a 220 volt AC outlet or 140 volts rms for a 110 volt AC outlet between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.
Warning Labels
Read and obey all posted warning labels. 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 and the printer's front panel 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® 6250 Color Laser Printer 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 is a class of laser product that does not emit hazardous laser radiation; this 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.
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Phaser 6250 Color Printer
Servicing Electrical Components
Before starting any service procedure, switch off the printer power 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. Warning Turning the power off by using the On/Off switch does not completely deenergize the printer. You must also disconnect the printer power cord from the AC outlet. Position the power cord so that it is easily accessible during servicing. Warning Do not touch any electrical component unless you are instructed to do so by a service procedure.
S7300-02
Servicing Mechanical Components
When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears. Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.
S7300-03
Servicing Fuser Components
Warning This printer uses heat to fuse the toner image to media. The Fuser Assembly is VERY HOT. Turn the printer power off and wait at least 5 minutes for the Fuser to cool before you attempt to service the Fuser Assembly or adjacent components.
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Regulatory Specifications
Federal Communications Compliance
The equipment described in this manual generates and uses radio frequency energy. If it is not installed properly in strict accordance with Xerox instructions, it may cause interference with radio and television reception or may not function properly due to interference from another device. 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, which 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:
Reorient or relocate the receiver (device being interfered with). Increase the separation between the printer and the receiver. Connect the printer into an outlet on a circuit different from that which the receiver is connected. Route the interface cables on the printer away from the receiver Consult the dealer, Xerox service, or an experienced radio/television technician for help.
Changes or modifications not expressly approved by Xerox can affect the emission and immunity compliance and could void the user's authority to operate this product. To ensure compliance, use shielded interface cables. A shielded parallel cable can be purchased directly from Xerox at www.xerox.com/office/6250supplies. Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a normal office environment. This product is also suitable for use in a residential environment based on the levels tested. In the United States this product complies with the requirements of an unintentional radiator in part 15 of the FCC rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference; (2) this device must accept any interference received, including interference that may cause undesired operation. This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications, ICES-003. Le présent appareil numérique n'émet pas de bruits radioélectrique dépassant les limits applicables aux appareils numériques de la classe B prescrites dans le Réglement sur le brouillage radioélectrique édicté par le ministere des Communications du Canada, NMB-003.
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Phaser 6250 Color Printer
Declaration of Conformity
Xerox Corporation, declares, under our sole responsibility that the printer to which this declaration relates, is in conformity with the following standards and other normative documents:
In the European Union
following the provisions of the Low Voltage Directive 73/23/EEC and its amendments:
EN 60950 (IEC 950) "Safety of Information Technology Equipment including Electrical Business Equipment"
following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC and its amendments:
EN55022:1998 (CISPR 22) EN61000-3-2:1995 +A1:1998+A2:1998 (IEC61000-3-2) EN61000-3-3:1995 (IEC61000-3-3) EN55024:1998 (CISPR 24) "Limits and Methods of measurement of radio interference characteristics of Information Technology Equipment." Class B. "Part 3: Limits - Section 2: Limits for harmonic current emissions (equipment input current less than or equal to 16A per phase)." "Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker in low-voltage supply systems for equipment with rated current less than or equal to 16A." "Information technology equipment - Immunity characteristics - Limits and methods of measurement. "
CISPR 24 Immunity Phenomena
Electrostatic Discharge Radio-Frequency Electromagnetic Field (radiated) Fast Burst Transients
Basic Standard
IEC61000-4-2:1995 IEC61000-4-3:1995
Test Specification
6kV Contact, 10kV Air 80-1000 MHz, 3V/m, 80% AM @ 1KHz
IEC61000-4-4:1995
5/50 Tr/Th ns, 5kHz Rep. Freq 0.5kV on Signal Lines 1kV on AC Mains Combination wave 2.0kV Common mode 2.0kV Differential mode 0.15 - 80 MHz, 3V, 80% AM @ 1kHz
Line Surge
IEC61000-4-5:1995
Radio-Frequency Electromagnetic Field (Conducted) Line voltage dips
IEC61000-4-6:1996
IEC61000-4-11:1994
>95% dip for ½ cycle @ 50 Hz 30% dip for 25 cycles @ 50 Hz
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CISPR 24 Immunity Phenomena
Line voltage drop-out
Basic Standard
IEC61000-4-11:1994
Test Specification
>95% dropout for 250 cycles @ 50 Hz
This product, if used properly in accordance with the user's instructions is neither dangerous for the consumer nor for the environment. A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.
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Phaser 6250 Color Printer
Contents
Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . vii Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
1 General Information
Printer Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Printer Memory and RAM Capabilities . . . . . . . . . . . . . . . . . . . . . 1-4 Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Phaser 6250 Front Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Routine Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Consumable Life Counter Behavior . . . . . . . . . . . . . . . . . . . . . . 1-10 Printer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . 1-11 Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
2 Theory of Operation
Overview of the Phaser 6250 Color Laser Printer Theory of Operation . . 2-2 Summary of the Printing Process . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Printer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Paper Size Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Selective Control; Paper Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Laser Light Intensity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 LED Light Density CTD (ADC) Control of Sensor . . . . . . . . . . . . . 2-8 Color Registration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Transfer Roller Assembly Control. . . . . . . . . . . . . . . . . . . . . . . . 2-11 Toner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Fuser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Paper Path of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Paper Path Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
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Major Assemblies and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame and Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Drive Assembly - Transmission Route . . . . . . . . . . . . . . . Gear Layout - Print Engine and Tray 1 . . . . . . . . . . . . . . . . . . . . Paper Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Feed - Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HCF Drive and Gears - Transmission Route . . . . . . . . . . . . . . . . 500-Sheet Feeder Drive and Gears - Transmission Route . . . . . Retard Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chute Assembly In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chute Assembly Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chute Assembly Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duplex Motor Drive and Gear - Transmission Route . . . . . . . . . Chute Assembly Registration (REGI) . . . . . . . . . . . . . . . . . . . . . Transfer Roller and Fuser Assembly . . . . . . . . . . . . . . . . . . . . . Fuser Drive Assembly - Transmission Route . . . . . . . . . . . . . . . Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Imaging Unit Charge Voltage Contacts . . . . . . . . . . . . . . . . . . . Toner Cartridge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Toner Cartridge Assembly - cont'd . . . . . . . . . . . . . . . . . . . . . . Toner Motor Drive Assembly - Transmission Route . . . . . . . . . Developer Assembly Transmission Route . . . . . . . . . . . . . . . . .
2-16 2-16 2-17 2-18 2-19 2-20 2-25 2-26 2-27 2-28 2-29 2-30 2-31 2-32 2-33 2-34 2-35 2-36 2-38 2-39 2-40 2-40
3 Error Messages and Codes
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . 3-4 General Notes on Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 3-4 Voltage Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Service Diagnostic Front Panel Button Descriptions . . . . . . . . . . 3-7 Diagnostic Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Service Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Jam History Error Codes Table . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Error Messages and Codes Summary Table . . . . . . . . . . . . . . . 3-17 Jam Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Jam at Fuser: Jam F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Jam at Duplex: Jam D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Jam at Registration Roller: Jam RR . . . . . . . . . . . . . . . . . . . . . . 3-23 Misfeed at Tray 1 (MPT): Jam T1. . . . . . . . . . . . . . . . . . . . . . . . 3-25 Misfeed at Tray 2: Jam T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Misfeed at Tray 3: Jam T3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Misfeed at Tray 4: Jam T4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Door and Cover Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Close Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Consumable Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
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Phaser 6250 Color Printer
Install or Reseat Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . Replace Imaging Unit or Imaging Unit is Near End of Life. . . . . . . . . . . . . . . . . . . . . . Install or Reseat Transfer Roller. . . . . . . . . . . . . . . . . . . . . . . . . Replace Transfer Roller or Transfer Roller is at End of Life . . . . . . . . . . . . . . . . . . . . . . Install or Reseat Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace Fuser or Fuser is Near End of Life. . . . . . . . . . . . . . . . . Install or Lock [Y] [M] [C] [K] Toner Cartridge . . . . . . . . . . . . . Replace [Y] [M] [C] [K]Toner Cartridge or [Y] [M] [C] [K] Toner Is Low . . . . . . . . . . . . . . . . . . . . . . . . Dusty Density Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Tray is Full, Unload Paper. . . . . . . . . . . . . . . . . . . . . . . . Remove Ribbon from [Y] [M] [C] [K] Toner Cartridge . . . . . . . . Tray and Media Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insert Tray [2] or Tray [2] Missing. . . . . . . . . . . . . . . . . . . . . . . Insert Tray [3] [4] or Tray [3] [4] Missing . . . . . . . . . . . . . . . . . Tray 2 Paper is Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tray [3] [4] Paper is Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Out of Paper; Load Tray 1 (MPT) with [size] [type] . . . . . . . . . . Out of Paper; Load Tray [2] [3] [4] with [size] [type]. . . . . . . . . Wrong Paper Size; Load Tray 2 with [size] [type] . . . . . . . . . . . Wrong Paper Size; Load Tray [3] [4] with [size] [type] . . . . . . . Wrong Paper Type; Load Tray [1 (MPT)] [2] [3] [4] with [size] [type] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laser Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Density Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser Failure (cont'd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser Failure (cont'd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generic Fan Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Firmware Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Imaging Unit Firmware Failure . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser Firmware Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller to Engine Communications Failure . . . . . . . . . . . . . . Engine NVRAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace [Y] [M] [C] [K] Toner Cartridge . . . . . . . . . . . . . . . . . . [Y] [M] [C] [K] Toner Cartridge Failure . . . . . . . . . . . . . . . . . . . Non-Phaser 6250 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Phaser 6250 Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Sensor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . .
3-37 3-38 3-39 3-40 3-41 3-42 3-43 3-45 3-47 3-48 3-49 3-50 3-50 3-52 3-54 3-55 3-56 3-57 3-58 3-60 3-62 3-63 3-63 3-64 3-65 3-66 3-67 3-68 3-69 3-70 3-71 3-72 3-73 3-74 3-75 3-76 3-77 3-78 3-79 3-80
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4 General Troubleshooting
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Printer Status Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Power-Up Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 System Start-Up and POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 System Boot Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Power On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 POST Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 LED Blink Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 POST Diagnostic Test Descriptions . . . . . . . . . . . . . . . . . . . . . . . 4-7 Front Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 No Front Panel Display after Power is Turned ON . . . . . . . . . . . . 4-8 Front Panel LED is on, Front Panel Display is Blank. . . . . . . . . . . 4-8 Front Panel Continually Displays "Warming Up...". . . . . . . . . . . . 4-8 Front Panel Continually Displays "Install or Reseat Imaging Unit" 4-8 Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Inoperable Printer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Engine Power-Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Printer Does Not Come to a "Ready" State . . . . . . . . . . . . . . . . . . 4-9 Paper Size Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 AC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 DC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Media Jams and the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . 4-17 Macintosh printing problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Windows printing problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Network Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
5 Print-Quality Troubleshooting
Print-Quality Problems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Defects Associated with Specific Printer Components. . . . . . . . . 5-3 Front Panel Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Test Print 1: CMYK Sample Page . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Test Print 2: RGB Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Service Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Test Print 3: Test Pattern Sample . . . . . . . . . . . . . . . . . . . . . . . . 5-6 600 x 600 Service Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Print Engine Test Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Print-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Light Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Light Print in Only One Color . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Black Prints with White Margin Border . . . . . . . . . . . . . . . . . . . 5-14 Solid Dark or Dirty Prints, No Border. . . . . . . . . . . . . . . . . . . . . 5-15
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Missing Band, Voids Or Streaks In a Single Color or All Colors Parallel to the Leading Edge. . . . . . . . . . . . . . . Missing Band, Voids or Streaks in a Single Color or All Colors in Direction of Paper Travel . . . . . . . . . . . . . . . Repeating and/or Random Spots . . . . . . . . . . . . . . . . . . . . . . . . Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . Residual Image, Ghosting or Hot Offset . . . . . . . . . . . . . . . . . . . Incomplete Fusing or Cold Offset . . . . . . . . . . . . . . . . . . . . . . . . Mis-Registration, Color Layer not Correctly Registered in the Process Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dirty Vertical Streaks on the Edges of the Page . . . . . . . . . . . . .
5-16 5-18 5-19 5-20 5-22 5-23 5-24 5-25
6 Adjustments and Calibrations
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Color Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Margin Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal and Vertical Color Registration . . . . . . . . . . . . . . . . . . Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PostScript NVRAM Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Diagnostics PostScript NVRAM Resets. . . . . . . . . . . . . . . . . . . . 6-2 6-2 6-2 6-3 6-3 6-4 6-4 6-8
7 Cleaning and Maintenance
Service Preventive Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . 7-2 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
8 Service Part Disassembly
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Standard Orientation of the Printer. . . . . . . . . . . . . . . . . . . . . . . . 8-2 General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Removing Routine Maintenance Items and Consumables . . . . . . . . . . . . 8-4 Transfer Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Imaging Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Fuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Toner Cartridge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Print Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Front Cover (PL 1.1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Front Panel (PL 1.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Fuser Fan (PL 1.1.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Top Main Cover (PL1.1.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Image Unit Top Cover (Door C) (PL1.1.10) . . . . . . . . . . . . . . . . 8-10 Right and Left Side Covers (PL1.1.24), (PL1.1.30) . . . . . . . . . . 8-11
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Rear Cover (PL 1.1.20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Left and Right Links (PL 1.1.23) . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Tray 1 (MPT) (PL1.1.99) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Front Right Cover (PL 1.1.25) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Front Left Cover Assembly (PL1.1.29) . . . . . . . . . . . . . . . . . . . . 8-16 Paper Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Paper Feed Roller (PL 2.1.2) (Routine Maintenance Item). . . . . 8-18 Turn Chute Assembly (PL3.1.2). . . . . . . . . . . . . . . . . . . . . . . . . 8-19 Printer Chassis/Feeder Assembly. . . . . . . . . . . . . . . . . . . . . . . . 8-20 Paper Pick Assembly (PL3.3.1) . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Right and Left Housing (PL 3.2) . . . . . . . . . . . . . . . . . . . . . . . . 8-23 Temperature/Humidity Harness (PL3.2.1) and Sensor (PL3.2.2) 8-24 High-Capacity Feeder Harness (PL3.2.3) . . . . . . . . . . . . . . . . . . 8-25 Paper Size Switch Assembly (PL3.2.4) . . . . . . . . . . . . . . . . . . . 8-26 Low Paper Lever (PL3.2.7), Indicator (PL3.2.8) and Indicator Guide (PL3.2.10). . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 Paper Pick Rollers (PL3.3.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29 No Paper Actuator (PL3.3.5), No/Low Paper Sensor (PL3.3.4) . 8-30 Link Actuator (PL3.3.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32 Feed Solenoid (PL3.3.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33 Turn Clutch Assembly (PL3.3.18) . . . . . . . . . . . . . . . . . . . . . . . 8-34 Roll Turn Assembly (PL3.3.20) . . . . . . . . . . . . . . . . . . . . . . . . . 8-35 Paper Feed Roller (Routine Maintenance Item) . . . . . . . . . . . . . 8-36 Retard Roller Housing Assembly (PL4.1.1) . . . . . . . . . . . . . . . . 8-37 Turn Roll (PL 4.1.2), Turn Clutch (PL 4.1.9), and Friction Clutch Assembly (PL 4.1.4) . . . . . . . . . . . . . . . 8-38 Retard Roller Assembly (PL4.1.5) . . . . . . . . . . . . . . . . . . . . . . . 8-39 Chute Assembly In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41 Chute Assembly In (PL 5.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41 CTD (ADC) Sensor (PL 5.1.11) . . . . . . . . . . . . . . . . . . . . . . . . . 8-42 Toner Full Sensor (PL 5.1.13) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43 Fuser Drive Assembly (PL 5.1.18) . . . . . . . . . . . . . . . . . . . . . . . 8-44 Right Latch (Door A) (PL 5.1.21). . . . . . . . . . . . . . . . . . . . . . . . 8-45 Left Latch (PL 5.1.30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46 Chute Assembly Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47 Chute Assembly Out (PL6.1.1). . . . . . . . . . . . . . . . . . . . . . . . . . 8-47 Output Tray Full Actuator (PL 6.1.5) and Full Stack Sensor (PL 6.1.4). . . . . . . . . . . . . . . . . . . . . . . . . 8-50 Duplex Actuator (PL 6.1.13) and Duplex Sensor (PL 6.1.4). . . . 8-51 Tray 1 Actuator (PL 6.1.37) and Tray 1 Sensor (PL 6.1.4). . . . . 8-53 Static Eliminator Assembly (PL 6.1.9) . . . . . . . . . . . . . . . . . . . . 8-55 Duplex Roller (PL 6.1.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56 Latch Plate (PL 6.1.17), Latch Out (PL 6.1.18), Latch Holder (PL 6.1.19), and Latch Spring Out (PL 6.1.20) 8-57 Tray 1 Paper Pick Assembly (PL 6.1.27) (Roll Feed) . . . . . . . . . 8-58 Tray 1 Feed Solenoid (PL 6.1.40). . . . . . . . . . . . . . . . . . . . . . . . 8-59
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Tray 1 Shaft (PL 6.1.28). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60 Tray 1 Bottom Plate (PL 6.1.42). . . . . . . . . . . . . . . . . . . . . . . . . 8-61 Chute Assembly Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62 Chute Assembly Exit (PL 7.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . 8-62 Exit Roller (PL 7.1.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63 Mid Roller (PL 7.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64 Duplex Motor Assembly (PL 7.1.8) . . . . . . . . . . . . . . . . . . . . . . 8-65 Exit Actuator (Fuser) (PL 8.1.7) . . . . . . . . . . . . . . . . . . . . . . . . . 8-66 Strap (PL 8.1.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67 Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68 Laser Unit (PL 9.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68 Housing Assembly Bias (PL 9.1.4). . . . . . . . . . . . . . . . . . . . . . . 8-69 Chute Assembly Registration (PL 9.1.6) and Housing Assembly Electric (PL 9.1.11) . . . . . . . . . . . . . . . . 8-71 Registration Sensor Actuator (PL 9.1.9) and Registration Sensor (PL 9.1.8) . . . . . . . . . . . . . . . . . . . . . . . 8-73 OHP Sensor and Harness (Kit) (PL 9.1.12) . . . . . . . . . . . . . . . . 8-75 Toner Cartridge Holder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77 Toner Cartridge Holder Unit Assembly (PL 10.1) . . . . . . . . . . . . 8-77 Toner Cartridge Holder Assembly. . . . . . . . . . . . . . . . . . . . . . . . 8-80 Toner Present Switch Bracket and Actuator (PL 10.1.6 and 10.1.22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82 Toner Low Sensor (PL 10.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84 CRUM Reader Box Assembly (PL 10.1.21) . . . . . . . . . . . . . . . . 8-85 EEPROM Board (PL 10.1.14) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86 Sub-High Voltage Power Supply Board (PL 10.1.15) . . . . . . . . . 8-87 Frame and Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88 Left Lever Plate (PL 11.1.1), Lever Bracket (PL 11.1.2), Lever Link (PL 11.1.3), Lever Drum (PL 11.1.4), and Lever Spring (PL 11.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88 Lever Plate Right (PL 11.1.7), Lever Bracket (PL 11.1.2), Lever Link (PL 11.1.6), Lever Drum (PL 11.1.4), and Lever Spring (PL 11.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91 Main Drive Assembly (PL 11.1.14). . . . . . . . . . . . . . . . . . . . . . . 8-94 Developer Drive Assembly (PL 11.1.13). . . . . . . . . . . . . . . . . . . 8-95 Actuator, I/L (PL 11.1.8) and Spring, I/L (PL 11.1.9) . . . . . . . . . 8-96 Earth Ground Circuit Board (PL 11.1.16) . . . . . . . . . . . . . . . . . . 8-97 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98 AC Switch Harness Assembly (PL 12.1.11) . . . . . . . . . . . . . . . . 8-98 Low-Voltage Power Supply (PL 12.1.10) . . . . . . . . . . . . . . . . . . 8-99 Motor Driver Board (PL 12.1.12) . . . . . . . . . . . . . . . . . . . . . . . 8-101 Rear Fan (PL 12.1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102 Card Cage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103 Housing Assembly Contact (PL 12.1.14) . . . . . . . . . . . . . . . . . 8-106 Engine Control Circuit Board (PL12.1.1) . . . . . . . . . . . . . . . . . 8-107 Image Processor Board (PL12.1.4) . . . . . . . . . . . . . . . . . . . . . 8-110
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Optional High Capacity Feeder Disassembly . . . . . . . . . . . . . . . . . . . . 8-111 Cover Front (PL14.2.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111 Cover, Right (PL14.2.1) and Cover, Left (PL14.2.3) . . . . . . . . 8-112 Turn Chute Assembly (PL14.3.7). . . . . . . . . . . . . . . . . . . . . . . 8-113 Tray 3 Harness Assembly (PL14.5.3), Tray 4 Harness Assembly (PL14.5.4), and HCF Plug Harness Assembly (PL14.5.2) . 8-114 Circuit Board, HCF (PL14.5.1) . . . . . . . . . . . . . . . . . . . . . . . . . 8-116 Drive Feeder Assembly (PL14.5.5). . . . . . . . . . . . . . . . . . . . . . 8-117 Indicator Assembly (PL14.5.9) . . . . . . . . . . . . . . . . . . . . . . . . 8-118 Right Tray Guide (PL14.3.5)and Low Paper Lever (PL 14.5.8) 8-119 Left Tray Guide (PL14.3.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-122 Link Actuator (PL 14.4.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-124 HCF Paper Pick Assembly (PL14.4.1) . . . . . . . . . . . . . . . . . . . 8-125 Idler Gear (PL14.5.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-126 No Paper, Low Paper Sensor (PL14.5.7) . . . . . . . . . . . . . . . . . 8-127 Paper Size Switch Assembly (PL14.3.6) . . . . . . . . . . . . . . . . . 8-128 Casters, Locking (PL 14.2.5)/Non-Locking (PL 14.2.6) . . . . . . 8-129 Optional 500-sheet Feeder Disassembly . . . . . . . . . . . . . . . . . . . . . . . 8-130 Cover Front (PL15.2.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-130 Cover, Right (PL15.2.2) and Cover, Left (PL15.2.1) . . . . . . . . 8-131 Turn Chute Assembly (PL15.3.9). . . . . . . . . . . . . . . . . . . . . . . 8-132 Tray 3 Harness Assembly (PL15.5.3) and STF Plug Harness Assembly (PL15.5.2). . . . . . . . . . . . . . . 8-133 Circuit Board, STF (PL15.5.1) . . . . . . . . . . . . . . . . . . . . . . . . . 8-135 Drive Feeder Assembly (PL15.5.5). . . . . . . . . . . . . . . . . . . . . . 8-136 Indicator Assembly (PL15.5.8) . . . . . . . . . . . . . . . . . . . . . . . . 8-137 Right Tray Guide (PL15.3.5)and Low Paper Lever (PL 15.5.7) 8-138 Left Tray Guide (PL15.3.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-141 Link Actuator (PL 15.4.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-143 STF Paper Pick Assembly (PL15.4.1) . . . . . . . . . . . . . . . . . . . 8-144 No Paper, Low Paper Sensor (PL15.5.6) . . . . . . . . . . . . . . . . . 8-145 Paper Size Switch Assembly (PL15.3.6) . . . . . . . . . . . . . . . . . 8-146
9 Parts List
Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Print Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 PL 1.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 PL 2.1 Universal Paper Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 PL 3.1 Paper Feed I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 PL 3.2 Paper Feed II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 PL 3.3 Paper Feed III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 PL 4.1 Housing Assembly Retard . . . . . . . . . . . . . . . . . . . . . . . 9-14 PL 5.1 Chute Assembly In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 PL 6.1 Chute Assembly Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
xx
Phaser 6250 Color Printer
PL 7.1 Chute Assembly Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . PL 8.1 Transfer Roller & Fuser Assembly (RMIs) . . . . . . . . . . . PL 9.1 Xerographics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PL 10.1 Holder Toner Cartridge Assembly . . . . . . . . . . . . . . . . . PL 11.1 Frame and Drive Assemblies. . . . . . . . . . . . . . . . . . . . . PL 12.1 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PL 13.1 Harness Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional High-Capacity Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PL 14.1 Paper Trays 3 & 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PL 14.2 High-Capacity Feeder Covers . . . . . . . . . . . . . . . . . . . . PL 14.3 High-Capacity Feeder Guides and Turn Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PL 14.4 Paper Pick Assembly Trays 3 & 4 . . . . . . . . . . . . . . . . . PL 14.5 High-Capacity Feeder Harness, Board and Motor . . . . . Optional 500-sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PL 15.1 Paper Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PL 15.2 500-sheet Feeder Covers. . . . . . . . . . . . . . . . . . . . . . . . PL 15.3 500-sheet Feeder Guides and Turn Chute Assembly . . . PL 15.4 Paper Pick Assembly Tray 3 . . . . . . . . . . . . . . . . . . . . . PL 15.5 500-sheet Feeder Harness, Board and Motor . . . . . . . . Xerox Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-22 9-24 9-26 9-28 9-30 9-32 9-34 9-36 9-36 9-37 9-38 9-40 9-42 9-44 9-44 9-45 9-46 9-48 9-50 9-51
10 Wiring Diagrams
Plug/Jack Locator Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Map 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Map 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Map 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Map 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 High-Capacity Feeder Plug/Jack Locator Table . . . . . . . . . . . . . . . . . . 10-10 Map 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 500-sheet Feeder Plug/Jack Locator Table . . . . . . . . . . . . . . . . . . . . . 10-12 Map 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Print Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Notations used in Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 10-14 Main Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Paper Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Developer Section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Developer Section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Laser Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 Xerographics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 Xerographics 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Service Manual
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Printer Options Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Capacity Feeder Main Wiring Diagram. . . . . . . . . . . . . . . Drive Section (HCF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-sheet Feeder Main Wiring Diagram. . . . . . . . . . . . . . . . . . Drive Section (STF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-27 10-27 10-28 10-29 10-30 10-31 10-32 10-33
A Appendix
Printer Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Index
xxii
Phaser 6250 Color Printer
General Information
In this chapter...
Printer Introduction and Overview Printer Configurations Parts of the Printer Phaser 6250 Front Panel Configuration Image Processor Board Routine Maintenance Items Printer Specifications
Chapter
1
Printer Introduction and Overview
The Xerox Phaser® 6250 Color Laser Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. To ensure complete understanding of this product, participation in Xerox Phaser 6250 Service Training is strongly recommended.
Phaser 6250 Color Laser Printer shown with the Optional HighCapacity Feeder
1 [MPT]
2
3
4
6250-010
Printer Configurations
The Phaser 6250 Printer combines a single-pass, tandem color laser design, with an image processor supporting PostScript 3 and PCL5c page description languages. The printer is a high performance, A4, 26 page per minute (ppm) desktop color laser printer supporting resolutions up to 2400 x 600 dots-per-inch (dpi). The Phaser 6250 comes in five configurations. The main differences are optional networking, standard memory, optional high-capacity feeder, duplexing (2-sided printing) capabilities, and optional internal hard drive.
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Phaser 6250 Color Laser Printer Service Manual
A replaceable "Configuration Chip" holds configuration information that enables or disables built-in features as described below.
Printer Configuration Features 6250B
Max Print Speed Memory (Mbytes) PostScript Fonts PCL Fonts Embedded PCL Job Pipelining Secure, Proof, and Saved Print Jobs PDF 1.4 support Banner-Size printing Default Resolutions (dpi) Photo Mode Job Collation Auto-Duplex Single Tray, 500-Sheet Feeder Tray 3 1000-Sheet High-Capacity Feeder Trays 3 & 4 Ethernet capabilities USB, Parallel Hard Drive 26 128 137 81 Yes No No No No 2400x600 No No No Opt
6250N
26 256 137 81 Yes Yes Opt* Opt* Opt* 2400x600 Yes Opt* No Opt
6250DP
26 256 137 81 Yes Yes Opt* Opt* Opt* 2400x600 Yes Opt* Yes Opt
6250DT
26 512 137 81 Yes Yes Opt* Opt* Yes 2400x600 Yes Opt* Yes Yes***
6250DX
26 512 137 81 Yes Yes Yes Yes Yes 2400x600 Yes Yes Yes No
Opt
Opt
Opt
Opt
Yes
Opt Yes Opt**
Yes Yes Opt
Yes Yes Opt
Yes Yes Opt
Yes Yes Yes
* Requires optional hard drive ** Hard drive will work but does require N upgrade to support storage features *** 500-Sheet Feeder is not stackable
General Information
1-3
Printer Memory and RAM Capabilities
The printer features two slots that accept 64, 128, and 256 Mbytes of SDRAM. All combinations are allowed for 64, 128, 256, 320, 384, and 512 Mbytes. Memory modules must have the following characteristics:
PC133 DRAM Standard 144 Pin SODIMM Serial Presence Detect 3.3 Volt
The startup Page and the Configuration Page list the amount of RAM installed in the Printer. If the memory does not meet the above specifications, it will be ignored by the printer.
1-4
Phaser 6250 Color Laser Printer Service Manual
Parts of the Printer
Exterior
1
2 3
7 8
4
9
5
6
6250-021
1. Top Cover (Output Tray) 2. Control Panel (Front Panel) 3. Front Cover 4. Tray 1 (Multi-Purpose Tray) 5. Tray 2 (Universal Paper Tray)
6. High-Capacity Feeder with Tray 3 and Tray 4 7. Door Latch B 8. Door Latch A 9. Power On/Off Switch
General Information
1-5
Phaser 6250 Front Panel Configuration
The Front Panel contains one tricolor LED, a display window and six function buttons. These buttons navigate the menu system shown in the display window, perform various functions, and select modes of operation for the printer.
LED Indicators:
Green = Ready to Print or Printing Flashing Yellow = Warning
Flashing Green = Receiving, Processing Data, Printing or Power Saver Mode Flashing Red = Error
Front Panel Button Descriptions
3 5
Phaser 6250
OK
1
2
4
6
7
8
6250-022
1 2 3 4
LED (Power/Status) Graphic front panel display
5 6 7 8
Up Arrow Button - scrolls up the menu system Down Arrow Button - scrolls down the menu system OK (select) Button Information Button - for additional explanation or help
Cancel Button Back Button
Front Panel Shortcuts
Mode
Skip execution of POST diagnostics Print Service Diagnostics Map Reset PostScript NVRAM Password Bypass Enter Service Diagnostics
Press this selection at Power On
OK INFO BACK+OK UP+DOWN BACK+INFO
1-6
Phaser 6250 Color Laser Printer Service Manual
Rear View
1
2
3
4
5
6250-019
6 7 8
1. Top Cover 2. Toner Cartidges 3. AC Power Connector
5. Paper Tray Rear Cover 6. USB Connector 7. Ethernet 10BaseT and 100Tx Connector 8. IEEE 1284 Parallel Connector
4. Image Processor Board
Rear Panel Configuration Interfaces
IEEE 1284 Parallel Ethernet 10BaseT and 100Tx USB
General Information
1-7
Image Processor Board
The components identified in the following figure need to be transferred from the old board to the new board when installing a new Image Processor Board in the printer. Data stored in the NVRAM can be transferred to the new board using the MCU NVRAM Store/Restore functions instead of by moving the component. Detailed information on the Store/Restore functions is available in "Service Diagnostic Tests" on page 3-9.
pin 1
2
1
3
4
6250-023
1. Hard Drive (available option) 2. Configuration Chip
3. NVRAM 4. Memory (RAM) DIMM 1 and DIMM 2 (available option)
1-8
Phaser 6250 Color Laser Printer Service Manual
Routine Maintenance Items
A printer part or assembly that has a limited life, and requires periodic replacement.
1
2
3
1. Transfer Roller 2. Imaging Unit
6250-020
3. Fuser Assembly
Consumables
Consumables consist of the four toner cartridges used in the printer.
6250-495
General Information
1-9
Consumable Life Counter Behavior
Internal counters track Consumables and Routine Maintenance Items life usage and store the values in NVRAM. The image processor board monitors these counters in order to display the near end-of-life and end-of-use messages. Life ratings are based on A-size sheets at 5% coverage. Imaging Unit life ratings are based on average 4 page job length.
Consumables
Toner Cartridges High-Capacity Standard Capacity
Print Life
8,000 4,000
Routine Maintenance Items
Imaging Unit Fuser Assembly Transfer Roller and Waste Box Feed Roller Kit* * No life tracking for this item 30,000 100,000 15,000 up to 100,000
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Phaser 6250 Color Laser Printer Service Manual
Printer Specifications
Physical Dimensions and Clearances
Print Engine Dimensions
Height: Width: Depth: Weight:
Value
445 mm (17.52 in.) 439 cm (17.28 in.) 638 mm (25.12 in.) Approximately 36.5 kg (80.5 lb.) Print engine Approximately 56.5 kg (124.5 lb.) with Paper Tray(s) installed
Optional High-Capacity Feeder Dimensions
Height: Width: Depth: Weight:
Value
336 mm (13.23 in.) Optional Paper Tray Assembly 439 cm (17.28 in.) 563 cm (22.17 in.) Approximately 15 kg (33 lb.) no Paper Tray(s) installed Approximately 20 kg (44 lb.) with Paper Tray(s) installed
Optional 500-sheet Feeder Dimensions
Height: Width: Depth: Weight:
Value
172 mm (6.77 in.) Optional Paper Tray Assembly 439 cm (17.28 in.) 563 cm (22.17 in.) Approximately 7 kg (15.4 lb.) no Paper Tray installed Approximately 12 kg (26.4 lb.) with Paper Tray installed
Clearance
Top: Left: Right: Front: Rear: Mounting surface level tolerance:
Value
350 mm (13.78 in.) 100 mm (3.94 in.) 150 mm (5.91 in.) 600 mm (23.62 in.) 200 mm (7.87 in.) Within 3 degrees of horizontal with all four feet in contact with the surface.
General Information
1-11
Functional Specifications
Functional Specifications
Characteristic
Printing process
Specification
Imaging System - 4-tandem drums, electro-photographic system using intermediate drum transfer rolls (IDTs). Exposure System - Semiconductor laser, simultaneous scanning by 4 beams. Development System - Dry type 2-component developer. Fusing System - Heat fusing, free nip-belt system. Yellow, Magenta, Cyan, and Black Toner Cartridges Draft 600 x 600 dpi Enhanced 2400 x 600 dpi (Default) Photo 2400 x 600 dpi* * Not available on the Phaser 6250B. Print Mode: Print Engine capable of making prints immediately. Ready Mode: 20 seconds from completion of a print. Sleep/ Low Power/ Power Saver Mode: Entered after a specified period of Print Engine inactivity since completion of the last print. Mode 600/2400 dpi Paper Size / wt g/m2 Letter / A4 65 -130 100-163 160-216 Legal 65 -130 100-163 160-216 Envelope/Postcard 160-216 Letter / A4 / OHP Letter / A4 Photo Glossy Paper 100-200 Simplex Duplex
Color medium Resolution / Addressability
Operating Modes
Continuuous Operating Printing Speed ppm = pages per minute ipm = inches per minute
26/24 ppm 15 ipm 13/12 ppm 7.8 ipm 13/12 ppm N/A
600/2400 dpi
19 ppm 10 ppm 10 ppm
16 ipm 7.8 ipm N/A
600/2400 dpi
13 ppm 8.6/8 ppm 8.6/8 ppm
N/A
600/2400 dpi
5 ipm
Cleaning Cycle interval for continuous printing
Print speed will be reduced if the print job is larger than the cleaning cycle interval. IU Print Volume Draft Enhanced Photo Pages Pages Pages 0 - 5 K Pages 53 31 22 5 - 10 K Pages 35 26 18 10 - 15 K Pages 35 26 18 15 - 20 K Pages 35 26 18 20 - 25 K Pages 29 22 13 25 - 30 K Pages 29 22 13 >30 K Pages 29 22 13
1-12
Phaser 6250 Color Laser Printer Service Manual
Functional Specifications (Continued)
Characteristic
First Print-Out (in seconds) (Letter/A4) (printer in Ready state)
Specification
Mode Simplex, 600 dpi Duplex, 600 dpi Simplex, half-speed Duplex, half-speed Tray 1 14.5 23 23.5 38.5 Tray 2 15 23.5 24.5 39.5 Tray 3 16.5 25 27.5 42.5 Tray 4 18 26.5 30.5 45.5
Warm-up time
30 seconds from cold start (power off condition)
Electrical Specifications
Characteristic
Primary line voltages Primary line voltage frequency range Power consumption at rated voltage input
Specification
110-127 V Printer - (90 - 140 V) 13 amp circuit 220-240 V Printer - (198 - 264 V) 7-8 amp circuit 100-120 V Printer - 50/60 Hz + 3Hz 220-240 V Printer - 50/60 Hz + 3Hz Mode Print Mode Ready Mode Sleep Mode Condition Max.. Fuser On Fuser Off 100/120 VAC 1000 W or less 180 W or less 45 W or less 220/240 VAC 1000 W or less 180 W or less 45 W or less
Environmental Specifications
Characteristic
Temperature: Operating Transportation Storage 24 month maximum 1 month maximum Humidity Operating Transportation Storage Altitude Operating Transportation Acoustic Noise Idle Printing
Specification
Optimal print-quality range: 17o to 26o C (62o to 80o F) 10o C to 32o C (50o F to 90o F) -30o C to +50o C (-22o F to 122o F) Normal: 0o C to 35o C (32o F to 95o F) Severe: -20o C to 40o C (-4o F to 104o F) Optimal print-quality range: 35% to 70% 10% - 85% 30% - 85% 5% - 95% 0 - 2,500 meters (8,000 ft.) 0 - 6,092 meters (20,000 ft.) Printer Only 35.0db or less 55.0db or less (Full Speed) 52.0db or less (Half Speed) With Feeder Option 35.0db or less 55.0db or less (Full Speed) 53.0db or less (Half Speed)
General Information
1-13
Media and Tray Specifications
Specification
Printable Area Supported Media Sizes Minimum margins = 5 mm (0.2 in.) on all sides Maximum paper size = 215.9 mm x 355.6 mm (8.5 in. x 14 in.) Minimum paper size = 88.9 mm x 139.7 mm (3.5 in. x 5.5 in.) Paper Type Letter Legal Executive Statement US Folio A4 A5* A6 B5 JIS ISO B5 Custom Size & Banner Size 8.5 x 11 in. 8.5 x 14 in. 7.25 x 10.5 in. 5.5 x 8.5 in. 8.5 x 13 in. 210 x 297 mm 148 x 210 mm 105 x 148 mm 182 x 257 mm 176 x 250 mm 8.5 x 22.86 in.
Trays
All Trays
All Trays All Trays All Trays Tray 1 Only All Trays All Trays Tray 1 Only Tray 1 Only All Trays Tray 1 Only Tray 1 Only All Trays All Trays Tray 1 & 2 Tray 1 Only Tray 1 Only Tray 1 & 2 All Trays All Trays Tray 1 Only Tray 1 Only Tray 1 Only Tray 1 Only Tray 1 Only Tray 1 & 2 Tray 1 Only
Supported Media Types and Weights
Type Weight Plain Paper 64- 90 g/m2 (17 - 24 lb. Bond) Heavy Plain Paper 85 - 130 g/m2 (22 - 28 lb. Bond) Phaser 25-Series Premium Transparency Film (Only) Thin Card Stock 100 - 163 g/m2 (26 - 60 lb. Cover) Thick Card Stock 160 - 216 g/m2 (59 - 80 lb. Cover) Labels N/A Letterhead 85 - 130 g/m2 (22 - 28 lb. Bond) Glossy Coated Paper** 120 - 163 g/m2 (81 - 110 lb.) Business & Greeting Cards N/A CD/DVD Labels and InsertsN/A Digital Photo Paper 163 g/m2 (60 lb. Cover) Phaser Premium Post176 g/m2 (65 lb. Cover) cards Phaser Glossy Trifold 176 g/m2 (65 lb. Cover) Brochures Phaser Weatherproof 100 g/m2 (27 lb. Bond) Paper Envelopes Weight 20 - 24 lb. Bond Commercial #10 4.12 x 9.5 in Monarch Envelope 3.87 x 7.5 in A7 Envelope 5.25 x 7.25 in Custom DL Envelope 110 x 220 mm C5 Envelope 162 x 229 mm C6 Envelope 114 x 162 mm B5 Envelope 176 x 250 mm Envelopes with hot melt type glue are not supported in this printer. Do not use envelopes with windows or metal clasps.
Supported Envelopes*
* Some wrinkling and embossing may occur when printing envelopes.
1-14
Phaser 6250 Color Laser Printer Service Manual
Specification
Speciality Media Phaser 25-Series Premium Transparencies Letter 216 x 279 mm 8.5 x 11 in. A4 210 x 297 mm 8.27 x 11.69 in. Other sizes will be handled through Tray 1 with use of the custom size option. Phaser Premium Postcards Letter 216 x 279 mm 8.5 x 11 in. A4 210 x 297 mm 8.27 x 11.69 in. Phaser Glossy Trifold Brochures Letter 216 x 279 mm 8.5 x 11 in. A4 210 x 297 mm 8.27 x 11.69 in. Weather Proof Paper Letter 216 x 279 mm 8.5 x 11 in. A4 210 x 297 mm 8.27 x 11.69 in. Standard Paper Transparency Envelopes Universal Tray 500 Sheets 100 Sheets*** N/A Tray 1/