Xerox Phaser 6100 Service Manual
®
Phaser
Color Laser Printer
6100
Service
Manual
XEROX
X
Phaser 6100 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: February 2003
071-0872-00
Copyright © 2004, 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 Unpublished rights reserved under the copyright laws of the United States.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
TekColor
, The Document Company®, the stylized X®, CentreWare®, infoSMART®, Made For Each Other®, Phaser®, PhaserSMART®, and
®
are registered trademarks of Xerox Corporation in the United States and/or other countries. PhaserPort™ and PhaserTools™ are
trademarks of Xerox Corporation.
®
Reader®, Illustrator®, PageMaker®, Photoshop®, PostScript®, ATM®, Adobe Garamond®, Birch®, Carta®, Mythos®, Quake®, and
Adobe
®
are registered trademarks of Adobe Systems Incorporated in the United States and/or other countries. Adobe Jenson™, Adobe Brilliant
Tek to n
™
Screens
Apple
Yo r k
technology, and IntelliSelect™ are trademarks of Adobe Systems Incorporated.
®
, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, AppleTalk®, TrueType®, Apple Chancery®, Chicago®, Geneva®, Monaco®, and New
®
are registered trademarks of Apple Computer, Inc. in the United States and/or other countries. QuickDraw™ is a trademark of Apple
Computer, Inc.
®
and HP-GL® are registered trademarks of Hewlett-Packard Corporation in the United States and/or other countries.
PCL
®
is a registered trademark of International Business Machines Corporation in the United States and/or other countries.
IBM
®
Windows
Novell
other countries. IPX
Sun
SWOP
UNIX
, Windows NT®, and Wingdings® are registered trademarks of Microsoft Corporation in the United States and/or other countries.
®
, NetWare®, NDPS®, NDS®, and Novell Directory Services® are registered trademarks of Novell, Incorporated in the United States and/or
®
and Sun Microsystems® are registered trademarks of Sun Microsystems, Incorporated in the United States and/or other countries.
®
is a registered trademark of SWOP, Inc.
®
is a registered trademark in the United States and other countries, licensed exclusively through X/Open Company Limited.
™
and Novell Distributed Print Services™ are trademarks of Novell, Incorporated.
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.
®
PANTONE
PANTONE
Colors generated may not match PANTONE-identified standards. Consult current PANTONE Publications for accurate color.
®
and other Pantone, Inc. trademarks are the property of Pantone, Inc. © Pantone, Inc., 2000.
.
Contents
1 Precautions
1. Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.1 Manual Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.2 Product Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3.1 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3.2 Disconnecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Electrostatic Discharge (ESD) Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Service Safety Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5.1 General Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5.2 Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5.3 Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5.4 Servicing Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5.5 Servicing Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5.6 Servicing Fuser Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6 Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.1 Federal Communications Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.2 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2 Reference Information
2. Reference Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Tools for Troubleshooting the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Selecting a Location for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Printer Serial Number Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3 Specifications
3.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Controller Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Electrical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Environmental Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Periodically Replaced Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5.2 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5.3 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6 Media Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.6.1 Paper Size and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.6.1 Paper Size and Weights (cont’d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.6.2 Print Margins and Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.6.3 PC (Host) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4 Product Summary
4.1 System Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Major Assemblies of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
i
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Motor and Fan Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.1.3 Clutch and Solenoid Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.1.4 Sensor and Switch Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.1.5 Main Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.1.6 LVPS (SMPS) Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.1.7 HVPS (High Voltage Supply) Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
5 System Outline
5.1 Color Laser Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Imaging Unit (Drum Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 LSU (Exposure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.3 Toner Cartridge (Development Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.4 Image Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.1.5 Fuser (Fusing Process). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.1.6 Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.1.7 Waste Toner Collection Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.2 System Start-Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.2.1 System Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.2.2 Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.2.3 Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.2.4 Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.2.5 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.2.6 Post-Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
6 Disassembly
6.1.1 Precautions for Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.2 Precautions When Removing Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Maintenance and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Printer Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Information Related to Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.1 Service Part Assemblies Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Screws Used in the Printer (Hardware Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.2 Removing Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.4 Replacing the Waste Toner Cartridge (PL 9.1.57). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.1 Top Cover (PL 9.1.17) and Front Cover (PL 9.1.15). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.4.2 Control Panel (PL 9.2.19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.4.3 Rear Cover (PL 9.1.16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.4.4a Duplex Cover - Door C (PL 9.6.0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.4.4b Duplex Unit (PL 9.6.2) and Transfer Roller (PL 9.1.54). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.3.5a Fuser (PL 9.1.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.4.5b Fuser Base Cover (PL 9.13.29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.4.6 Exit Cover - Door B (PL 9.5.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.4.7a Low-Voltage Power Supply - LVPS/SMPS (PL 9.1.19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.4.7b Main Controller Board (PL 9.1.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6.4.8 Fuser Fan Assembly (PL 9.1.27) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.4.9 Main Drive Assembly (PL 9.1.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6.4.10 HVPS (High Voltage Power Supply) (PL 9.1.20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
ii
6.4.11 Developer Drive Assembly (PL 9.1.8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.4.12 DEVE Drive Board (PL 9.13.20) and
DEVE Cover Open Switch (PL 9.15.36) (Door A Interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6.4.13 DEVE Drive Motor (PL 9.7.16) and
Clutch Cam Solenoid (PL9.1.33) (T1 Clean) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
6.4.14 Erase Lamp (PL 9.13.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.4.15a Laser Brush (PL 9.1.49) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.4.15 DEVE Cover - Door A (PL 9.1.18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.4.16 Laser Unit (PL 9.1.21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6.4.17 DEVE OEM Key Board - CRUM Reader Board (PL 9.14.36) . . . . . . . . . . . . . . . . . . . . . . . . 6-39
6.4.18 Waste Toner Auger Assembly (PL 9.13.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6.4.18a Waste Toner Cartridge Full Sensor (PL 9.14.1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6.4.19 MPT (Multi-Purpose Tray) Feed Assembly and Roller (PL 9.17.0) . . . . . . . . . . . . . . . . . . . . 6-42
6.4.20 Main Frame (PL 9.13) and Base Frame (PL 9.16). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6.4.21 Pick Roller Assembly, Tray1 (PL 9.18.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6.4.22 Pick Roller (PL 9.18.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
6.4.23 Paper Pickup Solenoid (PL 9.16.22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6.4.24 Temperature Sensor (PL 9.16.23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
6.4.25 Paper Feed Roller (PL 9.19.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
6.4.26 Paper Feed Roller Mid (PL 9.19.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
6.4.27 Feed Sensor (PL 9.20.2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
6.4.28 Fuser Exit Sensor (PL 9.14.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
6.4.29 500-Sheet Feeder (PL 9.1.44) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
7 Maintenance and Diagnostics
7.1 Paper path and Paper jam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.2 Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Jam Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.1 Factors that Cause Paper to Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Sample Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3.1 Printing a Demo Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3.2 Printing a Configuration Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3.3 Customer Mode Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3.4 Checking Consumable Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.3.5 Checking Other Routine Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.4 Control Panel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4.1 The Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4.2 Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4.3 Control Panel Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.5 Repeating Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6 How to use Engine Diagnostic Control Mode (EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6.1 What is EDC Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6.1.1 Entering EDC Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6.1.2 Functions of the Buttons While in EDC Mode . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6.1.3 LCD Functions and Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6.2 EDC Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.6.2.1 Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.6.2.2 Solenoid Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.6.2.3 Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.6.2.5 Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
iii
7.6.2.6 HVPS Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.6.2.7 Regi.Set Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.6.2.8 Color Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
8 Troubleshooting
8.1 Verifying Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1.1 Basic Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.1.2 Initial Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.1.3 Check the Consumable Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.2 Print-Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.3 Paper Feed Problems and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.3.1 Trouble with the Top Margin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.3.2 Jam at Tray 1 / Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.3.3 Jam at C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.3.4 Jam at B, C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.3.5 Jam at C (in the duplex area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.3.6 Jam at MPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.3.7 Multi-Feeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.3.8 Paper Wrapped in the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.4 Printer Symptoms and General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.4.1 Fuser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.4.2 Laser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.4.3 Fuser Does Not Work Due to the Drive Gear Having Heat Damage . . . . . . . . . . . . . . . . . . . . 8-13
8.4.4 Paper Empty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.4.5 Paper Empty not Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.4.6 Cover Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.4.7 Cover Open Not Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.4.8 Defective Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.4.9 No Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.4.10 Curved or Distorted Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.4.11 Low Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.4.12 Replace Toner [Color] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.5 Error Message Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
9 Parts List
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.0 Consumables, Routine Maintenance Items and Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1 Main Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.3 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.4 DEVE Cover (Door A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.5 Exit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.6 Duplex Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.7 DEVE Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.8 Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.9 Fuser Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.10 Paper Tray, Tray 1 (FCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.11 Paper Tray, Tray 2 (SCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
iv
9.12 Optional 500-Sheet Feeder (SCF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.13 Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.14 Front Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.15 Rear Frame Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.16 Base Frame Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.17 MPT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.18 Pickup Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.19 Feeder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.20 Paper Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.21 Transfer Belt Cam Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.22 Fuser Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.23 Xerox Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
10 Block Diagram
10. Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 Controller Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
11 Connection Diagram
v
Precautions
Precautions
1
1. Precautions
In order to prevent accidents and damage to the printer, please read all the precautions listed in this section carefully
before servicing the printer.
1.1 Service Terms
1.1.1 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.
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.
1.1.2 Product Terms
Caution: A personal injury hazard exists that may not be apparent. For example, a panel may cover the hazardous
area.
Service Manual 1-1
Precautions
1.2 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
30 min.
The surface is hot while the printer is running. After turning off
the power, wait 30 minutes.
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.
1-2
Precautions
1.3 Power Safety Precautions
1.3.1 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 260 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 power cord, with a 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.
1.3.2 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.
Service Manual 1-3
Precautions
1.4 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 electrostatically 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).
1.5Service Safety Summary
1.5.1 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 260 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.
1-4
Precautions
1.5.2 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.
1.5.3 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® 6100 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.
1.5.4 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 de-energize 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
1.5.5 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
Service Manual 1-5
Precautions
1.5.6 Servicing Fuser Components
Warning
This printer uses heat to fuse the toner image to media. The fuser is VERY HOT. Turn the printer power off,
open Door B, and wait at least 5 minutes for the Fuser to cool before you attempt to service the Fuser
Assembly or adjacent components.
1.6 Regulatory Specifications
1.6.1 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/6100supplies
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.
.
1.6.2 Declaration of Conformity
Xerox Corporation, declares, under our sole responsibility that the printer to which this declaration relates, is in
conformity with the standards and other normative documents:
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.
1-6
Reference Information
Reference Information
2
2. Reference Information
This section contains a tools list, list of abbreviations used in this manual, and a clearance required specification when
installing the Phaser 6100 printer.
2.1 Tools for Troubleshooting the Printer
The following tools are recommended for safe and easy troubleshooting as described in this service manual.
■ DVM (Digital Voltage Meter) standard: indicating more than 3 digits
■ Screwdrivers:
■ Tweezers
■ Cotton swabs
■ Cleaning equipment: Standard: dry, lint-free cloth and/ or mild detergent
■ Toner Type II Vacuum
■ Soft bristle brush
■ Printer Installer and Utilities CD-ROM
Service Manual 2-1
Reference Information
2.2 Acronyms and Abbreviations
Definition Definition
ADC Analog-to-digital Conversion F/W Firmware
AP Access Point FCF/FCT Tray 1 or First Cassette Feeder
AC Alternating Current FISO Front In, Side Out
ASIC Circuit Application Specific Integrated FPOT First Print Out Time
Ass’y Assembly GDI Windows Graphic Device Interface
BIOS Basic Input Output Sytem GIF Graphic Interchange Format
BLDC Motor Brushless Dc Motor GND Ground
CMOS Complementary Metal Oxide
Semiconductor
CMYK Cyan, Magenta, Yellow, Black HDD Hard Disk Drive
CN Connector HTML Hyper-text Transfer Protocol
CON Connector HV High Voltage
CPU Central Processing Unit HVPS High Voltage Power Supply
CTD Sensor Color Toner Density Sensor I/F Interface
dB Decibal I/O Input/output
dBA A Weighted Decibel lb Pound(S)
dBm Decibel Milliwatt IC Integrated Circuit
DC Direct Current ICC International Color Consortium
DCU Diagnostic Control Unit IDE Intelligent/integrated Drive Electronics
DIMM Dual In-line Memory Module IEEE Institute Of Electrical And Electronics
DPI Pots Per Inch IOT Image Output Terminal (Color Printer,
DRAM Dynamic Random Access Memory IPA Isopropyl Alcohol
HBP Host Based Printing
Engineers, Inc.
Copier)
DVM Digital Voltmeter IPC Inter Process Communication
ECP Enhanced Capability Port IPM Images Per Minute
ECU Engine Control Unit ITB Image Transfer Belt (Transfer Belt)
EEPROM Electronically Erasable
Programmable Read Only Memeory
EMI Electro Magnetic Interference LBP Laser Beam Printer
EP Electro Photographic LCD Liquid Crystal Display
EPP Enhanced Parallel Port LED Light Emitting Diode
LAN Local Area Network
LSU Laser Scanning Unit
2-2
Reference Information
Definition Definition
LVPS Low Voltage Power Supply Or SMPS
MB Megabyte Q’ty Quantity
MHz Megahertz RAM Random Access Memory
MPBF Mean Prints Between Failure ROM Read Only Memory
MPF/MPT Multi-purpose Tray SCF/SCT Tray 2 Or Second Cassette Feeder
NIC Network Interface Card SMPS Switching Mode Power Supply or LVPS
NPC Network Printer Card SPGPm Samsung Printer Graphic Processor
NVRAM Non-volitale Random Access Memory SPL Samsung Printer Language
OPC Organic Photo Conductor Spool Simultaneous Peripheral Operation Online
PBA Print Board Assembly SW Switch
PCI Peripheral Component Interconnect SURF Surface Rapid Fusing
PCL Printer Command Language Sync Synchronous
PDF Portable Document Format T1 ITB or Transfer Belt Imaging
PDL Page Description Language T2 Transfer Roller Imaging
Ping Packet Internet Or Inter-network
Grouper
PPD Postscript Printer Description PnP Universal Plug-n-play
PPM Pages Per Minute URL Uniform Resource Locator
PS Postscript USB Universal Serial Bus
PTL Pre-transfer (Erase) Lamp
PWM Pulse Width Moduration
TRC Toner Reproductive Curve
Service Manual 2-3
Reference Information
2.3 Selecting a Location for the Printer
■ Leave enough room to open the printer trays, covers, and allow for proper ventilation.
■ Provide the proper environment
■ A sturdy, level surface
■ Away from the direct airflow of air conditioners, heaters, or ventilators.
■ Free from extreme fluctuations in temperature, sunlight, or humidity.
■ Clean, dry, and free from excessive dust.
2-4
Reference Information
2.4 Printer Serial Number Format
Changes to Xerox products are made to accommodate improved components as they become available. It is
important when ordering parts to include the following information:
■ Component's part number
■ Product type or model number
■ Serial number of the printer
Serial numbering. Particular fields in the serial number indicate the modification level of the printer, the date of its
manufacture and the sequence number of the printer produced on that day.
The serial number is coded as follows:
■ RENXXXXXX - 110V Printer
■ REPXXXXXX - 220V Printer
■ 1st three alpha = Product Code
■ 1st numeric value = Revision of the Printer.
■ Remaining 5 numeric values indicate the printers serial number.
BD serial number ranges - 30,000~ 59,999
DN serial number ranges - 60,000 and above
Serial Number Example:
REN130159...
REN: 110V printer
1: revision 1
30159: serial number, BD configuration
Service Manual 2-5
Reference Information
2-6
Specifications
Specifications
3
The specifiations in this manual are correct at the time of printing. Product specifications are subject to change
without notice.
3.1 General Specifications
Item Description
Print Method Non-impact electro-photography
Developing system Non-magnetic, Mono-component, Non-contact method
Exposure System Semiconductor laser diode beam scanning
Fuser (toner fixing) Thermal rollers fusing with pressure (heat lamp: 800 watts)
Resolution True: 600 x 600 dpi
Addressable: 1200 x 1200 dpi
Warm-up time 110 and 220 volt units: 120 seconds (2 minutes from power on to ready)
FPOT Mono: Less than 15 seconds (Ready to 1st page out)
Color: Less than 24 seconds (Ready to 1st page out)
Feed Method MPT (Multi-Purpose Tray), Tray 1 (FCT-First CassetteTray),
Tray 2 (SCT-Second Cassette (Tray)
Dimensions Width: 510 mm (20.07 in)
Depth: 470 mm (18.5 in)
Height: 405 mm (15.94 in)
Weight Printer: 35 kg (77.2 lb) with consumables
Optional Tray 2: 3 kg (6.6 lb) with packaging
Acoustic Noise Standby: less than 41 dB
Printing: less than 48 dB (color)
Power Saver Mode Available, user settings enabled
Service Manual 3-1
Specifications
3.2 Controller Specification
Item Description
Processor SPGPM (Samsung Printer Graphic Processor) Clock speed 120 MHz
Memory The controller has 64 MB SDRAM and 4 MB flash ROM on Board.
1 DIMM expansion slot for SDRAM DIMM Package: DIMM; 100-pin
Type: SDRAM
DIMM Type: Unbuffered (SEC Custom, support other products within SEC)
Error Checking: Non-parity
Speed: 120/133 MHz
Voltage: 3.3 V
Samsung proprietary design 64/128MB
(128 MB Not currently supported)
Emulation SPL-Color
Operating Systems Win 95/98/Me/NT/2000/XP, Mac OS 9 USB only, Linux
Interface One parallel port
IEEE 1284 -1994 compliant, (Bi-directional, ECP/Nibble/Byte Mode)
One USB port
USB v.2.0 compliant
Color-coded to meet WHQL requirements, connector must be Pantone 426C
One 10/100 BaseT NIC connector
- The printer supports an internal Network Interface Card (NIC), which can be
installed pre-configured at the factory. This NIC supports all of the major
Network Operating Systems, such as the Novell NetWare, TCP/IP, etc.
Interface switching Automatic
Interface time-out 5 min (max.)
Font Windows Font
Color Management ICC ICM V3.4
3.3 Electrical Specification
Item Description
Input Voltage Low voltage: 100-127 VAC High voltage: 220-240 VAC
Input Range 90-135 VAC 180-264 VAC
Nominal Frequency: +/- 47/63 Hz +/- 47/63 Hz
Frequency tolerance +3 Hz +3 Hz
Power Consumption Print mode: 450 watts or less
Standby mode: 160 watts
Sleep mode: 35 watts
3-2
3.4 Environmental Range
Items Operating Storage (packaged) Optimum
Specifications
Temperature
Humidity 20 - 80% RH 20 - 80 % RH 30 - 70% RH
Altitude 2,500 meters (8,200 feet)
15 ~ 30oC (59 ~ 86oF) 5 ~ 35 oC (41 ~ 95oF) 20 - 25 oC
3.5 Periodically Replaced Parts
Item Life Expectancy
Imaging Unit 50,000 images User replaceable
Transfer Belt 50,000 images User replaceable
Fuser 100,000 pages mono / 50,000 pages color User replaceable
Transfer Roller (T2) 50,000 pages (simplex prints) User replaceable
Waste Toner Cartridge 3,000 to 5,000 pages (color 5%) User replaceable
Printer 300,000 images or 5 years
3.5.2 Consumables
Item Life based on 5% coverage
Standard Toner Cartridge: Black
High capacity
Standard Toner Cartridge: Cyan
High capacity
Standard Toner Cartridge: Yellow
High capacity
Standard Toner Cartridge: Magenta
High capacity
3,000
7,000
2,000
5,000
2,000
5,000
2,000
5,000
3.5.3 Options
Item Description
Tray 2 (SCT) Paper capacity: 500 Sheets (20lb.)
Paper weight: 60 ~ 90 g/m
2
(16 - 24 lb)
Service Manual 3-3
Specifications
3.6 Media Specifications
3.6.1 Paper Size and Weights
The supported media types for this printer include, but are not limited to: labels, envelopes, cardstock, plain paper,
transparency, letterhead and colored paper.
Paper Type Size Tray Support
A4 210 x 297mm All Trays
Letter 8.5” x 11” (216 x 279 mm) All Trays
Folio (Legal 13”) 8.5” x 13” (216 x 330 mm) MPT
Legal (Legal 14”) 8.5” x 14” (216 x 356 mm) MPT
Executive 7.25” x 10.5” (184 x 267 mm) MPT
Statement 5.5” x 8.5” (140 x 216 mm) MPT
ISO B5 176 x 250 mm MPT
JIS B5 182 x 257 mm MPT
A5 148 x 210 mm MPT
A6 105 x 148 mm MPT
Com-10 Envelope 4.15” x 9.5” (105 x 241 mm) MPT
#9 Envelope 3.88” x 8.88” MPT
Monarch Envelope 3.88” x 7.5” (98 x 191 mm) MPT
DL Envelope 110 x 220 mm (4.33” x 8.66”) MPT
C5 Envelope 162 x 229 (6.38” x 9”) MPT
C6 Envelope 114 x 162 (4.5” x 6.38”) MPT
B5 Emvelope MPT
OHP Transparency*, Paper Label, Card stock MPT
Custom size paper 90 x 140 mm (3” x 5”)
216 x 356 mm (8.5” x 14”)
* Transparencies CANNOT
white) ONLY
.
be used for color prints in this printer. monochrome (black and
MPT
3-4
3.6.1 Paper Size and Weights (cont’d)
Tray Support Media Types / Capacity Sizes Weight
Specifications
Tray 1
Tray 2
MPT
Auto Duplex
Output Tray
Paper; 250 sheets (20 lb)
Paper; 500 sheets (20 lb)
Paper; 100 sheets
Envelope; 10
Label; 10 sheets
Transparency; 30 sheets
Card stock; N/A
Paper A4, Letter, Folio, Legal 20 ~ 24 lb
Paper; 250 sheets (20 lb)
A4, Letter 16 ~ 24 lb
A4, Letter, Legal, Folio, Executive,
A5, ISO and JISB5, A6, Statement,
Monarch, COM10, #9, C5, B5 Env.
and DL
3.6.2 Print Margins and Skew
Print Margins
Side print position accuracy +/- 2.0 mm (+/- 0.08”)
Lead print position accuracy +/- 3.0 mm (+/- 0.12”)
Skew
A rectangular box of 189 mm x 256 mm will be used to measure skew.
60 ~ 90 gsm
16 ~ 43 lb
60 ~ 163 gsm
75 ~ 90 gsm
b
Simplex Tray 1, 2 MPT
A: Vertical < 2.0 mm (+/- 0.08”) < 2.0 mm (+/- 0.08”)
B: Horizontal < 1.5 mm (+/- 0.06”) < 1.5 mm (+/- 0.06”)
Duplex
1.5 times simplex printing
3.6.3 PC (Host) Specifications
For reliable operation, the following PC configurations are recommended:
■ Windows 98, Me; Pentioum 166 MHz; 64 MB RAM
■ Windows NT 4.0, 2000, XP, Server 2003; Pentium 233 MHz; 128 MB RAM
■ Mac OS9; USB only; Power Macintosh G3, G4, iMac, PowerBook, iBook
■ All; 200 MB free hard drive space, CD-ROM Drive
a
Service Manual 3-5
Specifications
3-6
Product Summary
HVPS
Eraser Lamp
DEV. - Black
DEV. - Yellow
Pick-up
Roller
DEV. - Magenta
DEV. - Cyan
CASSETTE
LSU
Feeder
DUPLEX
Fuser Unit
EXIT Unit
MPF
SCF
Deve Cover
Transfer
Belt
Transfer
Roller
Imaging Unit
w/OPC Drum
PTL
SCF Path
Pick-up
Roller
Pick-up
Roller
4
4.1 System Structure
4.1.1 Major Assemblies of the Printer
Summary of Product
Fuser Unit
EXIT Unit
HVPS
Roller
Transfer
Belt
Transfer
PTL
DEV. - Black
Pick-up
DUPLEX
Eraser Lamp
Imaging Unit
w/OPC Drum
DEV. - Yellow
DEV. - Magenta
LSU
DEV. - Cyan
Roller
Feeder
Roller
Pick-up
Tray 1
MPT
Roller
Pick-up
Tray 2
Deve Cover
Service Manual 4-1
Summary of Product
Conrtoller Board
Deve Cover
Open S/W
(Interlock Door A)
Front View
Control Panel
Rear View
Deve OEM
Board
CRUM
Reader
Waster Toner Sensor
Waster Toner Motor
Deve DriveDeve Drive
Duplex Cover
Duplex Cover
Open Switch
Open Switch
4-2
Fuser FanFuser Fan
Main DriveMain Drive
LVPSLVPS
Deve Drive
Deve Drive
Board
Board
Deve Cover
Open S/W
(Interlock Door A)
Conrtoller Board
Summary of Product
1) Imaging Unit
The imaging unit creates the image using an electro-photo process. The imaging unit consists of the following:
■ An OPC Drum
■ Waste Toner Assembly
■ Charge Roller Assembly
2) Transfer Belt (ITB)
ITB stands for Image Transfer Belt. The image developed on the drum is transferred first to the transfer belt. This
is called the T1 transfer (Primary Image Transfer).
■ The printer uses a four pass process to place the image on the transfer belt.
■ The image is created on the drum and transferred to the transfer belt in the following order: first yellow (Y),
then magenta, then cyan, and finally black.
3) Transfer Roller
Once the transfer of the image from the drum to the belt is complete, the full image is transferred from the belt to
the transfer roller. The transfer roller then transfers the image to paper. This is called the T2 transfer (Secondary
Image Transfer).
4) Tray 1 or FCT (First Cassette Tray)
Tray 1 stores and feeds paper to the printer. A pick roller picks paper, controls drive, feeds paper, and removes
static electricity from the paper.
Tray 1 Specifications:
■ Paper Feed: side registration
■ Paper Direction: Long edge
■ Paper Discharge: Separation Claw
■ Capacity: 250 Sheets
■ Paper Size: A4, Letter
■ Paper Weight (average): 60~90gsm (16~24lbs)
■ Paper Type: *see the approved Xerox media specifications in Section 3.
5) Tray 2 SCT (Second Cassette Tray) (contained in the Optional 500-Sheet Feeder)
Same as Tray 1, but holds up to 500(20 lb) sheets of paper.
6) MPT (Multi Purpose Tray)
The Multi-Purpose Tray supports custom size media and manual feed.
MPT Specifications:
■ Capacity: Cut Sheet: 100 Sheets (75 gsm / 20lb)
■ OHP: 30 Sheets, Envelopes, Labels, and Card Stock: 10 Sheets
■ Paper Arrangement: Side Registration
■ Drive: Main Motor (Brushless DC (BLDC))
■ Driving Management: Solenoid
■ Paper Discharge: Friction Pad Method
■ Paper Size: Legal, Folio, A4, Letter, Executive, JIS B5, A5, A6, Statement, Monarch (7 3/4), #9, C5, B5
Envelope, DL
■ Paper Weight and Type: See the approved Xerox media specifications in Section 3.
■ Paper Empty Sensor
Service Manual 4-3
Summary of Product
7) Feeder
■ Paper Arrangement: Side Registration.
■ Drive: Main Motor DC
■ Paper Management: Feed Clutch
8) Duplex Unit
The duplex unit is used to reverse paper feed to print the on backside of paper. The duplex unit is not an option.
The transfer roller is part of the duplex unit.
Duplex Unit Specifications
■ Drive: Main Motor DC
■ Paper Reversal: After the front side of the original document is printed and begins reaches the exit path, the
exit roller pulls the paper back through the duplex unit for printing on the reverse side.
9) Exit Unit
The exit unit guides the paper to the output tray.
Exit Unit Specification
■ Capacity : 250 sheets standard (20 lb)A4/Letter (There is no output tray full sensor)
■ Paper Direction: Face Down
■ Exit Roller Drive: Driven by the main motor DC, rotating clockwise for normal feed and counter-clockwise
to reverse feed for duplex printing.
10) Toner Cartridges
There are four toner cartridges, one each for C (Cyan), M (Magenta), Y (Yellow) , and K (Black).
11) Fuser Unit
The fuser unit consists of 2 heat lamps, 2 heat rollers, 2 thermostats and one thermister. After the image is
transferred from the transfer roller onto the media, the fuser melts and fuses the toner to the paper by applying
pressure and heat to complete the print job.
12) Laser Unit (LSU)
The laser unit forms the latent image on the surface of the drum using a static charge.
13) Main Motor (Brushless DC)
The main motor drives the following components: imaging unit, transfer belt, feeder, fuser, exit, and duplex unit.
Main Motor Specification:
■ Power: 40W Max (24V)
14) DEVE Drive Motor
The DEVE motor drives the toner cartridges and transfer belt cleaning cam.
DEVE Motor Specification:
■ Power : 40W Max (24V)
4-4
Loading...